Automated Rigging System Performance Specifications

Automated Rigging System Performance Specifications 1.00 GENERAL 1.01 SCOPE A. This section describes an automated rigging system, which includes motorized hoists, control hardware/software, networking and automatic safety systems. A qualified specialist contractor, trained and authorized by the system manufacture shall install, test and configure this system. The specialist contractor shall also provide owner training in system usage and mandatory safety procedures. B. Related work not included in this section: 1. Any structural steel required to support the rigging system. Also, any catwalks, ladders or miscellaneous metals required to provide appropriate access to system components. 2. Conduit, wire, distribution panels, terminations and other electrical work required to install the rigging system. 3. Lighting control equipment, electrical distribution and fixtures. 4. Loud speakers, video displays, amplifiers and other audio/visual equipment. 5. Orchestra shells and portable staging. 6. Stage drapery and track. 1.02 BIDDER QUALIFICATION & SUBMISSIONS A. Specified equipment performance is based on the products of J.R. Clancy Inc. (Syracuse NY, USA). Where substantively equal manufacturers and products have been identified and approved, they are listed within this document by name. B. Bidder requests for approval that include products from other manufacturers are welcome. To be considered, all requests must: 1. Be complete and submitted in writing, no less than 10 days prior to bid opening. 2. Include a complete Bill of Materials, prepared by the equipment manufacturer. 3. Include an engineered electrical riser diagram 4. Include a published manufacturer s warranty statement 5. Include a specific listing of any exceptions/deviations taken from the equipment specified. C. A complete submission of project specific engineering drawings shall be required and approved before equipment fabrication or installation may proceed. The submission shall be supported by appropriate cut sheets, schedules, operation guides and other materials required to document the form, function, fabrication, installation and use of all system components. 1.03 SYSTEM SAFETY AND WARRANTY A. The manufacturer of the motorized rigging system shall provide a three year warranty against defects in materials or workmanship that goes into effect on the date of system installation. The three-year warranty is contingent on inspection of the equipment and training on its use being provided annually by a factory authorized technician. It is the responsibility of the end user to make arrangements with factory for the annual inspection ST10 / PowerLift Specification Pg. 1

2.00 PRODUCTS and training. Failure to obtain the inspection and training annually will void the three-year warranty. The warranty will not cover equipment that has become defective due to misuse, abuse, accident, act of God, alteration, vandalism, ordinary wear and tear, improper maintenance, or used not in a manner intended. 2.01 APPROVED MANUFACTURERS A. Theatrical rigging systems involve moving loads overhead of people. Specialized engineering and manufacturing expertise are required to mitigate risk. Theatrical rigging manufacturers who do not meet all of the requirements of section 2.01B shall be prohibited from bidding or contracting for this work. Approval to bid does not release the manufacturer from meeting these requirements. B. Automated rigging system provided shall be the products of a single manufacturer who: 1. Engineers all products furnished as an integrated system. Accessory items such as wire rope, fittings, and curtain tracks may be the products of other specialized manufacturers. 2. Has manufactured automated rigging systems for a minimum of ten years and references no less than 25 successful installations of comparable scope and complexity. Proof shall be provided as part of the contract document submittal. 3. Has a quality management system certified to ISO 9001:2008. Provide proof of ISO certification as part of the contract document submittal. 4. Carries primary product and general liability insurance of $2,000,000 each, with excess liability coverage of $10,000,000 and a Contractors Professional Liability policy with $2,000,000 coverage. The theatrical manufacture shall provide proof of these insurances in force before a contract is issued. 5. Control systems shall be Listed by a National Recognized Testing Laboratory (NRTL) as meeting UL 508A Standard for Industrial Control Panels. Hoists shall be Listed by a NRTL as meeting with UL 1340 Standard for Hoists. Proof of listing and compliance shall be provided as part of the contract document submittal. C. Automated rigging hoists, controls and networking equipment shall be manufactured and supported by: J.R. Clancy, Inc 7041 Interstate Island Road Syracuse, New York 13209 www.jrclancy.com 2.02 DESIGN FOR SAFETY AND RELIABILITY A. All hardware and components shall be industrial grade, selected to provide long term reliability in environments where wide temperature variations, dirt and electromagnetic interference must be assumed. Critical components shall be the off-the-shelf products of major manufacturers and obtainable worldwide. This requirement exists to facilitate ongoing maintenance and prevent early system obsolescence. B. Control system hardware shall be based on Siemens Programmable Logic Controllers (PLCs) and sealed industrial grade computers. Home/office computers shall not be acceptable. ST10 / PowerLift Specification Pg. 2

C. Data communication between controllers, motor starters and drives shall be Profibus, an open architecture, bi-directional industrial automation protocol. D. In the case of loss of data communication hoists shall stop for safety. Individual hoist controllers shall retain cue and position data, even without power. Systems that lose data when not powered may require time consuming reprogramming and loss of performances, and are not acceptable. E. "Hold to Run (also known as Deadman") operation shall be required. Systems that allow motion without an operator present at the console and holding down a button or joystick are not acceptable. F. Automatic service indicator lights shall be provided that signal when routine service and inspections of the automated rigging system are required. G. All motorized hoists shall be provided with two redundant safety brakes. The primary motor brake shall be spring applied and electrically released, so it will fail to the brake position. A secondary brake on the load side of the gearbox shall also be provided. It shall automatically trigger when excess speed, positioning mismatches or hardware failures are detected. Use of drag or Weston style motor brake is not acceptable, as these devices generate wear, heat and considerable noise. H. All motorized hoists shall be provided with separate normal and overtravel mechanically activated safety limit switches. Actuation of the normal end of travel limit switches shall only allow movement away from the limit switch. The redundant overtravel limit switches will remove power from the hoist using a UL580E Type 2, non-welding positive break contactor. I. For fire and electrical safety, all motor control systems shall conform to the National Electrical Code (NFPA 70) and be constructed in accordance with UL Standard 508, and be touch safe per IEC 204-1 Protection against direct contact rules. J. Variable speed hoists shall use closed loop vector drives, providing full torque at zero speed. Variable frequency or open loop drives are not acceptable. K. All motorized hoists shall provide electrical over-current, electrical over-load, and electrical phase-loss protection. L. All automated rigging systems shall provide emergency stop (E-Stop) systems: 1. The E-Stop system shall conform to NFPA-79 (Electrical Standards for Industrial Machinery) and shall remove power, thru the use of UL580E Type 2, non-welding, positive break contactors. 2. Resetting the E-Stop circuit shall not initiate motion. 3. All hoists that run faster 50 fpm shall be provided with Category 2 controlled E-stop, as described by NFPA-79. This protocol ramps the hoist to a quick stop to control shock to the load and building structure. 2.03 SURETARGET 10 A. General: The control system shall be specifically designed for the control of theatrical rigging, including operational and reliability needs. The system shall provide easily ST10 / PowerLift Specification Pg. 3

understandable and reliable position control of PowerLift hoists. The controller shall be available in compact wall or rack mounted configurations. B. Operation: 1. A 6" color, industrial touch screen display will provide clear, easy to understand graphics for simplicity of operation. Movements will be set up using the touch screen. UP, DOWN, GO TARGET pushbuttons and a joystick are provided for initiation and control of movements. 2. Operation styles available shall range from direct position control using UP and DOWN buttons to composing presets with hoist speed, acceleration, deceleration, and target positions. Presets can be composed, stored, modified, and recalled to allow simple recording and re-creation of movements. 3. The SceneControl graphic user interface shall provide a hoist controller; preset creation and editing facilities; and a display of the current position and target position of each hoist. A complete display of hoist status and faults shall be provided for ease of troubleshooting and maintenance. 4. Actual pushbuttons and a joystick shall be provided for initiation and control of motion. For safety, no movement will be initiated from the touch screen. "Deadman" operation is required, so that the operator must be at the console and pressing a button for motion to continue. 5. The system shall include password-protected access, with separate levels for user, supervisor, and setup functions. 6. A mushroom head "EMERGENCY STOP" button wired to a failsafe circuit that conforms to NPFA 79 requirements shall be provided. 7. An "ON/OFF" key operated switch shall be provided that removes power to the console, motor starters and drives. Any control system that requires motors and drives energized while the system is not in use is not acceptable. 8. In systems with the load monitoring option, the SceneControl shall monitor the loads on PowerLift hoists, first learning the characteristics of a new load, then monitoring each move for changes in the load. Load information shall be obtained from solid state load cells on the PowerLift hoists. The load monitoring system shall be able to accommodate changing loads, such as the weight of borderlight cable which changes with elevation, without false tripping. C. Reliability 1. The control system shall use an off the shelf industrial grade Programmable Logic Controller (PLC) selected for long term, reliable operation under the conditions and environment at the site. "Home" or "office" computers are not allowed, as they do not provide the level of reliability necessary for overhead lifting. 2. All hardware components shall be industrial grade equipment designed for use in a typical theatre environment. These components shall be widely available on an international basis to ensure ease of replacement and maintenance. 3. The system program shall be embedded in ROM (Read Only Memory) to prevent corruption or unauthorized changes. 4. Actual pushbuttons and a joystick shall be provided for initiation and control of motion. Systems that allow motion to be initiated from a touch screen are known to allow unintended movement and are not safe. 5. A Service indicator shall be provided to indicate when routine service and inspection of the rigging system is required. Control systems shall be UL or ETL marked as meeting UL 508A Standard for Industrial control Panels. ST10 / PowerLift Specification Pg. 4

2.04 POWERLIFT AUTOMATED PACKAGED HOIST A. PowerLift - General 1. The PowerLift hoist shall have an integral frame incorporating adjustable mounting clips for fast and simple mounting, horizontally or vertically. 2. The PowerLift hoist shall use a moving drum which minimizes wear of the wire rope lift lines. The drum slides along its axis while rotating and that keeps cable takeoff points consistently aligned. This zero fleet angle design shall be a requirement of this project. 3. Hoists shall be Listed as meeting the UL Standard 1340 for Hoists. 4. UL 1340 compliant hoist covers shall be provided where specified. B. PowerLift - Gearmotor and Redundant Safety Brake Systems 1. The electric motor, primary brake, and gearbox shall be a single quiet and reliable assembly. A continuous shaft shall link the brake, motor armature, and the first stage pinion gear, with no internal couplings. The motor shall be a high-efficiency motor meeting IEC 60034-30. 2. The gear reducer shall employ helical gearing. The gear case shall be constructed of cast iron to protect against shock damage and to minimize transmission of noise. The output shaft shall have triple lip oil seals to prevent gear oil leaks. 3. The integral electro-magnetic primary safety brake shall be spring applied and electrically released. Loss of power shall cause the brake to set automatically. 4. A second redundant safety brake system brake shall be installed between the gearbox output shaft and the drum. This safety device shall apply the brake automatically when over-speed or speed mismatch fault conditions are detected, or when stopped. C. PowerLift - Hoist Drum 1. The hoist drum shall be helically grooved and sized to accept a single cable layer of sufficient length to accommodate rated distance plus three dead wraps per cable. Random wind drum, conical wind drum, and pileup drum designs shall not be considered acceptable. All cause lift lines to wear excessively. Random wind and conical wind drums are specifically disallowed due to their tendency to cross-wind and jam. Both create significant safety hazards. 2. Lift line cables shall be retained by a copper Nicopress stop sleeve. The cable retention system shall allow replacement of lift lines in situ. 3. Preloaded cable chase rollers shall be provided to keep lift lines inside their grooves. 4. The drum shall be molybdenum disulphide filled nylon. D. PowerLift - Sheaves All sheaves shall have a minimum 26:1 D:d ratio, meeting wire rope manufacturer s recommendations. Depth of sheave grooves shall exceed the cable diameter to provide physical protection. Sheaves shall be equipped with a 12 mm diameter machined steel shaft and two sealed, precision ball bearings. Spacers shall positively retain the cable. E. PowerLift - Power & Control Wiring 1. One eight foot long SO power cable terminated by a NEMA connector shall be provided with each hoist. One eight foot long control cable terminated by a locking connector shall also be provided. 2. Matching power and control distribution wireways (or outlet boxes) shall be provided ST10 / PowerLift Specification Pg. 5

3. A maintenance pendant shall be provided for direct hoist control. The pendant shall contain Up/Down pushbuttons, an Overtravel Bypass switch and a key operated On/Off switch. F. Loft Blocks 1. Loft blocks shall have 12-gauge steel (minimum) side plates which fully enclose the sheave. Side plates shall be bolted to the base angles. Base angles shall be a minimum 1-½" x 1-½" x 3/16" angle punched with a universal hole pattern. There shall be a minimum of six ¼ bolts with spacers between the side plates, four of which prevent a cable from escaping the sheave groove. 2. The block and associated mounting hardware shall have a recommended working load of at least 500 lbs, and shall be designed for upright or underhung use. 3. Loft blocks shall be provided with idlers to support ongoing lift lines with an individual groove for each lift line to prevent tangling. The use of ungrooved idler drums is known to cause cable tangling and jams. Ungrooved drums shall not be acceptable. G. Pipe Battens 1. Battens shall have the ability to accept standard lighting fixture clamps, scenery chains, and pipe clamps. 2. All battens shall be constructed of 1-1/2" nominal diameter, schedule 40 black steel pipe. All joints shall be spliced with 18" long sleeves and held by two 3/8" hex bolts and lock nuts on each side of the joint. 3. Each batten end shall be covered with a bright yellow, soft vinyl safety cap that indicates set capacity. 4. Lift line termination at the battens shall fully encompass the batten, and have a manufacturer s recommended working load rating of at least 500 lbs. Acceptable terminations include a 1/4" Grade 63, hardened alloy trim chain with a black finish to eliminate glare, meeting OSHA 1910.184(e)(5) with a forged shackle or a load rated full pipe clamp. 2.05 AUTOMATED RIGGING SYSTEM EQUIPMENT BILL OF MATERIALS A. Provide hoists in the quantities, capacities and speeds listed: Model Speed Capacity Quantity 018-P0220VE 0 20 fpm 2,000 lbs 018-P1212VE 0 120 fpm 1,200 lbs 018-P1220VE 0 120 fpm 2,000 lbs 018-P1812VE 0 180 fpm 1,200 lbs B. Provide control system components as listed: Model Description Accept 050-ST10 SureTarget 10 - wall mount console 050-ST10P Sure Target 10 Pendant controller 018-PLLOAD Load monitoring option ST10 / PowerLift Specification Pg. 6

C. Provide battens, loft blocks and other related equipment as shown on the drawings and as required to produce a complete working system. 3.0 INSTALLATION 3.01 EQUIPMENT INSTALLATION A. Equipment installation and commissioning shall be performed by manufacturer authorized and trained specialty contractors. Installation shall be performed in a workman like manner. B. All blocks, rollers and guides shall be installed in a manner which provides proper alignment, specified fleet angles and prevents contact with other surfaces. C. Control system turn-on, and user instruction shall be performed by a factory authorized and trained technician. All wiring must be complete, limits switches set and all other predecessor activities required by the manufacturer completed before system turn on. D. Installation practices shall be in accordance with all local codes. All welding must be performed in full compliance with the latest edition of the Structural Welding Code (ANSI/AWS D1.1). 3.02 SYSTEM INSPECTION AND TESTING A. During system installation, the specialty contractor shall make his work available and accessible for regular inspection by owner representatives. B. When rough installation is completed, the specialty contractor shall conduct a complete pre-test of all components to ensure the system is safe and working properly. The specialty contractor must demonstrate that all normal and over travel limit switches have been correctly set and tested. C. Once finish installation is completed, the specialty contractor shall notify the specifier and a system inspection will be scheduled. As part of the inspection, the specialty contractor will operate all equipment and to perform such adjustments and tests as the specifier may require. Any equipment that fails inspection shall be repaired or replaced and a reinspection will be scheduled. D. Each hoist shall be tested dynamically at 100% of its load rating. Each of the two brakes on every hoist shall be tested individually with a static load of 125% the hoists capacity for 5 minutes. 3.03 OWNER SAFETY AND USAGE INSTRUCTION A. The specialty contractor shall submit three copies of a manufacturer supplied Operations and Maintenance Manual which includes as built shop drawings, equipment descriptions, and parts lists. B. The specialty contractor shall also provide safety and usage instruction classes as the owner may require. The safety and usage classes shall be recorded and DVD copies provided to the owner. ST10 / PowerLift Specification Pg. 7

C. Appropriate permanent signage which provides operating instructions and warning information shall be posted within the venue. Signage shall be in conformance with ANSI- Z535. 3.04 FOLLOW-UP SAFETY INSPECTION A. One year after the project is completed, the specialty contractor shall return to the venue and provide the following services: 1. Inspect the system as required. 2. Make all required adjustments. 3. Correct all warranty repair items and provide a written report to owner and system manufacturer. 4. List any non-warranty changes recommended. Provide a written report to system manufacturer. 5. Conduct a one hour rigging safety and operations refresher class. 6. Schedule the next year s maintenance and safety check. ST10 / PowerLift Specification Pg. 8