5:14A-7.21 Electrical requirements

(a) Scope:

1. This section provides guidelines for the electrical components, their installation and procedures, used in amusement rides or devices. This general section includes all electrical components from the point of electrical power connection through the amusement ride or device.

2. The National Electrical Code (NEC, NFPA 70-2002), NFPA 79 1997, and UL508A are the basis for the design and manufacture of electrical systems and components in these requirements, except as modified by these rules. This section provides supplemental requirements to these codes and standards to improve the level of electrical design for amusement rides and devices. Other equivalent standards or alternate methods may be used.

i. In Subsection 525.21(A) of the National Electrical Code, Rides, Tents and Concessions, Disconnecting Means, the phrase "Where accessible to unqualified persons" shall be deleted.

3. This subchapter does not cover the following:

i. Electrical systems or components prior to the connection point of the electrical lead wires to the source of power for the amusement ride or device; or
ii. A building, structure, or facility that is not defined as an amusement ride or device.

4. Section arrangement: This section is divided into subsections which follow the general layout of NFPA 70, National Electrical Code (NEC) See Table 7.21 below.

i. In this section, subsections (a) through (d) apply generally to all amusement rides and devices; subsections (e) through (l) are for special types of equipment, occupancy or conditions, which may modify subsections (a) through (d).

TABLE 7.21

5. Compliance: All existing equipment that undergoes a major rewire must be comply with this section. Major rewire is defined as replacement of one-third or more of the electrical wiring and/or components.

6. Documentation requirements for all rides and devices:

i. Signage Requirements: There shall be a plaque, permanently mounted on main electrical panel that contains, as a minimum, the following information:

(1) The main supply voltage – power;
(2) The main supply voltage – lighting;
(3) The total power load amperage;
(4) The total motor load amperage;
(5) The total lighting load amperage;
(6) The number of electrical power phases;
(7) The number of lighting power phases;
(8) The electrical power frequency;
(9) The year version of NEC used for design;
(10) The year version of ASTM 1159 used in design;
(11) The date of electrical system manufacture; and
(12) The name of the responsible engineer or designer.

ii. All amusement rides and devices shall have a complete set of electrical schematics and diagrams available.
iii. All electrical outlets operating at more than 120 volts to the ground shall be clearly marked to indicate their voltage.

(b) General requirements for electrical installations:

1. Wiring and protection:

i. Branch Circuits Required: An individual 125 volt 20-ampere branch circuit with at least one GFCI protected receptacle outlet shall be provided on each ride for use as a service or utility outlet.

2. Disconnects:

i. Multiple disconnecting means shall be grouped and shall be labeled, as appropriate, at the disconnecting location.
ii. Rides or devices with other voltage sources (that is, central battery systems, etc.) shall have a disconnecting means with an approved means of lockout/tag-out. This disconnect shall either be located immediately adjacent to the primary main disconnect or the primary main disconnect(s) shall be labeled to show the location of this disconnect.

3. Grounding:

i. All stepping and control transformer secondaries shall be grounded;
ii. All enclosures, switchboards and panel boards shall have an approved grounding bar installed; and
iii. No overcurrent protection device shall be installed in neutral or grounding conductors.

(c) Wiring methods and materials:

1. Wiring systems shall be protected against damage from unique conditions inherent on amusement rides and devices.

2. All electrical enclosures used for a portable ride or device shall be rated minimum “NEMA 3R,” equivalent, or better as necessary to address environmental conditions.

3. Exposed switches shall be protected against damage from unique conditions inherent on amusement rides and devices.

4. Wiring systems and methods shall follow the NEC and other accepted electrical industry standards and procedures.

(d) Equipment for general use:

1. Lighting fixtures:

i. Lighting fixtures made onto or from structural components of the ride or device must meet the criteria of the NEC for electrical installation, including cord restraints, outlet boxes, and wiring. Fixtures shall have provisions for the unique conditions inherent on amusement rides and devices.

ii. All fluorescent lighting systems located on a moving component of the ride or device and or within seven feet six inches of a guest shall have a protective covering and a means of tube retention for the light tubes.

iii. Quartz halogen double-ended bulbs:

(1) The bulb shall have a protective shield or film tape over diffuser lens to protect from falling glass;

(2) The bulb may not be mounted only by the yoke or neck on any moving or portable component of the ride or device; and

(3) Light sockets: Due to the nature of decorative lighting flasher systems, the screw shell base of the bulb may be energized except where riders and bystanders may have access to it. When energized bases are used, warning labels shall be used which indicate the need to de-energize the lamps prior to replacement of light bulbs. These labels shall be installed, as a minimum, on the lighting panel and on each extended light fixture or can.

2. Due to fine stranding of portable cable, methods and materials shall be used to ensure that all devices are used within their rating.

3. The motor size shall take into account the number of start cycles per hour and unique ambient operating conditions inherent on amusement rides and devices.

4. All Y to Y connected transformers shall have a common neutral.

5. Power capacitors used in the electrical system shall be labeled or shall have equivalent notification. Appropriate lockout /tag out procedures shall be available.

6. Collector ring/brush assemblies shall be of a type and size to carry 125 percent of rated load for each ring and brush assembly.

i. Provisions shall be made for a grounding ring(s) capable of carrying the largest overcurrent device feeding the slip ring set.

7. Recognized or listed components shall be of the “Industrial Equipment” type (UL508A) and used properly within their restrictions. These include, but are not limited to, terminal blocks, supplementary overcurrent protection, residual current detectors, fans, and relays, both mechanical and solid state.

8. Electrical equipment with temperature and/or humidity requirements shall be installed to insure the equipment manufacturer’s requirements are met.

(e) Special equipment:

1. Metal frames structures, which contain electrical devices but have no metal-to-metal direct bonding path, shall be bonded. A separate equipment-grounding conductor installed between the metal parts shall bond non-current carrying metal parts and main disconnect.

i. Grounding and bonding conductors shall be only of copper material.

2. Wet areas:

i. Three classification of wet areas exist which determine what NEC code is relevant:

(1) Class 1: Guest Immersion – NEC 680II Permanently Installed Pools;
(2) Class 2: Guest Contact – NEC 680V Fountains; and
(3) Class 3: Misting/Splashing/Pooling/Fogging – will be treated as a wet location.

3. Signs and outline lighting:

i. Systems with incandescent lamp holders shall be marked to indicate maximum wattage and voltage of lamps. Markings shall be permanently installed in letters at least one-quarter inch high (6.4 mm) and shall be either visible while re-lamping or shall be near or on the most visible lighting control or branch circuit overcurrent protection panel board.
ii. Metal poles used as supports for lighting and as raceway for wiring shall comply with the following conditions:

(1) Incandescent and fluorescent fixtures on any material shall be grounded with a mechanically affixed ground wire or shall be protected by a residual current device (RCD).

iii. Wiring terminations at the end of lighting circuits shall terminate in an approved insulated irreversible compression connector, or such means that the possibility of contacting any part of the ride or device while the lighting fixture is energized is reduced.

(f) Audio/communication systems:

1. When installed on amusement rides or devices to provide audio notifications announcements for safety, operation, evacuation, and/or maintenance of the ride or device, audio/communication system wiring shall be suitably protected to address the unique operating conditions inherent on amusement rides and devices.

(g) Portable ride assembly/disassembly conditions:

1. Wiring methods with connectors/plugs that are not rated to make/break under load shall be permanently marked at each connecting point or shall have a listed integral disconnect to make/break.

5:14A-7.22 Internal combustion engines

Internal combustion engines for amusement rides shall be of adequate type, design, and capacity to handle the design load.

5:14A-7.23 Chain

(a) Chain and related accessories shall be selected and designed for specified design loads, speed, corrosion, operating environmental and dynamic conditions, and for wear and fatigue.

(b) Chain manufacturer’s specifications shall include dimensions, strength, grade, and nominal breaking strength-working load limit, and shall be included in the maintenance instructions.

(c) The capacity of the chain and related accessories, for example, terminations, adapters, shall be verifiable either by certificates, manufacturer's markings, or testing.

(d) Chains in the primary load path that do not pass around sprockets or wheels shall have a minimum factor of safety of 5.

(e) Chains in the primary load path that pass around sprockets or wheels shall have a minimum factor of safety of 6.

(f) The chain factor of safety shall be defined as the ultimate tensile strength of the chain divided by the maximum steady state tension.

(g) A method shall be used to maintain proper chain contact with sprocket teeth and pulleys.

(h) The amusement ride and device manufacturer shall include in the maintenance instructions the method to measure chain wear and the maximum allowable change in pitch length.

(i) Metallic chain guides shall be lined or appropriately protected.

(j) The amusement ride and device manufacturer shall include cleaning and lubrication details in the maintenance instructions.

(k) Chains on lift hills shall be retained in the trough.

5:14A-7.24 Wire rope

(a) Wire rope may be used in systems such as drive, suspension, tension, braking, and counterweight.

(b) Wire rope consists of individual wires that are twisted into strands that form the rope.

(c) Wire rope used in aerial tramways and aerial lifts shall comply with ANSI B77.1, Passenger Ropeways.

(d) Wire rope and wire rope accessories, including terminations, adapters, and clamps, shall be designed for the specified design drive configuration, cycles, load(s), corrosion, dynamics, environment, wear, fatigue, and service conditions.

(e) Wire rope and wire rope accessories in the primary load patch shall have a minimum factor of safety of 6.

(f) The wire rope factor of safety is defined as the ultimate tensile strength of the wire rope divided by the maximum steady state tension.

(g) The capacity of the wire rope and related accessories, for example, terminations, adapters, shall be verifiable either by certificates, manufacturer's markings or testing.

(h) Wire rope systems shall be configured to minimize the forming of kinks or knots on any part of the wire rope system from normal use, and shall be designed to avoid excessive local stressing of individual elements. for example, individual wires or strands within the rope.

(i) Where indicated by the Ride Analysis, wire rope systems in operation should be configured so that operators and patrons are not exposed to hazards in the event that a rope or associated fitting derails and leaves its controlled or intended path.

(j) Where indicated by the Ride Analysis, wire rope systems in operation should be configured so that operators and patrons are not exposed to hazards in the event that a wire rope fails and fractures, unravels, or experiences fatigue.

(k) All splices shall be done according to the rope manufacturer’s wire rope splice specifications.

(l) A method shall be used to maintain proper rope contact with sheaves and pulleys.

(m) For fatigue applications, the minimal sheave to rope diameter (D/d) shall be 30. The sheave diameter is D and the rope diameter is d. When space restraints preclude this ratio, then other mitigating factors, such as more frequent in-service inspections or replacement criteria, shall be in place.

(n) Where determined by the Ride Analysis, sheave inertia shall be considered in the design to minimize scuffing.

(o) When determined by the Ride Analysis, life cycle tests per OIPEEC standards shall be performed to validate rope fatigue and life calculations.

(p) Wire rope guides shall be lined or appropriately protected.

(q) The wire rope manufacturer shall recommend the type and frequency of lubrication and corrosion protection. Ropes that have little or no motion, such as ropes in static tension systems, anchors, and guys, require special consideration for protection against corrosion.

5:14A-7.25 Anti-rollback devices

(a) Anti-rollback devices prevent an amusement attraction from unplanned or undesirable movement in the reverse direction.

(b) Anti-rollback devices are not required if, under any failure of the amusement ride or device, movement in the reverse direction will not result in injury or damage.

(c) Amusement rides or devices where cars or trains travel uphill, by being conveyed on an ascent ramp, for example, roller coaster lift, or being carried uphill by their own momentum or power, shall be provided with safety devices to prevent reverse direction of the car or train. Adequate load ratings must be considered in the design of this equipment pursuant to N.J.A.C. 5:14A-7.6, Loads and strengths. Vehicles that provide their own power and have manual or automatic braking systems are excluded from this requirement.

1. Safety devices include anti-rollback mechanisms or automatically acting brakes that do not depend on temporary stored energy, for example, electrical, hydraulic, pneumatic, etc.

(d) When the primary lift drive device is not configured to be an anti-rollback, no less than two anti-rollback devices are required. Both can be on the vehicle/train, both can be on the track, or one can be on the vehicle/train and one on the track. When a rollback has occurred, at least one anti-rollback device shall be engaged until the rollback has been corrected.

(e) Lift systems, for example, log rides, rapids rides, may have anti-rollback devices on the vehicle/boat, on the side of the track or on the conveyance device.

(f) Individual cars of trains that are not equipped with a secondary safety device to prevent uncontrolled reverse travel, shall be mechanically coupled together and have a secondary safety attachment between cars, for example, safety chain, safety cable, etc.

5:14A-7.26 Machine guards

(a) The manufacturer shall provide machine guards or other appropriate measures to inhibit employees and patrons from undesirable contact with belts, chains, pulleys, gears, drive lines, and similar moving machinery.

(b) When the ride analysis determines that parts, such as u-joint drives, may break free on power transmissions, provisions shall be made to contain the components.

(c) Drive shafts shall be provided with safety containment.

(d) Chain and sprocket guards shall be provided in compliance with ANSI/ASME B15.1, Safety Standards for Mechanical Power Transmission and Conveyors and Related Equipment.

5:14A-7.27 Patron lifting or elevating devices

(a) Hoists:

1. Hoist units associated with lifting or elevating patrons shall be visually inspected based on the amusement ride and device manufacturer's recommended inspection period, but not to exceed one year.

2. Hoist units (rope and chain hoists) shall be equipped with effective brakes or other equivalent devices. Stopping movement shall conform to N.J.A.C. 5:14A-7.20, Safety-related electrical/electronic/programmable electronic control systems.

3. The hoist unit shall be arranged so that the physical connection between the brake and sprocket cannot be interrupted. The brake shall be inseparably attached together in one unit.

4. Guard against over-travel malfunction of the hoist.

5. End limit protection shall be provided. The intent is not to restrict normal travel limits of the amusement ride or device, but the manufacturer is to provide specified maximum limits of travel.

6. If required by the Ride Analysis, overload protection shall be provided.

7. That part of the rope drum that contacts the rope shall be designed such that entanglement, overlay, and kinking shall be prevented by means of grooving, guiding, etc. A minimum of two full turns of rope shall remain on the drum when the attached lifting carriage is operated to its lowest possible position.

8. Hoist drums shall be no less than (D/d) of 30 to 1. D is the diameter of the drum and d is the diameter of the rope.

9. Means shall be provided to minimize variation in tension between all connected ropes or chains where more than one rope or chain is fixed to one common suspension point.

5:14A-7.28 Power screw drives and rack and pinion drives

(a) Power screw drives:

1. Power screw drives associated with lifting or elevating patrons shall be visually inspected based on the amusement ride and device manufacturer's recommended inspection period, but not to exceed one year.

i. Power screws used for amusement rides and devices shall be properly designed or selected for the application.
ii. End limit protection shall be provided. The intent is not to restrict normal travel limits of the amusement ride or device, but the manufacturer is to provide specified maximum limits of travel.

(b) Rack and pinion drives:

1. Rack and pinion drives associated with lifting or elevating patrons shall be visually inspected based on the amusement ride and device manufacture's recommended inspection period, but not to exceed one year.

2. Rack and pinions used for amusement rides and devices shall be properly designed or selected for the application.

3. A rack and pinion should have at least one pinion, one rack, and two backup rollers, which shall act on the same sections of rack as the drive pinion. Driving machines utilizing a two-sided rack, where two drive pinions are located so that they are opposite to each other and act as backup roller, shall be deemed to have met this requirement. (ASME A17.1, Section 1604.1)

4. Racks shall be fitted with devices at both ends to prevent the pinion from traveling beyond its designed maximum limits of travel at either end of the rack.

5. The design/configuration of driving pinions shall provide a minimum engagement with the rack of at least two-thirds of the tooth width and one-third of the tooth depth

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