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Vortek

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Vortek

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    PART 1 GENERAL

    1.01 GENERAL

    A. Drawings and general provisions of Contract, including General and Supplementary

    Conditions and Division-1 Specification sections, apply to work of this section.

    B. Related work in other Sections.

    1. Division 5: Structural Steel.

    2. Division 15: Mechanical and fire protection work. HVAC & Sprinkler/roof drains.

    3. Division 11065 / 16000: Electrical wire, data cable, raceway, disconnect switches,

    branch circuit protection and all high and low voltage terminations required for the

    automated rigging control system and motors.

    1.02 DESCRIPTION OF WORK:

    A. Extent of automated rigging including hoists and related control equipment as described

    herein and on the contract documents.

    1.03 SUBMITTALS:

    A. Product Data: Submit manufacturer's technical data for each type of product, material

    and device required for the work.

    B. Shop Drawings: Submit detailed drawings for fabrication and installation of rigging,

    hoists and related equipment. Indicate where scope of hoists and electrical work ends

    and Division 11065 / 16000 work begins.

    C. Provide with submittals a list of a minimum 7 completed installations using type of

    automated rigging specified in these specifications.

    D. Provide with submittals a list of five references relating to complete installations

    using type of automated rigging specified in these specifications.

    1.04 QUALITY ASSURANCE:

    A. Coordination of Work: Coordinate layout and installation of automated rigging with

    other adjacent work including structural steel, light fixtures, HVAC equipment, water

    drains and fire-suppression system components.

    B. Environmental Standards: Finish materials shall comply with the following:

    1. Environmental Protection Agency (EPA) requirements for less than 350 grams

    per liter of Volatile Organic Compounds (VOC) for finishes applied to components.

    C. Provide mock-ups (if required) for review at the manufacturer’s fabrication facility or

    provide mock-ups for review in place at the site. (See Mock-ups section in Division 1.)

    1.05 DELIVERY, STORAGE, AND HANDLING:

    A. Deliver work cartoned or crated to provide protection during transit and job storage.

    Provide additional sealed plastic wrapping for all items as required.

    B. Inspect work upon delivery for damage. Minor damages may be repaired provided

    refinished items are equal in all respects to new work and acceptable to Architect;

    otherwise, remove and replace damaged items as directed.

    C. Store all materials at building site under cover. Place components on minimum

    4" high wood blocking. Avoid the use of non-vented plastic or canvas shelters.

    1.06 PROJECT CONDITIONS:

    A. Space Enclosure: Do not install work until space is enclosed and weatherproof,

    wet-work in space is completed and nominally dry, work above is complete, and

    ambient conditions of temperature and humidity will be continuously maintained

    at values near those indicated for final occupancy.

    SL022508-09893 page 1 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    1.07 PROJECT WARRANTY:

    A. Provide written warranty, signed by contractor for the work in this Section.

    1. Warranty period is 1-Year after date of substantial completion of rigging system.

    1.08 SYSTEM CHARACTERISTICS

    A. Machinery: shall consist of a self-contained hoist module using a single motorized

    housing unit for each batten location. Each self-contained unit shall be comprised

    of all electronics, plugs, motors, sensing devices and lift lines.

    B. All wire rope shall have a design safety factor of 10:1 (safety factor depends on load distribution

    on the batten).

    PART 2 - PRODUCTS

    2.01 PRODUCTS

    A. Automated Batten Hoisting Equipment ? S Hoist Module attached horizontally 1. Each batten location shall have a single Vortek

    or vertically to structural steel provided by others. ?2. Vortek S Hoist shall have integral IEC standard totally enclosed fan cooled (TEFC)

    NEMA MGI brake motor with primary brake rated at a minimum of 150% of the motor torque,

    inverter duty AC motor and gearbox meeting AGMA standards with a minimum service factor ?of 1.0, attached to a Vortek mechanical load brake located intermediate ? the drum and the gearbox, and a helically grooved glass filled Nylatrontraveling drum ?fully enveloping 100% of the wire rope diameter. Each Vortek S Hoist Module to contain

    one electro-mechanical reversing contactor fitted with an overload relay of proper size, limit

    switches, electro mechanical load sensing devices (where applicable) and all necessary

    controls, hoist wiring termination points. Each unit to be tested by the manufacturer prior

    to shipment. ?3. Hoist module shall incorporate a mechanical, continuously applied Vortek Load Brake

    which runs in addition to the Motor Brake rated at 150% of the motor torque. Dual braking ? ? action shall be standard on every Vortek S hoist module. The VortekLoad Brake shall be

    located intermediate and directly attached to the reducing gearbox output shaft and the wire ?rope drum. Wire rope drum to load brake ratio shall be 1:1. The Vortek brake shall be

    engaged at all times and automatically adjusts its braking torque based on batten load.

    Braking shall occur instantaneously in the event of motor brake failure, drive system failure,

    drive shaft failure or power failure. Braking shall occur with virtually no impact to the load.

    Any type of over-speed brake which engages randomly, and requires recalibration after a single

    duty, crane brake, “secondary” or other “back-up” braking system in this configuration shall

    not be allowed. ? 4. Winches that do not have a continuously applied VortekLoad Brake attached intermediate

    (between) the drum and gearbox shall not be allowed.

    5. Where required and/or specified, each hoist module shall incorporate overload / underload

    detection. This shall be accomplished through an electro-mechanical device designed

    specifically to sense an overload/underload condition on each batten. The hoist will

    automatically disable itself should an overload/underload condition occur. Motor overload

    relays shall be included in this system for motor overcurrent protection. Thermal overload

    relays shall be used to protect the motor from overheating. All reversing contactors must

    be electrically and mechanically interlocked.

    SL022508-09893 page 2 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    6. Each hoist module shall have safety latching or twist-locking connectors for power and control

    connections. In addition to under and over load detection, each hoist module will also be

    protected by an appropriately sized re-settable short-circuit ground-fault circuit protection

    device located above each drop on the wireway or remotely located in a central distribution ? S models is panel based on model number. The input voltage requirement for all Vortek

    either 208-230 VAC? +/- 5% 50/60Hz or 460-480VAC +/- 5% 50/60 Hz Three Phase. ? 7. The Vortekhoist module shall have two levels of limit switch protection in both the

    up and down direction. Two levels of limit switch protection shall provide single mode failure

    protection, and virtually insure that dangerous, un-expected over-travel will never occur in a ? VortekS hoist module. These levels shall consist of: “Ultimate” ground-out limit switch and

    “Normal” end of travel/position limit switch. Four independent mechanical limit switches ? shall exist on each VortekS Hoist Module.

    At the upper travel limit position, there shall be two independent upper mechanical limit

    switches: One (1) x “Ultimate” ground-out limit switch and one (1) x “Normal”

    end of travel/position limit switch, shall ensure redundant safety from over-travel in the up

    direction. At the lower travel limit position, there shall be two independent

    lower mechanical limit switches: One (1) x “Ultimate” ground-out limit switch and

    one (1) x “Normal” end of travel/position limit switch, shall ensure redundant safety from

    over-travel in the down direction. The mechanical “Ultimate” ground-out limit switch shall

    be a ground-out device which shall immediately stop all movement of

    the hoist module when struck, and provide back up redundancy to the “Normal” end of

    travel/position limit switch. “Ultimate” ground-out limit switches shall provide the second

    and final line of defense against un-wanted over-travel. “Normal” end of travel/position limit

    switch shall be located to prevent mechanical wear or degradation of mechanical parts, and

    shall immediately stop all movement of the hoist module when struck. A qualified installer

    shall set all levels of limit switch protection. ? ?8. All components on VortekS hoist modules, including a glass filled Nylatron wire rope

    drum shall be treated or otherwise designed to avoid oxidation. Untreated or bare steel

    surfaces, which encourage oxidation, shall not be acceptable or incorporated in hoist module. ??9. The Vortek hoist module shall have a single glass filled Nylatron wire rope drum surface. ? Glass filled Nylatronhas been shown to be less abrasive to wire rope than steel by SAE. ?Glass filled Nylatron provides a quieter riding surface for wire rope. Each hoist module ?shall have one wire rope drum which incorporates one Vortek Load Brake located directly ? intermediate the drum and the gearbox. The glass filled Nylatronwire rope drum shall have ?a 1:1 ratio with each continuously applied Vortek Load Brake, and there shall be no

    universal joints, differentials or couplings in line to create fracture points anywhere in the

    drive train. All shafting shall be A.I.S.I. #1045.

    10. Steel wire rope drums shall not be allowed.

    11. Yo-Yo drums are not suitable for this hoisting application. Yo-Yo drums require lifting

    lines to “pile wind” which creates excessive wear, and with increased loads, may deform lifting

    lines. Yo-Yo drum applications may produce unregulated speeds which increase at higher

    elevations from the floor. Inconsistent “average” speeds must typically be calculated

    in a Yo-Yo drum “pile winding” application.

    12. Systems with multiple wire rope drums which do not have a 1:1 ratio with an intermediate load

    brake, or systems incorporating intermediate universal joints, differentials or couplings shall

    not be allowed.

    13. 1 ? “ schedule 40 pipe shall not be allowed for shafting material in this application. 14. Any system that uses 1 ?” schedule 40 pipe as shafting shall not be allowed.

    SL022508-09893 page 3 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    15. Each hoist and loft block shall have quick-attach beam clamps for ease of installation. Clips

    will be spring tension type to ensure continuous holding pressure on the mounting beam. ? S hoist module shall be fully enclosed in a vacuum formed enclosure. 16. The Vortek

    This enclosure shall enclose all moveable parts. This enclosure shall provide an acoustical

    barrier, which will significantly lower audible noise from escaping the enclosure. In addition

    this enclosure will act as a barrier to un-wanted contaminants, which could otherwise become

    fowled in the mechanism or come in contact with hoist module moving parts.

    17. Units, which do not incorporate a complete enclosure for sound dampening and complete

    coverage of all moving parts, shall not be allowed. ??18. Each hoist shall use Vortek loft blocks attached to building structural steel. Vortek loft

    blocks shall be capable of handling single or multiple wire rope applications. Each multiple

    wire rope block shall incorporate an idler block rotating at the same rate as the adjacent drop

    sheave to avoid any unnecessary wear or abrasion to the idler sheave. Independently turning ?idler blocks are not acceptable. Vortek loft blocks shall have cable entry guides to insure

    that the wire rope will not come out of the sheave. The loft block sheave will be injection

    molded from high strength, glass filled nylon with two (2) molded-in, shielded ball bearings.

    The sheave shall be rated for 100-year life within the tread pressure, temperature and moisture

    ranges shall be appropriate to the applicable geographic location.

     ?B. Vortek S Controls

    1. Low Voltage Push Button Control Station (Standard) ? 2. The manual control center for the VortekS Series self-contained rigging system

    shall be wall mountable and contain two momentary control push buttons for direction and

    a hoist enable selector switch for each hoist in the system. Maximum number of motors

    permitted to run simultaneously shall be limited to power availability or customer preference.

    A power on indicator and a keyed system maintained Emergency Stop mushroom head push

    button shall come standard with all control options. The manual control center shall house

    all hardware necessary to control each hoist module in the system independently. 3. Each hoist shall operate in open loop permitting the hoist to travel within its allowable

    trim limits.

    4. Each hoist shall be tested and commissioned at the factory to configure upper and lower soft

    limits as specified. Fine hard limit adjustment shall be done on site by a certified Vortek?

    representative.

    5. Each hoist will be equipped with hard struck over travel limits as well as a redundant ground

    out circuit designed to set the motor brake in the event of a switch failure. 6. Hard struck limit switches shall only be used as the first line of defense to prevent an

    overtravel occurrence. Under normal operation, the hoist will be permitted to travel within

    its hard struck limits. If a hard struck limit is engaged, the hoist must come to

    a complete stop and automatically disable any further movement in that direction.

     ? C. High Voltage Wireway for Hoist Power Distribution (VortekS Series):

    1. Each wireway section is to be delivered pre-engineered and tested per job according to the

    latest approved line set data sheet for that job.

    2. The wireway system will be used to house the power distribution buss that will ultimately ? deliver protected high voltage power points to each Vortekhoist in the system.

    3. The high voltage wireway system shall consist of extruded aluminum wireway, 3.375” x 4.75”

    in cross section, and in lengths of up to 10’ as specified.

    4. Wireway housing shall be fabricated of extruded aluminum alloy #6063-T6, formed into a

    raceway with internal corner gussets for strength and rigidity. Channels shall be extruded

    through the upper and lower ends of each section to allow for easy end-to-end splicing using

    predrilled 1-?” x 6” x 3/16 ” splice bars provided. Cover sections shall be interlocking and

    formed of the same alloy. Housing shall be inherently rustproof.

    SL022508-09893 page 4 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    5. Each wireway section must have an electro statically applied paint finish in Tek Blue ? identification #DC222B-2001, with drop centers identified by 1-?” high die cut Vortek

    numbers on the vertical surface of the wireway cover. Optional steel mounting brackets,

    .25” thick x 1.5” wide shall be provided and suitable for single or double hung wireway

    applications as specified.

    6. Wireway supports must be installed at a distance of no more than 60” on center unless

    otherwise specified. ? 7. Each Vortekpower point must be in modular form and shall be located within 1” on center ? of the corresponding Vortekhoist centerline per the latest approved line set data sheet for

    that job.

    8. The power point module must be integrated into the cover of the wireway and shall not

    exceed 9” in length.

    9. This module must house an appropriately sized, panel mounted, miniature circuit breaker

    (MCB) to be used in conjunction with a NEMA rated twist-locking receptacle or factory

    approved equivalent, mounted flush to the vertical surface of the cover. The MCB shall

    have a time-current trip characteristic of type “K” and must be recognized by the

    Underwriters Laboratories Standard UL1077 for supplementary circuit protectors

    in systems rated for 240/480VAC?.

    10. These power point modules will be fed from a series of power distribution blocks located

    inside of each wireway section. The power distribution blocks used must conform to UL

    Standard 1059 for terminal blocks and shall be UL component recognized. Each power

    distribution block shall be interconnected by 125?C, XLP insulated conductors of proper

    size and quantity to distribute power through the entire wireway system. Terminal blocks

    must be installed at all terminal access points for ease of splicing each section together.

    Terminal blocks shall be molded barrier type with screw terminals properly sized for the

    specific conductor gauge and ampacity.

    11. The entire wireway system must be listed and labeled by Underwriters Laboratories.

     ? D. Low Voltage Wireway for Hoist Control (VortekS Series):

    1. Each wireway section is to be delivered pre-engineered and tested per job according to the

    latest approved line set data sheet for that job. ? 2. The wireway system will be used to house the 24VDC control to each Vortekhoist in the

    system.

    3. The Low voltage wireway system shall consist of extruded aluminum wireway, 3.375” x 4.75”

    in cross section, and in lengths of up to 10’ as specified. Wireway housing shall be fabricated

    of extruded aluminum alloy #6063-T6, formed into a raceway with internal corner gussets for

    strength and rigidity. Channels shall be extruded through the upper and lower ends of each

    section to allow for easy end-to-end splicing using predrilled 1-?” x 6” x 3/16 ” splice bars

    provided. Cover sections shall be interlocking and formed of the same alloy. Housing shall

    be inherently rustproof.

    4. Each wireway section must have an electro statically applied paint finish in Tek Blue ?#DC222B-2001, with drop centers identified by 1-?” high die cut Vortek identification

    numbers on the vertical surface of the wireway cover. Optional steel mounting brackets,

    .25” thick x 1.5” wide shall be provided and suitable for single or double hung wireway

    applications as specified.

    5. Wireway supports must be installed at a distance of no more than 60” on center unless

    otherwise specified. One 6’ pre-terminated pigtail shall distribute the 24VDC control to each ? Vortekhoist in the system. Pigtails must be protected by ?” UL recognized flexible tubing

    suitable for continuous motion, vibration, and exposure to moisture, oil, dirt and dust. All

    tubing ends must be protected and sealed by an approved thermoplastic fitting suitable for

    indoor and outdoor corrosive environments. ? 6. Low voltage connector must be the female 10-pin mate to the Vorteklow voltage connector

    and must be assembled in a die cast zinc, free hanging latching hood for added protection.

    SL022508-09893 page 5 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    Connector must be screw termination with a minimum continuous contact current rating of

    10 amps.

    7. Low voltage conductors should be type THHN of proper size and quantity to distribute

    low voltage power through the entire wireway system. Control cable shall be specified per

    application. Terminal blocks must be installed at all terminal access points for ease of splicing

    each section together. Terminal blocks shall be molded barrier type with screw terminals

    properly sized for the specific conductor gauge and ampacity.

    8. The entire wireway system must be listed and labeled by Underwriters Laboratories.

    2.02 FINISHES

    A. FINISHES

    1. Manufacturer’s standard color.

    2.03 OPTIONS

    A. CABLE MANAGEMENT FOR ELECTRICS

    1. Each wireway section is to be delivered pre-engineered and tested per job according to the

    latest approved wireway specification. ? offers 2. The wireway system will be used to distribute all lighting circuits and control. Vortek

    the following standard electrical options as part of the lighting wireway assembly: 20A RPB

    Connector, 20A GPC Connector, 60A GPC Commector, 20A 120VAC GTL Connector, 20A

    208VAC GTL Commector, Cat5 Cable and RJ45 Connector, Audio Cable and 3 Pin XLR

    Connector and Hardwired Circuits from (1-72) based on model. Any component not

    mentioned above shall be considered available upon request.

    3. The high voltage wireway system shall consist of extruded aluminum wireway, 3.375” x 4.75”

    in cross section, and in lengths of up to 10’ as specified.

    4. Wireway housing shall be fabricated of extruded aluminum alloy #6063-T6, formed into a

    raceway with internal corner gussets for strength and rigidity. Channels shall be extruded

    through the upper and lower ends of each section to allow for easy end-to-end splicing using

    predrilled 1-1/2” x 6” x 3/16” splice bars provided. Cover sections shall be interlocking and

    formed of the same alloy. Housing shall be inherently rustproof.

    5. Each wireway section, must have an electro statically applied paint finish in Tek Blue

    #DC222B-2001, with drop centers identified by 1-1/2” high die cut Vortek identification

    numbers on the vertical surface of the wireway cover. Optional steel mounting brackets, .25”

    thick x 1.5” wide shall be provided and suitable for single or double hung wireway

    applications as specified.

    6. Wireway supports must be installed at a distance of nor more that 60” on center unless

    otherwise specified.

    7. Each lighting power point must be located within ?” on center of the corresponding fixture

    centerline per the latest approved layout detail.

    8. Terminal blocks must be installed at all terminal access points for ease of splicing each section

    together. Terminal blocks shall be molded barrier type with screw terminals properly sized for

    the specific conductor gauge and ampacity.

    9. The entire wireway system must be listed and labeled by Underwriters Laboratories. 10. All terminations shall pass thru the lead end of the wireway with suitable access for

    installation. The cable management system shall consist of self-folding, flat cable securely

    fastened to wire rope guided. Pivoting cable management brackets to prevent abrasion and

    insure a sysmmetrical cable stack.

    SL022508-09893 page 6 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

PART 3 - EXECUTION

    3.01 INSTALLATION

    A. General: Install materials in accordance with manufacturer's printed instructions, and to

    comply with governing regulations and standards applicable to work. ? approved dealer of the appropriate B. Installation shall be accomplished by a Vortek/ Vortek

    dealer level.

Division of Responsibilities Electrical Contractor Stage Rigging Contractor

    Provide Install Provide Install ITEM ? X X Vortek ? X X Vortek Race Way High Voltage ? X X Vortek Race Way Low Voltage ? X X Vortek Loft Blocks ? X X Vortek Lift Lines ? X X Vortek Battens ? X X VortekControl ? X X VortekMotor Control Cabinet ?X X All High Voltage Wire for Vortek System

    X X Power (High Voltage) Terminations

    X X High Voltage Wire Testing and Labeling ?X X Low Voltage Wire for Vortek System ?X X Termination of Vortek System Low Voltage Wire

    X X Control wire Continuity, Testing and Labeling

    X X Labeling Back boxes and Conduit

    X X Junction Boxes

    X X All Conduit, Wireways and Interconnecting Boxes ? X Vortek Motor Control Cabinet set-up

3.02 CLEANING

    A. Clean exposed surfaces of hoists and paint all related mounting surfaces. Comply with

    manufacturer’s instructions for cleaning and touch-up of minor finish damage. Remove and

    replace work, which cannot be successfully cleaned and repaired to permanently eliminate evidence

    of damage.

    3.03 DEMONSTRATION OF THE COMPLETED SYSTEM

    A. Provide the services of the field service representative to demonstrate the system's operation

    to the Theatre Consultant, Owner's representative(s) and Architect.

    B. Notify the Theatre Consultant, Owner and Architect at least one week in advance of the

    demonstration.

    C. Schedule the demonstration at a time convenient for all parties.

    SL022508-09893 page 7 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    3.04 TRAINING

    Provide the services of the field service representative to train the Owner's staff in the

    operation, programming, use and maintenance of the work in this Section.

    A. Schedule the demonstration at a time convenient for all parties.

    PART 4 Base Bid (Delete units as needed to create list of equipment to be in bid)

    Model# 7 Line Travel Load lbs. Speed - ft/min Add Quantities Here

VS2020 62’ 2000 20

    VS2045 62’ 1750 45

Additional Items

Controls

    Low Voltage Push Button Control

    High Voltage Wireways (by division as required) Low Voltage Wireways (by division as required) Additional E-Stop(s)

Cable Management

    Pantograph

Loft Blocks

    Multi-Line Loft Block

    Single-Line Loft Block

    Double Purchase return sheave with dead off hook Double Sheave Loft Block

Battens and Accessories

    Schedule 40 Pipe

    A-14

    A-14 Batten End Caps

    Schedule 40 Pipe End Caps

    SL022508-09893 page 8 VORTEK STANDARD SERIES Rev 004

    SECTION 11065-1

    VORTEK STANDARD SERIES AUTOMATED THEATRICAL RIGGING

    END SECTION 11065

    SL022508-09893 page 9 VORTEK STANDARD SERIES Rev 004

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