HVAC INSTRUMENTATION AND CONTROL 230900 - 1

SECTION 230900 - HVAC INSTRUMENTATION AND CONTROLS

PART ONE - GENERAL

1.1 SUMMARY

A. This Section includes control equipment for HVAC systems and components.

B. The Main HVAC Control Unit will be installed and Programmed by the contractor. The contractor shall provide and install all other components including end devices and wire to each of the points.

1.2 SUBMITTALS

A. Product Data: For each control device indicated.

1. Submittals shall be marked with Part Number.

B. Shop Drawings:

1. Schematic flow diagrams.

2. Power, signal, and control wiring diagrams.

3. Details of control panel faces.

4. Damper schedule.

5. Valve schedule.

6. DDC System Hardware: Wiring diagrams, schematic floor plans, and schematic control diagrams.

C. Field quality-control test reports.

D. Operation and maintenance data.

E. Warranty

F. Controls Contractor Certification and Qualifications

1.3 QUALITY ASSURANCE

A. System Integrator Qualifications:

1. Subject to qualifications, Owner Approved System Integrator Contractors include the following:

a. J.B. Electric.

b. W. J. O’Neil.

c. ControlNET

2. The HVAC Control System shall be furnished, and installed by Licensed Trade

Technicians. The contractor shall be an Echelon Certified Network Integrator or LonWorks Integrator. The contractor shall employ technicians who have completed

Echelon factory authorized training. The contractor shall employ technicians to provide instruction, routine maintenance, and emergency service within 24 hours upon receipt of request.

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3. The system integrator must be regularly engaged in the service and installation of Lonworks based systems as specified herein, and must have been so for a minimum of three (3) years.

4. The system integrator must be an authorized representative in good standing of the manufacturer of the proposed hardware and software components, and must have been so for a minimum of three (3) years.

5. The system integrator shall have an office that is staffed with designers trained in integrating interoperable systems and technicians fully capable of providing Lonworks instruction and routine emergency maintenance service on all system components.

6. The system integrator shall have in house capabilities to provide control strategies for whole building control. This includes HVAC, lighting, access, and security applications.

7. The system integrator shall have a service facility, staffed with qualified service personnel, capable of providing instructions and routine emergency maintenance service for networked control systems.

8. The system integrator shall Submit a list of no less than three (3) similar projects, which have Lonworks based Building Systems as specified herein installed by the system integrator These projects must be on-line and functional such that the Owners/Users representative can observe the system in full operation.

9. The system integrator must be a certified Lonworks Integrator, or submit resumes with the proposal indicating passing certificates for Echelon Corporation’s approved interoperable, or proof of equivalent training. Such proof must include summary of coursework and indicate both written and laboratory requirements of alternate training.

B. The manufacturer of the hardware and software components must be primarily engaged in the manufacture of Lonworks based systems as specified herein, and must have been so for a minimum of three (3) years.

C. The manufacturer of the hardware and software components as well as its subsidiaries must be a member in good standing of the LonMark Organization.

D. The manufacturer of the hardware and software components shall have an authorized representative capable of providing service and support as referenced in section B above, and must have done so for a minimum of three (3) years.

E. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

1.4 ACCEPTANCE PROCEDURE

A. Upon completion of the installation, Contractor shall start-up the system and perform all necessary calibration and testing to ensure proper operation of the project control systems.

B. Schedule a hardware demonstration and system acceptance test in the presence of the

Contracting Officer and/or the Engineer. The acceptance testing is defined as demonstrating the sequence of operation as indicated in the drawings. The hardware demonstration is specified in this Section. The Contractor shall perform all tests prior to scheduling the acceptance test and hardware demonstration to insure the overall system is ready for inspection and observations.

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C. When the system performance is deemed satisfactory in whole or in part by these observers, the system parts will be accepted for beneficial use and be deemed substantially complete as defined in Division 1.

1.5 WARRANTY

A. The HVAC Control System shall be free from defects in workmanship and material under normal use and service. If within eighteen (18) months from the date of substantial completion, the installed equipment is found to be defective in operation, workmanship or materials, the building systems contractor shall replace, repair or adjust the defect at no cost. Service shall be provided within 4 hours upon notice from Owner’s designated Representative.

B. The warranty shall extend to material that is supplied and installed by the Contractor. Material supplied but not installed by the Contractor shall be covered per the above to the extent of the product only. Installation labor shall be the responsibility of the trade contractor performing the installation.

1.6 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Do not install electronic hardware in the project until non-condensing environmental conditions have been established. Products installed in violation of this request maybe requested to be replaced at no additional cost to the project.

B. Coordinate storage requirements for factory mounted terminal control units on air terminal devices, air handling units or other packaged control equipment. Do not store control units on site in non-conditioned areas for more than two weeks.

C. Factory-Mounted Components: Where control devices specified in this section are indicated to be factory mounted on equipment, arrange for shipping control devices to unit manufacturer.

PART TWO – PRODUCTS

2.1 PRODUCTS GENERAL

A. All products (PROGRAMMABLE CONTROLLER’s, TDCU’s and ID’s) shall contain ANSI

EIA 709.1 LonTalk Protocol networking elements to allow ease of integration of devices from multiple vendors.

B. All materials, equipment and software shall be standard components, regularly manufactured for this and other systems and custom designed for this project. All systems and components shall be thoroughly tested.

C. Control system components shall be new and in conformance with the following applicable standards for products specified:

1. LonMark certified, and LNS Based.

2. ANSI EIA 709.1 LonTalk Protocol

D. Utilize standard PC components for all assemblies. Custom hardware, operating system, and utility software are not acceptable.

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E. All products (PROGRAMMABLE CONTROLLER’s, TDCU’s and ID’s) shall contain ANSI EIA 709.1 LonTalk Protocol networking elements to allow ease of integration of devices from multiple vendors.

F. All materials, equipment and software shall be standard components, regularly manufactured for this and other systems and custom designed for this project. All systems and components shall be thoroughly tested.

2.2 PROGRAMABLE UNIT CONTROLLERS (DDC-#)

A. Basis of Design, subject to requirements provide products indicated on the DRAWINGS or pre-approved equal.

2.3 TRANSFORMER (T-#)

1. Provide with outlet.

2.4 DDC ENCLOSURE (ENC-#)

1. Provide with slotted wire duct and din rails as indicated on DRAWINGS.

2. Coordinate with DMVA Control Technicians for Control Unit Mounting.

2.5 TEMPERATURE SENSORS AND TRANSMITTERS (TEMP#) (OAT-#)

2.6 CO2 SENSOR (CO2-#)

2.7 FREEZESTAT (FR-#)

2.8 VALVE ACTUATORS (ACT-#)

2.9 VAV UNIT CONTROLLER (VAV-#)

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2.10 THERMOWELLS

A. When thermowells are required, the sensor and well shall be supplied as a complete assembly including well head and greenfield fitting.

B. Thermowells shall be pressure rated and constructed in accordance with the system working pressure

C. Thermowells and sensors shall be mounted in a threadolet or 1/2" NPT saddle and allow easy access to the sensor for repair or replacement.

D. Thermowells shall be constructed of the following materials:

1. Chilled and Hot Water; brass.

2.11 CURRENT TRANSFORMERS

A. The current transformers shall be designed to be installed or removed without dismantling the primary bus or cables. The transformer shall be of a split core design.

B. The core and windings shall be completely encased in a UL approved thermoplastic rated 94VA. No metal parts shall be exposed other than the terminals.

C. The current transformers shall meet the following specifications:

1. Frequency Limits: 50 to 400 Hz.

2. Insulation: 0.6 KV Class, 10 KV BIL.

3. Accuracy: 1% at 5.0 to 25.0 VA accuracy class with U.P.F. burden.

4. Provide a disconnect switch for each current transformer.

2.12 ELECTRICAL CONTROL POWER AND LOW VOLTAGE WIRING

A. Provide interlock wiring between supply and exhaust fans, electrical wiring for relays (including power feed) for temperature and pressure indication.

B. Provide power wiring, conduit and connections for low temperature thermostats, high temperature thermostats, alarms, flow switches, actuating devices for temperature, humidity, pressure and flow indication, point resets and user disconnect switches for electric heating, appliances controlled by this Section.

C. Provide all other wiring required for the complete operation of the specified systems.

D. Install all wiring raceway systems complying with the requirements of the National Electrical Code. All installations shall be installed in EMT.

E. Network Communication Requirements

1. Wired network communication shall be via channels consisting of a 22 AWG twisted pair installed in a 3/4 EMT. Echelon approved wire only

2. In all communication conduits, provide one spare twisted pair to be installed, tagged and labeled at each end.

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3. Communication conduits shall not be installed closer than six feet from high power transformers or run parallel within six feet of electrical high power cables. Care shall be taken to route the cable as far from interference generating devices as possible.

4. All shields shall be ground (earth ground) at one point only, to eliminate ground loops.

5. There shall be no power wiring, in excess of 30 VAC rms, run in conduit with communications wiring. In cases where signal wiring is run in conduit with communication wiring, all communication wiring and signal wiring shall be run using separate twisted shielded pairs (22awg) with the shields grounded in accordance with the manufacturer’s wiring practices.

F. Input/Output Control Wiring

1. RTD wiring shall be two-wire or four-wire twisted, shielded, minimum number 18 gauge.

2. Other analog inputs shall be a minimum of number 18 gauge, twisted, shielded.

3. Binary control function wiring shall be a minimum of number 18 gauge.

4. Analog output control functions shall be a minimum of number 18 gauge, twisted, shielded.

5. Binary input wiring shall be a minimum of number 18 gauge.

G. Splices

1. Splices in shielded cables shall consist of terminations and the use of shielded cable couplers, which maintain the integrity of the shielding. Terminations shall be in accessible locations. Cables shall be harnessed with cable ties as specified herein.

H. Conduit and Fittings

1. Conduit for Control Wiring, Control Cable and Transmission Cable: Electrical metallic tubing (EMT) with compression fittings, cold rolled steel, zinc coated or zinc-coated rigid steel with threaded connections, Minimum size ¾”.

2. Outlet Boxes (Dry Location): Sherardized or galvanized drawn steel suited to each application, in general, four inches square or octagon with suitable raised cover.

3. Outlet Boxes (Exposed to Weather): Threaded hub cast aluminum or iron boxes with gasket device plate.

4. Pull and Junction Boxes: Size according to number, size, and position of entering raceway as required by National Electrical Codes. Enclosure type shall be suited to location.

I. Relays

1. Relays other than those associated with digital output cards shall be general purpose, enclosed plug-in type with 8-pin octal plug and protected by a heat and shock resistant duct cover. Number of contacts and operational function shall be as required.

J. Solid State Relays (SSR): Input/output isolation shall be greater than lOE9 ohms with a breakdown voltage of 1500V root mean square or greater at 60 Hz. The contact life shall be 10 x 10 E6 operations or greater. The ambient temperature range of SSRs shall be -20 to +140F.

Input impedance shall not be less than 500 ohms. Relays shall be rated for the application.

Operating and release time shall be for 100 milliseconds or less. Transient suppression shall be provided as an integral part of the relay.

K. Contactors: Contactors shall be of the single coil, electrically operated, mechanically held type. Positive locking shall be obtained without the use of hooks, latches, or semi-permanent magnets. Contractor shall be double-break-silver-to-silver type protected by arcing contacts.

The number of contacts and rating shall be selected for the application. Operating and release

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times shall be 100 milliseconds or less. Contactors shall be equipped with coil transient suppression devices.

2.13 IDENTIFICATION

A. Automatic Control Valve Tags

1. For valves, etc., use metal tags with a 2-inch minimum diameter, fabricated of brass, stainless steel or aluminum. Attach tags with chain of same materials. For lubrication instructions, use linen or heavy-duty shipping tag.

2. Tag valves with identifying number and system. Number valves by floor level, column location and system served.

3. Prepare lists of all tagged valves showing location, floor level, and tag number, use.

Prepare separate lists for each system. Include copies in each maintenance manual. And post in boiler room.

B. Wire Tags

1. All multi-conductor cables in pull boxes, at end devices, controllers and terminal strip cabinets shall be labeled.

2. Provide wire Tags as per Division 16.

C. Conduit Tags

1. Provide tagging or labeling of conduit so that it is always readily observable which conduit was installed or used in implementation of this Work.

D. Miscellaneous Equipment Identification

1. Screwed-on, engraved black lamacoid sheet with white lettering on all control panels and remote processing panels. Lettering sizes subject to approval.

2. Inscription, subject to review and acceptance, indicating equipment, system numbers, functions and switches. For panel interior wiring, input/output modules, local control panel device identification.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Verify that systems are ready to receive work.

B. Beginning of installation means installer accepts existing conditions.

C. The project plans shall be thoroughly examined for control device and equipment locations, and any discrepancies, conflicts, or omissions shall be reported to the Architect/Engineer for resolution before rough-in work is started.

D. The contractor shall inspect the site to verify that equipment is installable as show, and any discrepancies, conflicts, or omissions shall be reported to the Architect/Engineer for resolution before rough-in work is started.

E. The Control System Contractor shall examine the drawings and specifications for other parts of the work, and if head room or space conditions appear inadequate or if any discrepancies occur between the plans and his work and the plans for the work of others, he shall report such

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discrepancies to the Architect/Engineer and shall obtain written instructions for any changes necessary to accommodate his work with the work of others.

3.2 GENERAL INSTALLATION REQUIREMENTS

A. Install all control components in accordance with manufacturer's instructions and recommendations.

B. Mount control panels adjacent to associated equipment on vibration-free walls or freestanding angle iron supports. One cabinet may accommodate more than one system in same equipment room. Provide nameplates for instruments and controls inside cabinet and nameplates on cabinet face.

C. After completion of installation, test and adjust control equipment. Submit data showing setpoints and final adjustments of controls.

D. Install equipment, piping, wiring/conduit parallel to building lines (i.e., horizontal, vertical, and parallel to walls) wherever possible.

E. Provide sufficient slack and flexible connections to allow for vibration of piping and equipment.

F. Verify integrity of all wiring to ensure continuity and freedom from shorts and grounds.

G. All equipment, installation, and wiring shall comply with acceptable industry specifications and standards for performance, reliability, and compatibility and be executed in strict adherence to local codes and standard practices.

H. All communication switches and shelves for equipment will be installed by this contractor.

I. All setup of IP addresses will be completed by DMVA. Leave all web servers at static IP.

3.3 ELECTRICAL SYSTEM INSTALLATION

A. Install all low voltage power and LON and LAN communication trunks in conduit regardless of local building code allowances otherwise.

B. Conceal conduit within finished shafts, ceilings and wall as required. Install exposed conduit parallel with or at right angles to the building walls.

C. Where Class 2 wires are in concealed and accessible locations including ceiling return air plenums, approved cables not in raceway may be used provided that:

1. Circuits meet NEC Class 2 (current-limited) requirements. (Low-voltage power circuits shall be sub-fused when required to meet Class 2 current-limit.)

2. All cables shall be UL listed for application, i.e., cables used in ceiling plenums shall be

UL listed specifically for that purpose.

D. All wire-to-device connections shall be made at a terminal blocks or terminal strip. All wire-to-wire connections shall be at a terminal block, or with a crimped connector. All wiring

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within enclosures shall be neatly bundled and anchored to permit access and prevent restriction to devices and terminals.

E. Plug or cap all unused conduit openings and stub-ups. Do not use caulking compound.

F. Route all conduit to clear beams, plates, footings and structure members. Do not route conduit through column footings or grade beams.

G. Set conduits as follows:

1. Expanding silicone fire stop material sealed watertight where conduit is run between floors and through walls of fireproof shaft.

2. Oakum and lead, sealed watertight penetration through outside foundation walls.

H. Cap open ends of conduits until conductors are installed.

I. Where conduit is attached to vibrating or rotating equipment, flexible metal conduit with a minimum length of 18 inches and maximum length of 36 inches shall be installed and anchored in such a manner that vibration and equipment noise will not be transmitted to the rigid conduit.

J. Where exposed to the elements or in damp or wet locations, waterproof flexible conduit shall be installed. Installation shall be as specified for flexible metal conduit.

K. Provide floor, wall, and ceiling plates for all conduits passing through walls, floors or ceilings.

Use prime coated cast iron, split-ring type plates, except with polished chrome-plated finish in exposed finished spaces.

3.4 TEMPERATURE SENSORS

A. Temperature sensor assemblies shall be readily accessible and adaptable to each type of application in such manner as to allow for quick, easy replacement and servicing without special tools or skills.

B. Strap-on mountings shall not be permitted.

C. Outdoor installations shall be; of weatherproof construction or in appropriate NEMA enclosures. These installations shall be protected from solar radiation and wind effects.

Protective shield shall be stainless steel.

D. Sensors shall be with enclosure where located in finished space.

E. Sensors in ducts shall be mounted in locations to sense the correct temperature of the air only and shall not be located in dead air spaces or positions obstructed by ducts, equipment, and so forth. Locations where installed shall be within the vibration and velocity limit of the sensing element. Ducts shall be securely sealed where elements or connections penetrate ducts to avoid measuring false conditions.

F. All sensors measuring temperatures in pipes larger than 2 inches in diameter or in pressure vessels shall be supplied with wells properly fabricated for the service. Wells shall be noncorrosive to the medium being measured and shall have sufficient physical strength to withstand pressures and velocities to which they are subjected. Wells shall be installed in the

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piping at elbows where piping is smaller than the length of the well to affect proper flow across the entire area of the well.

3.5 ACTUATORS

A. Mount and link control damper actuators per manufacturer's instructions.

B. Valves - Actuators shall be mounted on valves with adapters approved by the actuator manufacturer. Actuators and adapters shall be mounted following manufacturer's recommendations.

3.6 IDENTIFICATION OF HARDWARE AND WIRING

A. All wiring and cabling including that within factory-fabricated panels shall be labeled at each end within 2" of termination with a cable identifier and other descriptive information.

B. Permanently label or code each point of field terminal strips to show the instrument or item served.

C. Identify control panels with minimum 1 inch letters on nameplates.

D. Identify all other control components with permanent labels. Identifiers shall match record documents.

E. Identify room sensors relating to terminal box or valves with nameplates.

3.7 PROGRAMMING

A. Provide sufficient internal memory for the specified control sequences and trend logging.

B. Point Naming: System point names shall be modular in design, allowing easy operator interface without the use of a written point index.

1. DEFINE THE POINT NAMING NOMENCLATURE FOR ABOVE. COORDINATE

WITH OWNER’S OPERATING STAFF.

C. Software Programming

1. Provide programming for the system as per specifications and adhere to the strategy algorithms provided. The HVAC Control System Contractor shall also provide all other system programming necessary for the operation of the system but not specified in this document. Imbed into the control program sufficient comment statements to clearly describe each section of the program. The comment statements reflect the language used in the sequence of operations.

3.8 CLEANING

A. This contractor shall clean up all debris resulting from his or her activities daily. The contractor shall remove all cartons, containers, crates, etc. under his control as soon as their contents have been removed. Waste shall be collected and placed in a location designated by the Construction Manager or General Contractor.

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B. At the completion of work in any area, the Contractor shall clean all of his/her work, equipment, etc., making it free from dirt and debris, etc.

C. At the completion of work, all equipment furnished under this Section shall be checked for paint damage, and any factory-finished paint that has been damaged shall be repaired to match the adjacent areas. Any metal cabinet or enclosure that has been deformed shall be replaced with new material and repainted to match the adjacent areas.

3.9 PROTECTION

A. The Contractor shall protect all work and material from damage by his/her work or workers, and shall be liable for all damage thus caused.

B. The Contractor shall be responsible for his/her work and equipment until finally inspected, tested, and accepted. The Contractor shall protect his/her work against theft or damage, and shall carefully store material and equipment received on-site that is not immediately installed.

The Contractor shall close all open ends of work with temporary covers or plugs during storage and construction to prevent entry of foreign objects.

3.10 FIELD QUALITY CONTROL

A. All work, materials and equipment shall comply with the rules and regulations of applicable local, state, and federal codes and ordinances as identified in Part 1 of this Section.

B. Contractor shall continually monitor the field installation for code compliance and quality of workmanship. All visible piping and/or wiring runs shall be installed parallel to building lines and properly supported.

C. Contractor shall arrange for field inspections by local and/or state authorities having jurisdiction over the work.

3.11 CHECK OUT, START UP AND TESTING

A. The control system shall be properly commissioned prior to acceptance. The Contractor shall coordinate with others (including mechanical, electrical and test and balance) to properly start up and verify the operation of the system. Provide as-built documentation as detailed in Part 1 of this Section.

3.12 ACCEPTANCE

A. The control systems will not be accepted as meeting the requirements of Completion until all tests described in this specification have been performed to the satisfaction of both the Engineer and Owner. Any tests that cannot be performed due to circumstances beyond the control of the Contractor may be exempt from the Completion requirements if stated as such in writing by the Owner's representative. Such tests shall then be performed as part of the warranty.

END OF SECTION 230900

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