260000A-ElectricalBasicRequirements-Testing-20210517.pdf

USDA Forest Service Project Specifications

5/17/2021 Timberline Lodge Boiler Replacement - Construction Set 1/6 Electrical Basic Requirements – Testing 26 00 -00A

SECTION 26 00 00A

ELECTRICAL BASIC REQUIREMENTS - TESTING

1. PART 1 – GENERAL

1.01 ELECTRICAL TESTING

A. This section 26 00 00A amends specification 26 00 00 Electrical Basic Requirements to add this new section 26 00 00A Testing of wiring and systems shown below.

B. This specification is in addition to testing requirements in 26 05 19 LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES, 3.02 Field Quality Control. Both specifications for testing apply and all other sections that require testing. Not all sections that require testing are listed here.

1.02 REFERENCE DOCUMENTS

A. 23 09 00 ‐ Instrumentation and Control Performance Specifications B. 26 00 00 Electrical basic requirements C. 26 09 00 Control and instrumentation D. 26 05 19 Low voltage electrical power conductors and cables E. 26 24 16 Panelboards F. 26 27 26 Wiring devices

2. PART 2 – PRODUCTS

2.01 NOT USED

3. PART 3 - EXECUTION

3.01 ADD THE FOLLOWING TEST REQUIREMENTS IN EXISTING SECTION 26 00 00 3.16

FIELD QUALITY CONTROL

3.16 TESTS (ADD THE FOLLOWING AFTER 26 00 00 3.16 TESTS)

A. General: Perform the tests as described below. Notify the COR in writing five days in advance of all tests in this and other sections of this specification. Perform all tests in the presence of the COR. Upon completion of all tests, submit written test results in duplicate for approval by the COR prior to acceptance.

B. Test Report Forms:

1. Submit a copy for approval of the proposed tabular data sheet to be used for each required test. Type column and heading titles on sheets. Submit data sheets for approval a minimum of 30 days before each test. Divide sheets into columns and rows with appropriate rulings and titles. Enter test data on tabular forms during tests by hand; do not recopy.

2. Furnish data in tabular form listing required test data, name of tested device, location, serial number, type and name of measurement instrument with scale settings.

3. The Government will furnish some test report forms after award in XLSX format, not all items are included, additional forms may be needed.

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C. Preliminary Tests (distribution panels control panels and motor control panels)

1. Install all mechanical and electrical equipment before any preliminary electrical tests are made and final connections are made.

2. Test all control and power conductors including neutrals and isolated grounds for insulation resistance and continuity as described below and in Section 260400 (before connection of conductors to control panels, controlled and pilot devices).

3. Connect all power and control conductors to distribution panels and control panel terminals after all preliminary tests have been done as described above.

D. Insulation Resistance: Test insulation resistance under normal climatic conditions. Conform to the following:

1. Measure resistance between all insulated conductors (including neutral and isolated ground) and ground as well as each other.

2. For circuits with 600 V rated insulation, make insulation resistance measurements on each power distribution and control panel, main feeder and each branch circuit and all control circuits. Make all measurements with loads disconnected and after all wiring is in place. Perform tests with Megohm meter having a minimum 10,000 megohm scale range and apply 1000 VDC. Minimum resistance shall be 200 megohms.

3. For circuits with less than 600 V rated insulation, other than control circuits, conductor insulation resistance as installed shall not be less than 200 megohms to ground. This does not apply to telephone or control cable. Perform tests with Megohm meter and apply DC voltage that does not exceed limit set by cable manufacturer.

E. Insulation Resistance Testing Procedure 600V rated wiring

1. Object of test: Measure the resistance of all insulated conductors to ground and to each other. This includes each power distribution and control panel, main feeder and each branch circuit and all control circuits.

2. Perform testing after all wiring is in place, with loads disconnected. All electronic devices must be disconnected to avoid damage. This includes electronic switches and outlets (GFI's). GFI breakers in branch panels must be removed, with the phase and neutral wires connected to an adjacent breaker for testing.

3. Open the main service switchgear disconnect switch.

4. Close the branch panel main switch and all branch circuit breakers.

5. Connect Megohm meter to phase, neutral, ground and isolated ground busses in the combinations shown in the following table. The neutral and isolated ground must be disconnected from ground at the main service switchgear in order to test the feeders.

6. The following table can be used to record readings:

TEST LOCATION________________________________

A B C N G IG

A n/a

B n/a n/a

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C n/a n/a n/a

N n/a n/a n/a n/a

G n/a n/a n/a n/a n/a

(Minimum of 10 readings w/o isolated ground) (Minimum of 15 readings with isolated ground)

7. Apply voltage to circuit:

a. Wires with 600 V rated insulation: Apply 1000 VDC. A minimum value of 200 megohm is required.

i. Exception. Outlets may arc at less than 1000 VDC. If this happens, reduce the voltage to a lesser value and record the megohm value.

b. Wires with less than 600 V rated insulation: Apply voltage which does not exceed manufacturer's recommendations. A minimum value of 200 megohm is required.

8. If the megohm value is less than 200 megohms, isolate the problem circuit by opening breakers one at a time.

F. Continuity Test (Control Panels Only) Perform at each control panel continuity tests on power and control circuits after connection of external controlled and pilot devices and sensors before connecting to power and control panels. Actuate all pilot devices (float switches, etc.) manually to check proper operation and electrical continuity.

1. Record the value of the loop resistance for each pair of conductors for each continuity test.

3.17 FINAL TESTS

A. Final Test: Start final tests after complete preliminary tests have been made. System performance shall conform to the following criteria. Note any deviations on the test reports with indication of corrective action taken or proposed.

B. Motor and other Load Current: Actual motor and all other equipment load current on each ungrounded conductor at maximum load conditions equal to or less than nameplate rated full load motor current at a service factor of 1.0. For equipment such as duct heaters, furnaces, or any other equipment that is controlled in stages, sequence the controllers for each piece of equipment and record load current in each phase as each stage is energized, and at full load nameplate current. Verify that the staging is proper with load at each stage point. Coordinate with equipment and control supplier to ensure that all equipment safety interlocks, and control actions are proper and equipment is being operated properly.

C. Power Distribution Panels and Motor Control Panels Submit the following information:

1. No load and full load voltage, phase-to-phase, to ground in each panel main feeder at maximum system load conditions.

2. Full load current on each branch circuit or motor circuit in each panel at maximum system load conditions. (Show staged current as described above) Testing is required for all existing and new circuits in existing and new power panels modified to add new circuits.

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3. Full load current on each main supply conductor to each panel and all feeders at maximum system load conditions.

4. Unbalanced neutral current in each panel. The above measurements are for worst case maximum load for each phase.

5. Demonstration of trip action on each GFI breaker by connection of a 15,000 ohm + 5% resistor between the "hot" line and ground on each receptacle connected to GFI breaker.

An outlet ground loop tester may be used for this test.

D. Final Control System Tests (Control Panels for Motor Control, HVAC, BMS, Special purpose systems):

1. Final operational preliminary tests of the control systems will be performed under the supervision of the control systems manufacturer's Field Engineer in the presence of the COR. Supply all labor and material required for testing.

2. Provide two weeks notice to the COR that the control panels are operational with all equipment checked out, before final tests described below:

3. Normal Operation Test: Test each control panel to demonstrate normal operation of the system including all pilot devices and sensors, (level flow, float and pressure switches, all instrumentation and monitoring), level probes, time delays, lights, indicator gages, controllers, etc., for correct operating sequence. All controlled devices (motors, solenoids, unit heaters, VAV boxes, VFD drives, HVAC equipment, etc.) will be connected and operating under normal load for tests. Final adjustment of all operating set points and other adjustments shall be permanently marked by etching a mark on control adjustment device and marking with red paint.

4. Motor test report forms. Perform mototor test and record all motor nameplate data and settings on motor test report forms.

E. Provide complete operational sequence checkout to verify all modes of operation both normal and alarm for each system.

F. Test all control systems that interact with each other as a complete system to demonstrate that all interconnections and interactions are correct and that all interwiring is functional.

G. Calibration of Equipment: Calibrate all equipment requiring calibration such as such as power supplies, instrumentation transmitters, pressure switches, flow switches, pressure gauges, and all sensors. Provide all calibrators and instruments for this calibration. Provide each sensor with the appropriate input over its full operating range to test sensor output, such as, pressure, flow, level, temperature, %RH, etc. to demonstrate the sensors output (4-20 mA) for example is linear and corresponds to the physical variable measured. Provide certified, calibrated test instruments that read these variables measuring the same media as the sensor.

H. Failure and Alarm Tests: Test all safety protection devices and circuits, indicator lights, sonalert, etc., to demonstrate each separate type of failure and proper circuit operation for each condition.

I. Show actual operation of all protective and normal operation sensors. Shorting around or opening of circuits to simulate activation will not be allowed on either normal operation tests above or failure tests.

J. Test each motor thermal overload relay by temporarily inserting a heater element in its overload relay sized to trip within 5 minutes or 67% of the actual measured running current of

5/17/2021 Timberline Lodge Boiler Replacement - Construction Set 5/6 Electrical Basic Requirements – Testing 26 00 -00A each motor or adjusting the solid state overload relay until the motor starter trips.. Control panel manufacturer will supply heater elements for tests.

K. Demonstrate that the motor thermal overload trip, and breaker alarm trip will energize the alarm circuit, de-energize the motor, and perform other required control functions within the time limit specified above or by the overload trip time characteristic curve.

L. Replace the proper thermal overload element in each starter or adjust the solid state overload relay to the correct setting or heater size after each test. Provide the COR the catalog numbers of the overload heaters and manufacturer's tables with trip ratings to verify that the heater elements have been properly sized according to the nameplate current, service factor, and any temperature derating factors.

M. Provide a Motor test report and motor nameplate data in a tabular list of nameplate rated currents, motor service factors, temperature derating multipliers, service factor derating multipliers and measured current for all motors to verify against overload trip ratings. The control panel manufacturer will supply overload heaters or change setting on adjustable overload relays if different ones are required.

N. Test Switch and Control Loop Operation: Use each test switch or current loop to simulate opening, shorting around and automatic operation of all pilot devices. Provide a current, voltage or other simulator to simulate all ranges of sensor inputs to test all controllers and signal loops from 0 - 100% of range for all control and alarm points. Demonstrate the normal operational sequence using the test switches, and all failure conditions which can be simulated with the test switches such as HOA switches on motor conrollers.

O. POLARITY AND GROUND LOOP IMPEDANCE TEST FOR OUTLETS

1. Test all 15 & 20A 120VAC receptacles for ground loop impedance with an electronic tester for the following items:

a. Polarity

b. Voltage drop at 15A

c. GFCI testing

d. AFCI testing

e. Ground loop impedance L-N, H-N L-G. Results shall be less than two ohms.

f. Use an Ideal 61-615 circuit analyzer or approved equal for outlet testing.

g. Use this instrument to test all GFCI trip levels.

P. Test Failure: Failure of any phase of the operation tests shall constitute failure of the system.

Correct failures and retest system. Repeat until the system is operating to required specifications.

Q. Test Reports

1. Submit dated "Electrical System Test Reports" indicating all tests performed and demonstrating conformance with the required system performance criteria in tabular form as described above. Include all voltage, current, and resistance test data of the electrical service, main feeders, panelboards, motor control panels, control system tests and ground systems as applicable. Submit test reports prior to final inspection.

R. Final Corrections:

1. Correct promptly any failure or defects revealed by these tests and reconduct tests on these corrected items. Make any final adjustments for optimum operation of all equipment.

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END OF SPECIFICATION 26 00 00A

b. Wires with less than 600 V rated insulation: Apply voltage which does not exceed manufacturer's recommendations. A minimum value of 200 megohm is required.

8. If the megohm value is less than 200 megohms, isolate the problem circuit by opening breakers one at a time.