P1-101 Submittal Transmittal
Date:
Project Name: P1-101 Sludge Dewatering and Odor
Control at Plant 1
4/10/13
Orange County Sanitation District
To:
From:
Grant Gourley
10844 Ellis Avenue
W.M. Lyles Co.
42142 Roick Drive
Temecula, CA 92590
Fountain Valley, CA 92708
Attn: Plant #1 Submittal Group, Division 760
Phone: (951) 973-7393
Drawings or Data are Submitted:
For Approval
For Information
Copies
Submittal
Number
Submittal Title
Spec.
Section(s)
8
14630.001.A
Bridge Crane
14630
1
Electronic Copy of Submittal 14630.001.A
Manufacturer / Sub:
WML
Complete either (a) or (b):
(a)
(b)
Check One
Check One
This is:
We have verified that the material or equipment
contained in this submittal meets all the requirements
specified or shown (no exceptions).
Original Submittal:
We have verified that the material or equipment
contained in this submittal meets all the requirements
specified or shown, except for the following
deviations (Listed Below):
Resubmittal:
Supplemental
Submittal:
Remarks / Deviations:
The specifications require a Brinell Hardness number for the wheels of 375-425, while the
supplier submittal calls out a Brinell Hardness number of 304. This was explained by the need
for the wheels to be softer than the rail, allowing the wheels to fail before rail. The wheels are
less costly and easier to replace.
Certification Statement:
By this Submittal, I hereby represent that I have determined and
verified all field measurements, field construction criteria,
materials, dimensions, catalog numbers, and similar data and I
have checked and coordinated each item with other applicable
approved Shop Drawings and all Contract Requirements.
FOR OCSD USE ONLY
Contractor's Authorized Signature
Date
Facilities Engineering
900 E. Orangefair Ln
Anaheim, CA 92801
Supplier Specification
Evaluation
Demag Cranes &
Components
Overhead Crane Supplier
General Information
Crane Capacity / Tons
Span
Voltage
Bridge Speed
Trolley Speed
Hoist Speed
CMAA Class
Crane Shipping Weight
Trolley Weight
Maximum Bridge Wheel Load
Runway Rail Size - Recommended
20.00 Ton
102 FT 0.000 IN
460/3/60
0-100 VFC FPM
0-65 VFC FPM
24/4 FPM
C
54450 LBS
4715 LBS
35350 LBS
60# ASCE
CMAA Member
ISO 9000 Components
Product Liability Insurance
Nearest Service Location
Nearest Parts Location
Factory Service School
Single Source Warranty
Yes
Yes
Yes
San Bernardino, CA
San Bernardino, CA
Yes
Yes
Bridge Girder Information
Girder Construction
Girder Material
Computer Design – Girder Section
Girder Steel Certification
Welders Certification Compliance
Girder to End Truck Connection
Connection Type
Camber
Trolley Rail Type
Facilities Engineering Job #100507
Welded Steel Torsion Box
A36
Yes
Yes
Yes
Bolted
Friction
Per CMAA
Square Bar, ST52
Page 1
Facilities Engineering
900 E. Orangefair Ln
Anaheim, CA 92801
Supplier Specification
Evaluation
Demag Cranes &
Components
Overhead Crane Supplier
Bridge Component Information
Bridge End Truck Manufacturer
End Truck Design
Number of Wheels / per Crane
Wheel Diameter
Wheel Material
Double Flange Wheels
Brinell Hardness
Bearing Type
Sealed bearings
Two Bearings per Wheel
L-10 Life
Rotating Axle
Enclosed Bridge Gearing
Crane Rail Sweeps
OSHA Approved Bumpers
Demag
Box
4
12.4 inch
Nodular* Cast Iron
Yes
304 Bhn
Roller
Yes
Yes
64258 Hours
Yes
Yes
Yes
Yes
Bridge Motor Manufacturer
Motor Type
Motor HP x Quantity of Motors
Nominal Motor RPM
Thermal Overload Protection
Brake Type
Brake Material
Demag
Squirrel cage - TEFC
7.1 HP @87Hz HP x 2
1500
Yes
DC Disc
Asbestos-Free
Bridge Gearbox Manufacturer
Gearbox Type
Gear Type
Lubrication
AGMA Class
Demag
Hollow Shaft
Helical
Oil Bath
* Wheels impregnated with
Spheroidal Graphite GGG70
Facilities Engineering Job #100507
Page 2
Facilities Engineering
900 E. Orangefair Ln
Anaheim, CA 92801
Supplier Specification
Evaluation
Demag Cranes &
Components
Overhead Crane Supplier
Trolley Information
Trolley Manufacturer
Number of Wheels
Wheel Diameter
Wheel Material
Brinell Hardness
Bearing Type
Sealed Bearings
Two Bearings per Wheel
L-10 Life
Rotating Axle
Enclosed Trolley Gearing
Demag
4
6.3 inch
Nodular* Cast Iron
304 Bhn
Ball
Yes
Yes
14495 Hours
Yes
Yes
Trolley Motor Manufacturer
Motor Type
Motor HP x Quantity of Motors
Nominal Motor RPM
Thermal Overload Protection
Brake Type
Brake Material
Demag
Squirrel Cage -TEFC
4.2 HP @100Hz HP
1500
Yes
DC Disc
Asbestos-Free
Trolley Gearbox Manufacturer
Gearbox Type
Gear Type
Lubrication
AGMA Class
Demag
Hollow Shaft
Helical
Oil Bath
* Wheels Impregnated with
Spheroidal Graphite GGG70
Facilities Engineering Job #100507
Page 3
Facilities Engineering
900 E. Orangefair Ln
Anaheim, CA 92801
Supplier Specification
Evaluation
Demag Cranes &
Components
Overhead Crane Supplier
Hoist Information
Hoist Manufacturer
Capacity / Tons
Lift (available on hoist)
Model
Wire Rope Size
Wire Rope Construction
Min. Wire Rope Safety Factor
Reeving
Rope Guide
Drum Material
Drum Bearing
Sheave Material
Demag
20.00 TON
44 Feet
DRPRO20-20 8/2-10.3 Z-6/1
7/10 inch (18 mm)
WRC 8 x 36
Breaking Strength 6.2:1
8 Parts Double
Yes
QSTE 380 N
Roller
Hardened Cast Iron
Hoist Motor Manufacturer
Motor Type
Motor HP
Nominal Motor RPM
Thermal Overload Protection
Brake Type
Brake Material
Mechanical Load Brake
Drum Brake (Load Halt Device)
Regenerative Braking
Demag
Squirrel cage - TEFC
5.5/35.0 HP
900/3600
Yes
DC DISC
Asbestos-Free
No
Optional
Yes
Hoist Gearbox Manufacturer
Gearbox Type
Gear Type
Lubrication
Drum Bearing
Facilities Engineering Job #100507
Demag
Offset/Parallel
Helical
Oil Bath
Roller
Page 4
Facilities Engineering
900 E. Orangefair Ln
Anaheim, CA 92801
Supplier Specification
Evaluation
Demag Cranes &
Components
Overhead Crane Supplier
Hoist Information - Continued
Hook Type
Hook Safety Latch
Hook Bearing
Hook Rotation
Geared Operational Limit Switch
Geared Emergency Limit Switch
Service Time Counter
Single
Yes
Thrust
360 Degrees
Optional
Yes
Yes
Electrical Information
Enclosure Type (All)
Motors Total Enclosed Fan Cooled
Motor Insulation
Branch and Control Fused
Mainline Disconnect
Mechanical Disconnect
Contactor Manufacturer
Contactor Type
Festoon System for Hoist/Trolley
High Temperature Flat Cable
Method of Control
Pushbutton Control Manufacturer
Quick Disconnect Push Button
Ergonomic Push Button Design
Facilities Engineering Job #100507
NEMA 12
Yes
Class F
Yes
Yes
Yes
Telemecanique
IEC
Yes
Yes
Pushbutton
DEMAG
Yes
Yes
Page 5
Equipment Features
CRANE TYPE: Feature: Toprunning double girder
crane type ZKKE. These rugged cranes of welded
box girder construction are designed for a heavy
duty service. A Demag DR or DH wire rope hoist is
standard.
Benefit: We offer standardized cranes for your
specific application. Designs are based on high
volume and are tested under the toughest
applications.
Job # 100507
Capacity: 20.00 T Span: 102'- 0.00"
Voltage: 460/3/60
Hoist/Trolley: EZDRPRO20-20 8/2-10.3 Z-6/1
GIRDERS: Feature: Girders for double girder
cranes are fabricated plate box sections, with
diaphragms, designed to resist all vertical horizontal,
and torsional forces. Trolley rails are ST52
rectangular sections welded directly over girder
webs, to optimize transmission of loads into the
girder structure.
Maximum allowable girder deflection is 1/888 of
span.
Benefit: The girder design insures the optimum
strength to weight ratio. This can save building costs
in new construction applications.
GIRDER CONNECTION: Feature: End trucks are
bolted to girder ends to form a rigid connection.
Bolts in shear or welded connections are not used.
Benefit: The girder connection is precision aligned to
insure proper tracking of the crane. Cranes do not
have to be field aligned thus saving installation time
and cost.
END TRUCKS: Feature: End trucks are of box
section type, having a side connection to the bridge
girder, with double flanged wheels supported on
rotating axles. The axles are supported by dual antifriction bearings having a minimum B-10 life in
accordance with the CMAA crane classification
specified. Wheels are cast and machined from
spheroidal graphite material. Wheels are designed to
carry the rated load without undue wear to
themselves or the crane runways rails. End trucks
are fitted with bumpers capable of decelerating and
Facilities Engineering Job #100507
Page 1
Equipment Features
stopping the crane within the limits stated by OSHA
and CMAA.
Benefit: Heavy duty high cycling drives and wheels
with low wearing wheels that self-lubricate as they
travel, and gearbox that improve lifetime of the travel
components.
BRIDGE DRIVES: Feature: Horizontal bridge drives
are of the CMAA type A-4. Motors are totally
enclosed, fan cooled and drive fully enclosed
gearing. All gear reduction stages are oil bath
lubricated. The gear reducers directly drive the
wheel axles through splined shafts. VFC (variable
frequency control) combined with Demag cylindrical
rotor motors offer smooth acceleration and
deceleration to minimize load swing. Motors have
Class F insulation and are thermally protected by
heat sensors imbedded in the windings.
Benefit: Smooth stepless acceleration and
deceleration provides the operator with exceptional
control.
CONTROLS: Feature: VFC bridge control provides
smooth accel and decel characteristics for accurate
load handling. The bridge inverter drive handles a
wide speed range and adds safety by reducing load
sway. Enclosures are selected to meet the service
requirements of the application. Standard enclosure
classification is NEMA 12, water tight and dust
resistant. Control voltage is isolated from the main
power supply by a transformer and does not exceed
120 volts. The standard control voltage for cranes
with type DR hoist is 48 volts.
Benefit: State of the art controls for smooth crane
operation
PUSHBUTTON STATION: Feature: Floor control is
provided by an ergonomically designed pushbutton
station. Slanted position and alert colors of the light,
high-impact resistant fiberglass casing promote safe
operation. The P.B. station is suspended from an
enclosed track system to enable separation of
operator and load. Plug connectors are used on
both ends of the pushbutton control cable for a ease
of maintenance or replacement. DR Pro hoists come
standard with a bar load readout, and will provide a
Facilities Engineering Job #100507
Page 2
Equipment Features
warning symbol in the event of an overload or if the
system requires maintenance.
Benefit: Ergonomic pushbutton station provides
crane status information to the operator for greater
safety.
BRIDGE ELECTRIFICATION: Feature:
Electrification across bridge for power and control
circuits consists of highly flexible neoprene covered
flat-section cable suspended from smooth running
enclosed track system.
Benefit: This provides a cost effective solution to
bridge electrification
PAINT: Feature: All structural and Component parts
are cleaned with solvent and or shot blasted or wire
brushed. Prime coat and finish coat are applied.
Standard colors are safety-yellow for structural parts
and Demag blue for machinery.
Benefit: The product has an exceptional appearance
due to the painting process.
HOIST TYPE: Feature: Demag DR PRO rope hoist
meets all the requirements for state-of-the-art hoists
for tomorrow’s needs. Besides the space-saving
design and particularly long service life, it also offers
a higher lifting speed for faster handling rates and a
comprehensive list of standard features at an
attractive price.
Standard features include: (DR Pro hoists)
Overload Protection
Condition Monitoring
Diagonostics for entire crane which are
downloadable with laptop or PDA interface
Self defense against operator plugging and
excessive jogging
Low current contactor switching
Duty and Load spectrum recording
Benefit: The DRPRO Hoist product line offers the
most advanced options as standard in the industry.
Facilities Engineering Job #100507
Page 3
Equipment Features
HOIST DESIGN: Feature: Demag is a member of
CMAA and HMI and our wire rope and electric chain
hoists are designed in strict conformance to all
applicable national and local codes and regulations.
Benefiit: You have insurance that cranes and hoists
designed meet application requirement. Demag is
also an ISO certified company as ISO 9001 and
ISO14001
HOIST CONTROLS: Feature: Technology package
is onboard and the standard package that offers a
wide array of diagnostic tools. Diagnostics available
includes service history along with overload
protection.
The controls also feature the following:
1. Anti-Jogging, Anti-plugging, and Phase
monitoring.
2. Brake wear monitoring.
3. Life Cycle calculation shows remaining life.
4. Pulse generator to monitor the hoist motor.
5. Hoist no current contact switching for long
contactor life
6. Pushbutton with LCD display readout for
crane and hoist update
7. Safety warning horn.
Benefits: The advanced standard hoist controls
protect the equipment for longer life and safe
operation. Resulting in less down time and
unnecessary shut downs. The onboard smart
controls and constant self-monitoring capability of
the standard DRPRO help the equipment achieve
this goal.
HOIST MOTOR: Feature: Demag designed and
manufactured, these motors offer dependable
performance with a minimum of maintenance. An
optimised motor design for low-vibration, quiet
operation
12/2-pole squirrel-cage motor with cylindrical rotor.
All motors have Class F insulation and are protected
from overheating by thermal protectors imbedded in
the windings. Motors are totally enclosed, fan
cooled (TEFC). Enclosure is outdoor rated IP 55
with a duty of 60% running time and 360 starts/hour.
Facilities Engineering Job #100507
Page 4
Equipment Features
Benefits: The hoist motor specifically designed and
manufactured by Demag insures to meet the
challenges of lifting applications.
HOIST BRAKE: Feature: Demags DC disk brake is
a fail-safe type, electrically released, spring set for
close positioning and motor start-up monitoring, with
a minimum brake safety factor of 1.8. The brake is
fast acting brake due to integrated electronic
modules. The hoist (DR Pro) includes a brake
sensor that monitors brake wear and will provide a
warning to the operator if a brake adjustment is
necessary. The high quality brake is designed for a
minimum of 5 years life under single shift operation.
Benefit: The hoist has failsafe braking that insures
safe lifting, spotting, and positioning of loads.
HOIST GEARING: Feature: All gear stages have
helical gearing and are case hardened for low noises
and smooth running. Each gear and hub connection
is designed with a conical bonded press-fit
connection. This means high resistance to vibration
and insensitivity against load peaks. Gear lubricant
is synthetic and does not require replacement for the
normal life of the hoist. The standard hoist design is
rated for FEM2+ (20% greater duty than FEM2).
Benefit: The heavy duty gears are permanently
immerse in a high grade synthetic oil that leads to
long life.
ROPE DRUM: Feature: Drum is of welded steel
construction, with machined groove, optimized to a
minimum depth of 0.375 times the rope diameter.
Supported at each end by sealed anti-friction
bearings, the drum is driven by a central splined
shaft. To assure positive winding of rope on the
drum and to prevent rope overlapping and potentially
dangerous groove peak contact, a hoisting rope
guide is employed.
Benefit: Reduce rope and drum wear and no risk of
double wrapping the rope on the drum.
Facilities Engineering Job #100507
Page 5
Equipment Features
WIRE ROPE: Feature: The hoisting wire rope is of
proper design and construction for hoist service.
The rated capacity load divided by the number of
parts of rope does not exceed 20% of the breaking
strength of the rope.
Benefit: long service life of the wire rope.
BOTTOM BLOCK: Feature: Bottom block has a
totally enclosed housing fabricated of steel. The
rope sheaves are supported on anti-friction bearings
and the hook is forged alloy-steel and supported on
an anti-friction thrust bearing. Hook is equipped with
a heavy spring safety latch. A handle recess makes
it easier to be gripped and handled. Moving plastic
elements close the opening where the rope enters
and leaves the bottom block thus preventing the
hands from getting caught and jammed.
Benefit: Safe handling by keeping operator hands in
handle and away from the load.
LIMIT SWITCH: Feature: Hoist is equipped with a 4
position geared upper and lower limit switch. This
switch is easily adjusted to set the extreme upper
and lower limits of hook travel. The limit switch is
equipped with a digital drum revolution counter for
use in evaluating service conditions and
maintenance intervals.
Benefit: Hoist slows than stops at the bottom and the
upper limit positions.
TROLLEY: Feature: The EZDR low headroom
trolley supports the hoist on one side of the beam
allowing an excellent high-hook dimension. The
precision machined and welded steel trolley frame
includes side guide rollers for precise tracking, and
an under flange pressure roller for consistant
horizontal drive traction and anti-kick-up. Lifting lugs
are provided for simple transport and installation and
the compact design allows for minimum hook
approach dimensions.
Benefit: Excellent approach height with low
headroom dimensions with excellent tracking
characteristic.
Facilities Engineering Job #100507
Page 6
Equipment Features
TROLLEY DRIVE: Feature: Motorized trolleys are
powered by a Demag cylindrical rotor motor with DC
brake. A frequency inverter provides true variable
speed travel motions for smooth safe
positioning, low-sway travel motions and exact
positioning.
Motors have Class F winding insulation and are
totally enclosed. Motors are protected from
overheating by thermal protectors imbedded in the
windings.
Benefiit: Smooth stepless trolley travel with low load
sway and excellent operator control.
AUDIBLE WARNING DEVICE: Feature: A warning
horn is provided as a standard feature on DR Pro
wire rope hoists. The horn is mounted on the hoist
electrical enclosure. The horn is activated by a 2
position horn button from either a DSE pushbutton
station or a DRC radio transmitter. The horn button
first position will result in a constant sound from the
horn. The second position will result in a pulsating
sound. The horn DB rating is 95 db (+/- 3db). The
warning horn will also sound if a control system error
is detected. Other optional AUDIBLE WARNING
DEVICES are available.
Benefit: Warning device to warn other poeple that
the crane is moving in a work area.
DR DIAGNOSTICS: Feature: The diagnostics tool
will help eliminate un-necessary down time and
remove the guessing game with maintenance
requirements. The performance and safety status of
your installation are kept under surveillance by the
monitoring system. The LED display within the
pendant control shows the operator or maintenance
engineer the relevant status information and any
unusual operating status, if applicable. Two way
communication is possible via PC/PDA
communication with hoist via IRDA (infrared) or
through Laptop comport cables.
Benefit: Condition monitoring data can be
downloaded and used to schedule preventative
maintenance.
Facilities Engineering Job #100507
Page 7
DUCT-O-BAR
Figure 8 Electrical Conductor Systems
For Overhead Cranes, Trolleys, Monorails, Hoists,
Conveyors, Automatic Stacker-Retrieval Systems. . .
any Application that Requires a Reliable, Safe, and
Economical Moving Power System.
• 90 AMP
• 110 AMP
• 160 AMP
• 250 AMP
• 350 AMP
• 500 AMP
Basic Figure 8
Systems
Heated Conductor
Systems
Rolled Galvanized Steel
Rolled Galvanized Steel
Rolled Stainless Steel —
Copper Laminated
Rolled Copper — Steel Laminated
Rolled Electrolytic Copper
Extruded Electrolytic Copper
Side Contact
Systems
Totally Enclosed
Systems
8-Bar
Systems
V-Bar
Systems
CAUTION
MAKE CERTAIN POWER SUPPLY IS DISCONNECTED BEFORE INSTALLING, REPAIRING,
OR WORKING IN THE PROXIMITY OF ANY
ELECTRICAL SYSTEM. ONLY QUALIFIED
ELECTRICAL PERSONNEL SHOULD INSTALL
OR REPAIR THESE PRODUCTS.
www.duct-o-wire.com
P.O. Box 519
1351 W. Second Street
379 Davis Road, Unit #3
Corona, California 92878-0519
Oconomowoc, Wisconsin 53066
Oakville, Ontario, Canada L6J 2X2
Phone: 909-735-8220; 800-543-3885; 800-735-1922
Phone: 262-567-2288
Phone: 905-844-1791; 800-361-9473
Fax: 909-735-2372; 800-752-6001; 800-735-0857
Fax: 262-567-0857
Fax: 905-844-2533; 800-663-0933
UL
LISTED
Conductor Bar Selection
®
File # E29805
Contr. 678L
Approved
in Canada
Determining Ampere Load
The conductor selected must be large enough to carry the
necessary ampere load safely without undue heating. To
compute the ampere load, proceed as follows:
1. List the horsepower of all motors used in the
application.
2. Determine the voltage and type of current that will feed
the conductor. For example: 230v dc 2 wire; 460v ac 3
phase; etc.
3. Refer to the Horsepower Conversion Table on page 3
and convert the horsepower to amperes.
4. Prepare the ampere load figure that will be used to size
the conductors as follows:
List the full load ampere rating of each motor used
on the crane or monorail unit. Determine the duty
cycle from the following paragraphs and apply the
corresponding factor.
Light Duty — Class A and B Crane Service
Standby or infrequent use. Up to two motors started
at a time. Two to five lifts per hour. Use a factor of
90% of the calculated ampere load.
Average Duty — Class C Crane Service
Moderate use during the work day. Five to ten lifts
per hour. Not over 50% of the lift at rated capacity.
Use a factor of 100% of the calculated ampere load.
Heavy Duty — Class D Crane Service
Used continually during the work day and usually for
more than one shift. Loads of 50% of rated capacity
or more handled constantly during the work period.
Use a factor of 110% of the calculated ampere load.
Severe Duty — Class E and F Crane Service
Used continually for two or more work shifts a day
for loads approaching 100% of capacity. Use a
factor of 120% of the calculated ampere load. Due
to the mechanical considerations on severe duty
use, contact the factory engineering group when
selecting the conductor system for this application.
5. If the conductors are to be located where the ambient
air temperature is unusually high, the current carrying
capacity of the conductor is reduced. Multiply the
current capacity of the selected conductor by the
derating factor in the following table.
Temperature Derating Table
Ambient Air Temperature
Derating Factor
100°F
95%
130°F
75%
160°F*
50%
* At this ambient temperature it will be neccessary to use the higher
rated conductor cover, XHT rated at 280°F.
Determining Voltage Drop
According to CMAA, the voltage drop to the unit motors
shall not be more than 3% from the power taps to the load
at the farthest point on the conductor run. To determine
the voltage drop use the appropriate formula in the
following table.
Current Type
Formula
AC 3 phase 60 cycle
V = L x I x Z x 1.73
AC 1 or 2 phase 60 cycle
V=LxIxZx2
DC 2 wire system
V=LxIxRx2
V = Voltage drop
L = Distance from power feed to end of conductor
I = Total amperes drawn as calculated from
conversion charts
Z = ac impedance
R = dc resistance
2
See Conductor Engineering Data Table on page 4 for
values of Z and R.
Divide voltage drop by system voltage to get the percent
of voltage drop.
Maximum voltage drops that are 3% of various supply
voltages are as follows:
Supply Voltage
460v ac
230v ac or dc
575v ac
Voltage Drop (V)
13.8
6.9
17.2
Volts lost that are equal to or less than the above values
when using the formulas above will help in selecting the
correct conductor.
Conductor Selection Example
Given a 300 foot runway, power fed at the center, using
460 volt, 3 phase, 60 cycle power supplied to a bridge
crane — there is a 40 h.p. hoist motor, a 20 h.p. bridge
motor, and a 5 h.p. trolley motor. The operation is Average
Duty. Ambient temperature varies from 50°F in winter to
90°F in summer on this Indoor installation.
Step 1 — Determining Ampere Load
See National Electric Code article 610-14(e) for
determining motor loads where there are multiple motors
on a single crane. Then from the Horse Power Conversion
Table 460v column (right):
40 h.p. hoist motor — 52 amps @ 100% = 52 amps
20 h.p. bridge motor — 27 amps @ 50% = 13.5 amps
5 h.p. trolley motor — 7.6 amps @ 50% = 3.8 amps
The total current load is 69.3 amperes.
With Average Duty cycle, the current load is
factored at 100%. Normal ambient conditions of
50°F to 90°F require no temperature derating.
Selecting a 90 amp conductor caused a voltage
drop of 4.3% using the formula. Since this is
unsatisfactory, use a 110 amp conductor (FE-908)
for Step 2.
Step 2 — Determining Voltage Drop
Use the AC 3 phase formula on page two.
V = L x I x Z x 1.73 where:
L = 150 ft. (Distance to the end of the runway from
the center power feed.)
I = 69.3 amperes
Z = .0008 for 110 amp conductor (From the
Conductor Engineering Data Table, page 4.)
1.73 = 3 phase constant
V = 150 x 69.3 x .0008 x 1.73
= 14.4 volts
14.4/460 = 3.1%
Since this voltage drop only occurs at the farthest end
when two or more motors are started simultaneously,
exceeding the 3% voltage drop goal by only 0.1% will not
cause a problem.
Horsepower Conversion Table
3 Phase AC — 60 Cycle
Amperes
H.P.
230v
460v
1/2
2
1
3/4
2.8
1
Direct Current
Amperes
575v
230v
.8
2.7
1.4
1.1
3.8
3.6
1.8
1.4
4.7
1-1/2
5.2
2.6
2.1
6.6
2
6.8
3.4
2.7
8.5
3
9.6
4.8
3.9
12.2
5
15.2
7.6
6.1
20
7-1/2
22
11
9
29
10
28
14
11
38
15
42
21
17
55
20
54
27
22
72
25
68
34
27
89
30
80
40
32
106
40
104
52
41
140
50
130
65
52
173
60
154
77
62
206
75
192
96
77
255
100
248
124
99
341
125
312
156
125
425
150
360
180
144
506
200
480
240
192
675
Ampere Load Calculations for Multiple Units
For information about sizing ampere loads for multiple
cranes on the same runway, see Article 610-14 (e) of the
National Electrical Code for the demand factors. This
article also covers additional loads on the bridge cranes
other than motor loads.
full-load current varying with speed. In these cases, use
the higher nameplate current rating.
Induction Type Squirrel Cage and Wound Rotor Motors
The Horsepower Conversion Table is taken from the 1996
NEC Article 430. The values are for motors running at
usual speeds with normal torque characteristics. Motors
built for especially low speeds or high torques may require
more running current, and multi-speed motors will have
For motors that are wound for single or double phase
operation, use the nameplate rating. For older slip ring
motors or models that have secondary windings be sure to
obtain both primary and secondary current ratings.
Secondary windings may also need separate conductors
or cables when updating the electrification.
The voltages listed are rated motor voltages. The current
listed shall be permitted for system voltage ranges of 110
to 120, 220 to 240, 440 to 480, and 550 to 600 volts.
Motors rated at 208v ac should increase the 230 volt
column figures by 10%.
3
Conductor Engineering Data Table
Conductor
Bar No.
Description
Weight per
Ampere Rating
Coefficient of
10' section
Linear Expansion
lbs.
Continuous Intermittent*
per °F
Resistance Factor
AC (z)
DC (R)
ohms/ft. ohms/ft.
Circular
Mills
FE-758
Galvanized Steel
4.5
90
135
.000007
.0011
.00072
130,000
FE-908
Galvanized Steel
6.5
110
165
.000007
.0008
.0005
189,000
FE-1608
Stainless/Copper Laminate
6.5
160
240
.000008
.000144 .0001
188,000
FE-2008
Copper/Steel Laminate
6.25
250
350
.000008
.000142 .0001
189,000
FE-3008
Rolled Copper
6.75
350
530
.000009
.000085 .000058
188,000
FE-5008
Extruded Copper
500
750
.000009
.000065 .000033
315,000
11.5
* Intermittent Service Rating is determined for one minute on, one minute off operation.
Miscellaneous Applications
Curves
Duct-O-Bars, except the Totally Enclosed System, can be
bent to form curved sections without damaging the
insulating cover or conductor. Bends with a five-foot radius
or greater can be done in the field by using a fly wheel,
monorail beam, or similar object to bend the conductor to
approximately the necessary radius. Hangers used on
curved sections must be placed at intervals of 2-1/2 feet
maximium — and closer if required. Use B-100 cross bolt
clamp type hangers and P-Series collectors.
Discontinuous Circuits
On discontinuous circuits a pickup guide assembly must
be installed to ensure that the self-centering type collectors
engage and disengage the conductor bar. The pickup
guide (FE-2JNN3 is illustrated) must have its own support
point.
The minimum spacing between conductors on curves is
three inches.
For curves of five-foot radius or more, use five-inch
collector shoes. For curves of less than five-foot radius use
three-inch collector shoes; also consult the factory for
additional information.
10"
Support Point
5' Max.
Pickup Guide
Assembly
DUCT-O-BAR
3"
3-1/2"
Transfer Cap
Self-Centering
Collector
Other Special Applications
Consult the factory for recommendations on applications
such as de-icing systems, totally enclosed systems, and
other systems not covered here.
4
Support Bracket
Support Bracket
2-1/2"
Interlocks, Switches, or Fixed Gaps
The maximum fixed gap occurring at interlocks is one-inch
when using 100 amp P-Series collectors and 1/2 inch
when using 40 amp collectors. Use transfer caps as shown
to ensure that the collector brushes transfer evenly and
smoothly. Also round both ends of the contact brushes to
facilitate the transfer. Use clamp type hangers only. When
both interlocks and curves of less than a four-foot radius
are encountered, the tandem 40 amp collector is
recommended.
Transfer Cap
1" Max. Gap — 100 AMP Collectors
1/2" Max. Gap — 40 AMP Collectors
Expansion Gaps
Expansion gaps should be placed at intervals determined
by 1) the expansion rate of the metal in the conductor
selected, and 2) the variation in temperature that will occur
at the conductor location over a full year of operation.
1. Steel Conductor Systems
Given that steel conductors expand 1" for every 150' of
runway with a temperature change of 100°F over a full
year of operation, put the length of the runway and the
maximum temperature change for the system to be used
into the following formula:
Total Steel Expansion (inches) = X/150' x Y/100°F
where X is the runway length and Y is the 12 month
temperature variation.
Example: A 450' long steel conductor (X) installed in a
building with an indoor temperature change of 40°F (Y).
Total Expansion = 450'/150' x 40°F/100°F = 1.2".
(See Section 3.)
2. Copper Conductor Systems
Given that copper conductors expand 1" for every 100' of
runway over a 100°F temperature change at the conductor
over a full year of operation, put the length of the runway
and the maximum temperature change for the system to
be used into the following formula:
Total Copper Expansion (inches) = X/100' x Y/100°F.
Example: A 300' long copper conductor system (X)
installed outdoors with an anticipated temperature
fluctuation of 80°F (Y).
Total Expansion = 300'/100' x 80°F/100°F = 2.4".
(See Section 3.)
3. Determine the Number of Expansion Gap Assemblies
After calculating the actual expansion of the runway
conductor system, use the following rule of thumb to pick
the number of expansion gap assemblies:
a. Under 1" of expansion, use no expansion assemblies.
Install one anchor clamp set at the center of the
conductor run.
b. From 1" to 2" of expansion, use one expansion
assembly in the center of the conductor run.
c. From 2" to 4" of expansion, use two expansion
assemblies. Locate them at 1/3 of the runway length in
from each end.
d. For systems with more than 4" of expansion, use one
expansion gap assembly for each 2" of expansion.
4. Anchors
Anchor clamps are required at midpoint on all systems
without expansion gaps and halfway between gaps and
from gaps to the end of systems with multiple gaps. See
the Figure 8 Installation Instructions on anchor locations.
The maximum gap opening for all ten foot
Figure 8 expansion gap assemblies is 1-3/4
inches.
Expansion assemblies are also required at
building expansion joints.
Conductor Assembly Selection
Duct-O-Wire Figure 8 Conductor Bars are furnished as
assemblies consisting of a ten-foot long conductor bar
rated at 600 volts, an insulating cover, splice cover, and
connector pins or joint clamps as applicable.
The insulating cover must be appropriate for the
environment — indoor, outdoor, or high temperature — in
which the conductor is to operate.
Indoor systems are for use in ambient temperatures up to
160°F. They have an Orange PVC Insulating Cover. They
are not recommended for outdoor use in direct sunlight.
Outdoor systems are for use in direct sunlight and ambient
temperatures up to 160°F. They have a Gray PVC
Insulating Cover with an ultraviolet additive.
High temperature systems are for use in ambient
temperatures up to 280°F. They have a Yellow Lexan
Insulating Cover.
From the table to the right, you can select the basic (FE)
conductor assembly with the appropriate bar and
insulating cover for your application.
For information on other conductor assemblies, see page 12.
Basic Figure 8 (FE) Conductor Assemblies
10 ft. Lengths
Conductor Weight
Bar No. Pounds
Assembly Catalog No.
Indoor
Use
Outdoor
Use
High Temp.
Use
FE-758
4.5
FE-758-2
FE-758-2-SC
FE-908
6.5
FE-908-2
FE-908-2-SC
FE-908-2XHT
FE-1608
6.5
FE-1608-2
FE-1608-2-SC
FE-1608-2XHT
FE-2008
6.25
FE-2008-2
FE-2008-2-SC
FE-2008-2XHT
FE-3008-2
FE-3008-2-SC
FE-3008-2XHT
FE-5008-2
FE-5008-2-SC
FE-5008-2XHT
FE-3008
FE-5008
6.75
11.5
FE-758-2XHT
Cross-sectional drawing of
Basic Figure 8 (FE) Conductor Assembly
5
Typical Conductor Mounting
Note:
S
indicates minimum conductor spacing.
Standard Vertical Mounted Conductors
Lateral Mounted Conductors
3-Phase System • Bottom Contact • 5 Ft. Maximum Support Spacing
4 Ft. Maximum Support Spacing.
Use only Lateral (L) Model Collectors.
NOTE: we will supply Standard
Vertical Mount with (4) Conductors
S
S
1-1/2" — Single Collectors – Staggered
3"
— Collectors Adjacent or when
pickup guides are used
Use Metal Hangers Only
on Lateral Systems
Monorail Application
Install two conductors on one side of the beam and one conductor on the opposite
side to balance the collector spring forces, particularly on light weight hoists.
2-1/2"
2-1/2"
1-1/2" — Single Collectors — Staggered
3"
— Collectors Adjacent or when
pickup guides are used
S
1-1/2" — Single Collectors – Staggered
3"
— Collectors Adjacent or when pickup guides are used
Duct-O-Bar Figure 8 (FE) Components
Catalog Number
Weight
Pounds
Description
Angle Brackets for Web Mounting
Brackets are galvanized 12 gage rolled steel
channel. Hangers are priced separately, but will
be factory installed at no charge when hanger
locations are shown on sketch.
6
B-100-BR1A
1.0
Bracket — 11-1/4" long.
B-100-BR7A
1.12
Bracket — 15-3/4" long.
B-100-BR7B
1.18
Bracket with gusset support — 15-3/4" long.
B-100-BR13A
1.5
Bracket — 20-1/4" long.
B-100-BR13B
1.57
Bracket with gusset support — 20-1/4" long.
Catalog Number
Weight
Pounds
Description
Straight Brackets for Top Flange
Mounting
Hole Spacing: 1-1/2 "
Typical Hole Dia.: 7/16"
Capped I-Beam
B-100-BR3A
B-100-BR4A
1.25
1.82
B-100-BR5A
B-100-BR6A
1.32
2.01
B-100-BR9A
B-100-BR10A
1.60
2.19
B-100-BR
B-100-TMC-U
8.0
.31
B-100-BR4A-J
1.75
B-100-BR6A-J
1.94
B-100-BR10A-J
2.12
“J” Bolts: 3/8-16 x 4”
Brackets are galvanized 12 gage rolled steel
channel. Hangers are priced separately, but will
be factory installed at no charge when hanger
locations are shown on sketch.
Bracket — 18" long.
Bracket with two Mounting Clamps and
hardware — 18" long.
Bracket — 21" long.
Bracket with two Mounting Clamps and
hardware — 21" long.
Bracket — 24" long.
Bracket with two Mounting Clamps and
hardware — 24" long.
Channel — 10 feet long.
Universal Mounting Clamps with hardware.
For 5/8" to 1-5/16" thick Beam Flanges.
Capped I-Beam Bracket with hardware.
18" long.
Capped I-Beam Bracket with hardware.
21" long.
Capped I-Beam Bracket with hardware.
24" long.
Hole Spacing: 1-1/2 "
Typical Hole Dia.: 7/16"
Straight Brackets w/ Mounting Plate
for Web Mounting
Mounting Plate Hole Spacing: 3-3/8"
Mounting Bolts: 1/2-13 x 2"
Brackets are primed 12 gage rolled steel
channel with mounting plate and hardware.
Hangers are priced separately, but will be
factory installed at no charge when hanger
locations are shown on sketch.
Bracket — 2 holes — 3-3/4" long.
Bracket — 3 holes — 5-1/4" long.
Bracket — 4 holes — 6-3/4" long.
Bracket — 5 holes — 8-1/4" long.
Bracket — 6 holes — 9-3/4" long.
Bracket — 7 holes — 11-1/4" long.
Bracket — 8 holes — 12-3/4" long.
Bracket — 9 holes — 14-1/4" long.
Bracket — 10 holes — 15-3/4" long.
Bracket — 11 holes — 17-1/4" long.
Bracket — 12 holes — 18-3/4" long.
B-100-BRCT1
B-100-BRCT2
B-100-BRCT3
B-100-BRCT4
B-100-BRCT5
B-100-BRCT6
B-100-BRCT7
B-100-BRCT8
B-100-BRCT9
B-100-BRCT10
B-100-BRCT11
1.2
1.3
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
Typical Hole Dia.: 7/16"
Bolts: 3/8-16 x 1-1/2"
Z-Brackets for Lateral Mounted
Conductors
B-100-BRZ1
1.0
B-100-BRZ2
1.2
B-100-BRZ3
1.64
B-100-BRZ4
1.8
B-100-BRZ5
2.3
Mounting Holes
Hanger Holes
3"
Brackets are red primed 10 gage steel.
Hangers are priced separately, but will be
factory installed at no charge when hanger
locations are shown on sketch.
Z-Bracket — 1-1/2" hanger spacing, 3"
mounting hole spacing. O.A.L. — 4-1/2"
Z-Bracket with hardware — 1-1/2" hanger
spacing, 3" mounting hole spacing.
O.A.L. — 4-1/2"
Z-Bracket — 3" hanger spacing, 6" mounting
hole spacing. O.A.L. — 7-1/2".
Z-Bracket with hardware — 3" hanger spacing,
6" mounting hole spacing. O.A.L. — 7-1/2".
Z-Bracket — 3" hanger spacing, 9" mounting
hole spacing. O.A.L. — 10-1/2".
7
Catalog Number
Weight
Pounds
Description
Threads: 3/8-16
Snap-In Type Hanger Assemblies
FE-908-2PF
FE-908-2PF
FE-908-2PFS
.10
.10
FE-908-2SF
FE-908-2SFE
FE-908-2SFS
.11
.11
.11
FE-908-2SF
These hangers are not recommended for
curves, switches or short runs unless separate
anchors are used. Refer to the Figure 8
Installation Instructions.
Nylon Insulating Hanger.
Nylon Insulating Hanger with Stainless Steel
Hardware.
DO NOT USE nylon hangers in temperatures
higher than 230°F. DO NOT exceed 4 lb. per foot
torque when tightening nut on mounting bolt.
Zinc Plated Steel Hanger.
Epoxy Coated Steel Hanger.
Stainless Steel Hanger with Stainless Steel
Hardware.
Snap-In Type Spring Hanger and
Insulator Assemblies for Outdoor, Wet
and Dirty Applications
Threads: 3/8-16
FE-908-2SFG
FE-908-2SFFG
FE-908-2SFSG
.20
.20
.20
Zinc Plated Steel Hanger with Insulator.
Epoxy Coated Steel Hanger with Insulator.
Stainless Steel Hanger with Insulator and
Stainless Steel Hardware.
Clamp Type Hanger Assemblies for All
Conductor Systems
Threads: 3/8-16
B-100-2FF
B-100-2FFE
.19
.19
B-100-2FFS
.19
Zinc Plated Steel Hanger.
Epoxy Coated Steel Hanger. For special
environments.
Stainless Steel Hanger with Stainless Steel
Hardware. For special environments.
Clamp Type Hanger and Insulator
Assemblies for Outdoor, Wet and Dirty
Applications.
Threads: 3/8-16
B-100-2FG
B-100-2FFG
B-100-2FSG
.30
.30
.30
Zinc Plated Steel Hanger with Insulator.
Epoxy Coated Steel Hanger with Insulator.
Stainless Steel Hanger with Stainless Steel
Hardware.
B-100-2F2
.40
B-100-2F3
.59
FE-908-2PF3
FE-908-2SF3
FE-908-2SF4
FE-908-2SF5
.50
.53
.72
.93
Plastic Triple Hanger Assembly.
Zinc Plated Steel Triple Hanger Assembly.
Zinc Plated Steel Four-Gang Hanger Assembly.
Zinc Plated Steel Five-Gang Hanger Assembly.
B-100-1G
.12
30% Glass-filled Nylon — 400°F rated. Suitable
for chemical or oil-laden atmospheres.
Clamp Type Special Hanger Assemblies
Threads: 3/8-16
Zinc Plated Steel Twin Hanger Assembly.
1-1/2" centers. For indoor applications.
Staggered Collectors.
Zinc Plated Steel Triple Hanger Assembly.
1-1/2" centers. For indoor dry applications only.
Staggered Collectors.
Snap-In Type Special Hanger Assemblies
Threads: 3/8-16
Centers: 1-1/2 "
FE-908-2SF3
Threads: 3/8-16
Mushroom Insulators with Hardware
8
Catalog Number
Weight
Pounds
Description
Power Feeds with Insulating Case
FE-908-2CP
.25
FE-1158-2CP
.26
FE-2008-2CP
.63
FE-3008-2CP
1.10
FE-758-GCTP
.14
FE-908-GCTP
.14
90 Amp Rated — Steel. For FE-758-2 systems.
Will accept up to # 4 AWG cable.
110 Amp Rated — Copper. For FE-908-2
systems. Will accept up to # 2 AWG cable.
250 Amp Rated — Bronze. For FE-1608-2 and
FE-2008-2 systems. Will accept up to # 1/0
AWG cable.
350 Amp Rated — Cast Bronze. For FE-3008-2
systems. Will accept up to # 3/0 cable.
End Power Feeds
40 Amp Rated. For all systems with FE-758
conductor bar.
40 Amp Rated. For all systems with FE-908,
FE-1608, FE-2008, and FE-3008 conductor bar.
Expansion Gap Assemblies
Anchor sets and connector pins are
included with the hardware package.
FE-758-2H10
FE-758-2H10-SC
FE-758-2H10XT
FE-908-2H10
FE-908-2H10-SC
FE-908-2H10XT
FE-1608-2H10
FE-1608-2H10-SC
FE-1608-2H10XT
FE-2008-2H10
FE-2008-2H10-SC
FE-2008-2H10XT
FE-3008-2H10
FE-3008-2H10-SC
FE-3008-2H10XT
FE-5008-2H10
FE-5008-2H10-SC
FE-5008-2H10XT
7.0
7.0
7.0
9.0
9.0
9.0
10.5
10.5
10.5
10.0
10.0
10.0
12.5
12.5
12.5
16.5
16.5
16.5
Each assembly consists of a ten-foot conductor
bar, insulating cover, connector pins for one
end, guide assembly, two power feeds with a
jumper cable and hanger set. Refer to the
Figure 8 Installation Instructions.
For Indoor System FE-758-2.
For Outdoor System FE-758-2-SC.
For High Temperature System FE-758-2XHT.
For Indoor System FE-908-2.
For Outdoor System FE-908-2-SC.
For High Temperature System FE-908-2XHT.
For Indoor System FE-1608-2.
For Outdoor System FE-1608-2-SC.
For High Temperature System FE-1608-2XHT.
For Indoor System FE-2008-2.
For Outdoor System FE-2008-2-SC.
For High Temperature System FE-2008-2XHT.
For Indoor System FE-3008-2.
For Outdoor System FE-3008-2-SC.
For High Temperature System FE-3008-2XHT.
For Indoor System FE-5008-2.
For Outdoor System FE-5008-2-SC.
For High Temperature System FE-5008-2XHT.
Special Application Components
FE-2JNN3
3.75
FE-2JNN4
4.50
Pickup Guide Assembly — 3" wide. Includes
clamps and two foot section of system
conductor. Specify conductor system.
Pickup Guide Assembly — 4" wide. Includes
clamps and two foot section of system
conductor. Specify conductor system.
9
Catalog Number
Weight
Pounds
Description
Special Application Components (cont.)
FE-758-GCT
FE-908-IP
FE-758-GCT
FE-758-GCTL
.08
.08
FE-758-GCTR
.08
FE-908-GCT
.08
FE-908-GCTL
.08
FE-908-GCTR
.08
FE-908-IP
.02
FE-908-IS
.19
B-100-TG
1.81
B-100-TGE
1.81
FE-908-IS
B-100-TG
Maximum O.A.L.: 12-1/4"
Transfer Cap. For FE-758 Bar only.
Transfer Cap. For FE-758 Bar only. Cut at 45°
for left hand curves.
Transfer Cap. For FE-758 Bar only. Cut at 45°
for right hand curves.
Transfer Cap. For FE-908, FE-1608, FE-2008,
and FE-3008 Bar.
Transfer Cap. For FE-908, FE-1608, FE-2008,
and FE-3008 Bar. Cut at 45° for left hand curves.
Transfer Cap. For FE-908, FE-1608, FE-2008,
and FE-3008 Bar. Cut at 45° for right hand
curves.
Isolating Piece — 1" long. For all bars except
FE-758 and FE-5008.
Isolating Piece — 8" long. For all bars except
FE-758 and FE-5008.
Steel Transfer Guide Assembly. For use with
isolating pieces.
Epoxy Coated Transfer Guide Assembly. For
use with isolating pieces.
C-Series Collector Assemblies
C-40-V3
C-40-L3
1.5
2.75
C-100-V5
1.80
C-100-L5
3.13
FC-TB1
3.25
C-100-V5
C-Series Collectors are used on short
continuous run systems. They feature steel pivot
points for good tracking capability.
40 Amp Collector — single shoe. Vertical mount.
40 Amp Collector — single shoe. Lateral mount
with steel counter weight. O.A.L. — 15"
100 Amp Collector — single shoe. Vertical
mount.
100 Amp Collector — single shoe. Lateral
mount with steel counter weights. O.A.L. — 16"
Collector Mounting Post
Bolts: 3/8 - 16 x 1-1/2"
Mounting Post with Hardware — 18" long.
Mounting plate is 4" square with 3" hole spacing
for C-Series and P-Series Collectors. (Contact
factory for special lengths or finishes.)
P-Series Collector Assemblies
Maximum O.A.L.: 15-1/4"
P-40-V3
P-40-L3
P-40-S3
P-100-V5
P-100-L5
P-100-S5
P-100-V5
10
2.19
2.50
2.25
2.44
2.55
2.60
P-Series Collectors are used on straight and
curved runs and transfers. The pantograph
design provides virtually constant spring
pressure for the entire stroke range. Lateral
Mount Collectors are provided with spring
balance. Conductor Bars must be spaced at
least 3 inches apart. To order bronze collectors
with stainless steel hardware, add “BR” to the
catalog number. Call factory for prices.
40 Amp Collector — single shoe. Vertical mount.
40 Amp Collector — single shoe. Lateral mount.
40 Amp Collector — single shoe. Self-centering.
100 Amp Collector — single shoe. Vertical mount.
100 Amp Collector — single shoe. Lateral mount.
100 Amp Collector — single shoe.
Self-centering.
Catalog Number
Weight
Pounds
Description
Maximum O.A.L.: 28"
P-Series Collector Assemblies (cont.)
P-80-VT3
4.34
80 Amp Collector — double shoe. Vertical mount.
P-80-LT3
4.35
80 Amp Collector — double shoe. Lateral mount.
P-80-ST3
4.5
80 Amp Collector — double shoe. Self-centering.
P-200-VT5
5.0
200 Amp Collector — double shoe. Vertical
mount.
P-200-LT5
4.63
200 Amp Collector — double shoe. Lateral
mount.
P-200-ST5
4.6
200 Amp Collector — double shoe. Selfcentering.
P-200-VT5
Additional Components
B-100-2L
.03
Spring Cover Clip — Zinc Plated Steel. Used
only to ensure alignment of the cover on laterally
mounted systems. Placed midway between
hangers.
B-100-2FEA
.30
Clamp Hanger Set — 2 pieces. Clamps both
sides of hanger.
FE-1GC
.04
Flexible PVC End Cap. For all Figure 8
conductor bars.
FE-908-A
.02
Nylon Anchor Pin. For drilled anchoring. Two
required at each hanger.
FE-1GC
B-100-2L
FE-2ER-EX
FE-908-1M
FE-908-1M
2.88
Connector Tool. One tool usually ordered for
each new system. Used to pull two sections of
bar together.
FE-908-1MB
.10
Connector Tool Pins — Pair.
FE-2ER-EX
.05
Splice Cover — Standard black. Use this part
number when ordering extra splice covers.
B-100-2FEA
Conductor Bar Cleaning Accessories
Contact the factory for application.
C-100-VCT
1.80
Complete C-Series Collector with cleaning head.
Vertical mount.
P-100-VCT
2.19
Complete P-Series Collector with cleaning head.
Vertical mount.
C-100-2ACT
.50
Cleaning Head only for C-Series or B-Series
Collectors.
P-100-2ACT
.57
Cleaning Head only for P-Series Collector.
B-40-2B3-CI
.17
Cast Iron Cleaning Shoe — 3" long x 1/4" wide.
B-100-2B5-CI
.26
Cast Iron Cleaning Shoe — 5" long x 1/4" wide.
C-100-CT
.14
Cleaning Brush — Stainless Steel.
B-100-TT
.08
Micro Hone — 1/4" x 4".
11
DUCT-O-BAR
Special Application Conductors
All Duct-O-Wire Figure 8 conductor systems can be sized electrically by using the general and
technical information contained in this brochure. For applications with special mechanical or
environmental considerations, refer to the table below for the proper Duct-O-Bar System to use.
Conductor System
Heated
(HFE)
Side Contact
(SFE)
Totally Enclosed
(EFE)
8-Bar
(8-BAR)
V-Bar
(VFE)
Application
or Usage
Price List
Technical or
Installation
Bulletin
To prevent ice build-up
problems such as outdoor
yard cranes or indoor
frozen food storage.
HFE-994
FE-01INST and
HFE Supplement
Monorails and some
underhung units which
require special mounting
hanger brackets to fit the
manufacturer’s tracks.
Not recommended for
outdoor use.
SFE-9911
SFE-97INST
Prevents airborn
contaminants from
collecting on conductor
surfaces.
EFE-9911
EFE-95INST
8-9911
8-95INST
VFE-961
VFE-95INST
When contour cover
shape is specified or
requested.
For V-tracking or side
contact applications
requiring insulated
hangers. Not recommended for outdoor use.
Duct-O-Wire representatives and distributors are located throughout the U.S.
and Canada. Call the factory for the representative or distributor closest to you.
Brochure FE-01
Replaces FE-98
© 2001 (DW-24)
Printed in U.S.A.
Section 14630
BRIDGE CRANES
PART 1 - GENERAL
1.1
THE REQUIREMENT
A. The CONTRACTOR shall furnish and install an electrically operated bridge crane
system complete, in accordance with the requirements of the Contract Documents. The
bridge crane shall be of the low headroom type, equipped for electric lift and travel in both
directions and it shall be mounted on standard I-beams, or specially fabricated sections.
1.2
RELATED WORK SPECIFIED ELSEWHERE
A. The requirements of the following Sections and divisions apply to the Work of this
section. Other Sections and divisions of the Specifications, not referenced below, shall
also apply to the extent required for proper performance of this Work.
1. Division 01, Additional General Requirements
2. Section 14600, Hoists and Cranes, General
1.3
REFERENCE SPECIFICATIONS, CODES, AND STANDARDS
A. All Work specified herein shall conform to or exceed the applicable requirements of
the referenced portions of the following publications to the extent that the provisions
thereof are not in conflict with other provisions of these Specifications.
B. Comply with the applicable editions of the following codes, regulations and
standards.
1. Industry Standards:
AISC
Specifications for the Design, Fabrication, and
Erection of Structural Steel for Buildings
ANSI/ASME B30.11
Overhead and Underhung Cranes - Safety
Standard for Cableways, Cranes, Derricks,
Hoists, Hooks, Jacks, and Slings
ANSI/ASME B30.16
Overhead Hoists (Underhung) - Safety Standard
for Cableways, Cranes, Derricks, Hoists, Hooks,
Jacks, and Slings
ASTM A 36
Standard Specification for Carbon Structural
Steel
2. Other Standards:
AGMA
American Gear Manufacturers Association
AISC
American Institute of Steel Construction
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
CONFORMED
BRIDGE CRANES
14630-1
ASME
American Society of Mechanical Engineers
CMAA
Crane Manufacturers Association of America
NEMA
National Electrical Manufacturers Association
UL
Underwriters Laboratories
C. Comply with the applicable reference Specifications as directed in the General
Requirements and Additional General Requirements.
1.4
CONTRACTOR SUBMITTALS
A. Submittals shall be made in accordance with the General Requirements, Additional
General Requirements and as specified herein.
1.5
QUALITY ASSURANCE
A. General:
1. Comply with the requirements specified herein and the applicable reference
Specifications of the General Requirements and Additional General Requirements.
2. Comply with the requirements of Section 14600, Hoists and Cranes, General.
PART 2 - PRODUCTS
2.1
GENERAL
A. Requirement: The bridge crane system shall be controlled from a pendant
pushbutton station and be furnished complete with all required safety devices and
overload protection. The power supply shall be from enclosed, UL-approved conductor
bar systems. The rails shall be standard I-beams, or specially fabricated steel sections,
firmly anchored to the structure, as shown. The track deflection shall not exceed 1/800 of
the span, or 1-1/4 inches, whichever is less. The completed crane system, except the
tracks, shall be the product of one crane manufacturer regularly engaged in the
manufacture of such equipment as indicated in Section 14600, Hoists and Cranes,
General.
B. Site Conditions:
Equipment No.:
15LCRN017
Location:
Thickening and Dewatering Facility
Atmosphere:
Indoors
C. Design Criteria: The bridge crane system shall have the following capacities and
dimensions:
Equipment No.:
15LCRN017
Type of Crane:
Top Running
Type of Bridge:
Double Girder
BRIDGE CRANES
14630-2
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
CONFORMED
2.2
Capacity (tons):
20-Ton
Maximum lift (feet):
35 feet
Length of track (feet):
250 feet
Length of bridge (feet):
102 feet
Span between tracks (feet):
100 feet
Speed Control:
Multiple Speed
Lifting Speed (fpm):
16/2.6 ft/min 2-Speed
Trolley Speed (fpm):
65 ft/min Stepless
Bridge Speed (fpm):
100 ft/min Stepless
Hoist Motor (hp):
25
Trolley Motor (hp):
2-1
Bridge Motor (hp):
2-3
Power Supply:
480 V, 3-phase, 60 Hz
FABRICATION
A. Hook and Wire Rope: The lifting hook shall be of drop-forged, heat-treated steel with
a 360-degree swivel on a shielded roller-thrust bearing with safety spring latch. The wire
ropes shall be improved plow steel with steel center complete with swaged fittings.
B. Hoist and Drive: The hoisting drum shall be a large diameter, deep grooved and
flanged drum with at least two full turns of rope to remain on the drum at the lowest hook
position, with heavy-duty, pre-lubricated sealed bearings. The drum shall be driven by a
helical gear reducer with external spur drum gear enclosed in an oil-tight housing. The
housing motor shall be a standard, 30-minute-duty-cycle motor, 1,750 rpm, with suitable
NEMA type shaft extension. The hoisting mechanism shall be provided with dc magnetactuated disc motor brake with hook drift. The motor shall be rated with minimum of 150
percent of full load torque, with gravity type upper and lower hook limit switch, and an
overload cut off switch to interrupt the raising circuit.
C. Trolley Assembly: The trolley assembly shall be a top-running type, as specified,
framed by a structural shape welded into a stable assembly for proper wheel and bearing
alignment. The trolley assembly shall be supported by trolley wheels of tread surfaces
hardened to 375 to 425 Brinell. The tread shall be tapered to provide suitable running
alignment for trolley. Each wheel shall be supported on tapered roller bearings suitable
to take radial and thrust loads. The wheel mounting shall be designed so that axles and
wheels can be removed without disturbing other truck elements of their alignment. The
wheel tread shall be smooth, true, and uniform within 0.010 inch tread diameter on all
wheels.
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
CONFORMED
BRIDGE CRANES
14630-3
D. The trolley shall be driven by a 30-minute-duty-cycle rated motor, through an oil-tight
gear reducer conforming to NEMA Specifications. The motor shall be provided with
cushion start and controller for smooth travel and load control. The driver shall provide
synchronous drive from gear reducer to both drive wheels. The trolley drive shall be
provided with integrally mounted spring set and an electrically released drag brake.
E. Crane Bridge Assembly: The crane bridge assembly shall be a single beam
overriding or top-running double beam, electrically driven, center-drive type. The bridge
beam shall be designed in accordance with the latest Specifications of the Crane
Manufacturers Association of America. It shall be fabricated of standard structural shape
per AISC Specifications. At full load, the beam shall be designed to limit the deflection to
1/600 of the span, but not to exceed 1-1/4-inch maximum deflection. An ASCE rail shall
be provided on top of the beam securely fastened in place to maintain center distance.
Provision shall be made to prevent creeping of bridge rails by means of positive stops at
the ends of the rails. Crane shall be reinforced with outrigger to provide squareness with
end truck, adequate lateral stiffness with a minimum lateral moment of inertia of 1/20 that
of the vertical beam moment of inertia. Outrigger shall furnish support for squaring shaft
and the crane drive motor and gear reducer assembly.
F. End Trucks: The end trucks shall be traversed by stable assembly of structural
shapes welded together to provide proper wheel and bearing alignment. The end truck
wheel base shall be a minimum of 1/7 of the crane span. One wheel of each end truck
shall be geared and meshed with the pinion mounted on the crane squaring shaft. The
crane and trucks shall contain diaphragm members welded to truck frames to maintain
alignment and distribute truck loads on inner and outer truck members. The truck shall
be designed so that, in case of a wheel axle or wheel failure, the drop of the load will be
limited to 1 inch. The end trucks shall be fastened to the bridge beams with bolts to
ensure alignment in assembly.
See Remarks
on Submittal
Cover Sheet
G. Crane Wheels: Crane wheels shall have tread surfaces hardened to 375 to
425 Brinell. Treads shall be tapered to provide suitable running alignment for crane.
Each wheel shall be supported on tapered roller bearings mounted on stationary axles,
suitable to take radial and thrust loads. The wheels shall be lubricated at the factory with
a sodium base grease, and provided with a suitable reservoir of lubricant to eliminate the
need for field lubrication. Wheel axles shall have mounting nuts for bearing adjustment.
Wheel mounting shall be designed so that axles and wheels can be removed without
disturbing other truck elements of their alignment. Wheel treads shall be smooth, true,
and uniform within 0.01-inch tread diameter on all wheels.
H. Crane Drive: The crane drive motor shall be totally enclosed, 30-minute cycle rated.
The motor shall be integral with a fully enclosed oil splash lubricated gear reduction. The
motor, the drive shaft, and the gear reduction shafts shall be supported by permanently
lubricated precision ball or roller bearings. The drive shaft shall provide synchronous
drive from the gear reduction to both end trucks. The crane drive shall include integrally
mounted spring set electrically released dc rectified disc brake.
I. Drive Shaft: The drive shaft of the crane shall be supported on lubricated, precision,
ball-bearing pillow blocks based on 10-foot maximum centers. These pillow blocks shall
be lubricated through pressure grease fittings. The crane drive shaft shall be steel and
designed to limit torsional shaft stress to 6,000 pounds per inch. Maximum torsional twist
angle in the drive shaft shall not exceed one degree of the wheel rotation under
maximum rated load, regardless of load location.
J. Bearing Life: All bearings in the crane wheels, those supporting the drive shafts, and
the gear reduction shafts, shall be designed for 5,000 hours B-10 bearing life minimum.
BRIDGE CRANES
14630-4
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
CONFORMED
K. Gearing: All gears shall be cut from solid blanks with 20-degree pressure angle
involute shape for high strength and shall comply with AGMA Specifications for load
ratings. All gears operating at higher than 20 fpm pitch line speed shall be fully enclosed
in oil-tight housings and lubricated by splash principle. All gear teeth shall have ductile
cores and be surface hardened to RC40 minimum. The gear shall provide for a minimum
service of 4,000 hours, compounded for intermittent operations corresponding to 5 years
minimum industrial use.
L. Bridge Stops: The bridge shall be provided with bumpers capable of stopping the
crane (not including the lifted load) at a rate of deceleration not to exceed 3 fps when
traveling in either direction at 20 percent of rated speed. The bumpers shall have
sufficient energy absorbing capacity to stop the crane when traveling at a speed of at
least 40 percent of the rated load speed. Bridge trucks shall be equipped with sweeps
that extend below the top of the rail and project in front of the crane wheel.
M. Runway Beams and Rails: The runway beams and rails shall be furnished as
specified or shown. The rails shall be an ASCE type securely fastened into the runway
beams. The runway beams shall be designed from an ASTM A 36 structural steel shape
and shall have a maximum deflection not to exceed 1/800 of the span. The beams shall
be equipped with stops on both ends capable of withstanding the impact of the fully
loaded crane at 50 percent of rated speed, and shall be field adjustable. All necessary
column supports or clamps, hanger rods, bolts, and fittings shall be provided.
N. Electrical Controls: Electrical controls shall be single speed or multiple speed as
required in each equipment Specification. Bridge control shall include a mainline
magnetic contactor, manually operated fused mainline disconnect with lockout provisions,
branch circuit fuses, reversing bridge control, and transformer with fused secondary.
Bridge control shall be mounted on bridge in NEMA 12 enclosure actuated from a
pendant pushbutton station suspended from movable trolley hoist 4 feet above operating
floor. Motors shall be provided with cushion start.
O. Conductor and Wiring: The runway shall be provided with enclosed conductor base
electrification adequately supported. The bridge shall have a rigid truck festoon type
electrification. All other wiring of the crane shall be in rigid or flexible conduit and in
accordance with National Electrical Code and complying with Fire Underwriters
specifications. When a crane is shipped knocked down, the wiring shall terminate in
approved terminal boxes and the wire end shall be provided with permanent marking
tags.
2.3
PAINTING
A. The entire crane assembly shall be shop coated in accordance with the Section
09800, Protective Coating.
PART 3 - EXECUTION
3.1
INSTALLATION
A. All bridge crane equipment shall be installed in strict conformance with the
manufacturer's published or written instructions. Cranes shall be factory assembled and
given a no-load test. All major components of the system shall be marked at the factory
to assure prompt and correct field identification.
B. After completion of the Work, the CONTRACTOR shall test all hoist and crane
equipment in the presence of the manufacturer's field representative, who shall certify, in
writing, that the equipment meets all applicable Standards and Specifications.
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
CONFORMED
BRIDGE CRANES
14630-5
3.2
MANUFACTURER’S FIELD SERVICES
A. Comply with the requirements of Specification section 14600, Hoists and Cranes,
General.
B. Comply with the requirements of Specification section 01820, Training of OCSD
Personnel.
******
BRIDGE CRANES
14630-6
Sludge Dewatering and Odor Control at Plant 1
Project No. P1-101
CONFORMED