13- 230900 sf - instrumentation and control for hvac.pdf

USDA / ARS

Repair Bldg 1 HVAC System Akron, CO

INSTRUMENTATION AND CONTROL FOR HVAC 230900 - Page 1 of 11

SECTION 230900 - INSTRUMENTATION AND CONTROL FOR HVAC

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes control equipment for HVAC systems and components, including control components for terminal heating and cooling units not supplied with factory-wired controls.

B. See Division 23 Section "Sequence of Operations for HVAC Controls" for requirements that relate to this Section.

1.2 SUBMITTALS

A. Product Data: For each control device indicated.

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.

7. Control System Software: Schematic diagrams, written descriptions, and points list.

C. Software and firmware operational documentation.

D. Operation and maintenance data.

1.3 QUALITY ASSURANCE

A. 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.

PART 2 - PRODUCTS

2.1 CONTROL SYSTEM

A. Manufacturers:

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1. American Auto-Matrix.

2. Johnson Controls, Inc.; Controls Group.

3. Siemens Building Technologies, Inc.

4. Trane; Worldwide Applied Systems Group.

B. Control system shall consist of sensors, indicators, actuators, final control elements, interface equipment, other apparatus, and accessories to control mechanical systems.

2.2 DDC EQUIPMENT

A. Control Units: Modular, comprising processor board with programmable, nonvolatile, random-access memory; local operator access and display panel; integral interface equipment; and backup power source.

1. Units monitor or control each I/O point; process information; execute commands from other control units, devices, and operator stations; and download from or upload to operator workstation.

2. Stand-alone mode control functions operate regardless of network status. Functions include the following:

a. Global communications.

b. Discrete/digital, analog, and pulse I/O.

c. Monitoring, controlling, or addressing data points.

d. Software applications, scheduling, and alarm processing.

e. Testing and developing control algorithms without disrupting field hardware and controlled environment.

B. Local Control Units: Modular, comprising processor board with electronically programmable, nonvolatile, read-only memory; and backup power source.

1. Units monitor or control each I/O point, process information, and download from or upload to operator workstation or diagnostic terminal unit.

2. Stand-alone mode control functions operate regardless of network status. Functions include the following:

a. Global communications.

b. Discrete/digital, analog, and pulse I/O.

c. Monitoring, controlling, or addressing data points.

3. Local operator interface provides for download from or upload to operator workstation.

C. I/O Interface: Hardwired inputs and outputs may tie into system through controllers. Protect points so that shorting will cause no damage to controllers.

1. Binary Inputs: Allow monitoring of on-off signals without external power.

2. Pulse Accumulation Inputs: Accept up to 10 pulses per second.

3. Analog Inputs: Allow monitoring of low-voltage (0- to 10-V dc), current (4 to 20 mA), or resistance signals.

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4. Binary Outputs: Provide on-off or pulsed low-voltage signal, selectable for normally open or normally closed operation.

5. Analog Outputs: Provide modulating signal, either low voltage (0- to 10-V dc) or current (4 to 20 mA.

6. Tri-State Outputs: Provide two coordinated binary outputs for control of three-point, floating-type electronic actuators.

7. Universal I/Os: Provide software selectable binary or analog outputs.

D. Power Supplies: Transformers with Class 2 current-limiting type or overcurrent protection;

limit connected loads to 80 percent of rated capacity. DC power supply shall match output current and voltage requirements and be full-wave rectifier type with the following:

1. Output ripple of 5.0 mV maximum peak to peak.

2. Combined 1 percent line and load regulation with 100-mic.sec. response time for 50 percent load changes.

3. Built-in overvoltage and overcurrent protection and be able to withstand 150 percent overload for at least 3 seconds without failure.

E. Power Line Filtering: Internal or external transient voltage and surge suppression for workstations or controllers with the following:

1. Minimum dielectric strength of 1000 V.

2. Maximum response time of 10 nanoseconds.

3. Minimum transverse-mode noise attenuation of 65 dB.

4. Minimum common-mode noise attenuation of 150 dB at 40 to 100 Hz.

2.3 UNITARY CONTROLLERS

A. Unitized, capable of stand-alone operation with sufficient memory to support its operating system, database, and programming requirements, and with sufficient I/O capacity for the application.

1. Configuration: Local keypad and display; diagnostic LEDs for power, communication, and processor; wiring termination to terminal strip or card connected with ribbon cable;

memory with bios; and 2-hour battery backup.

2. Operating System: Manage I/O communication to allow distributed controllers to share real and virtual object information and allow central monitoring and alarms. Perform automatic system diagnostics; monitor system and report failures.

3. Enclosure: Waterproof rated for operation at 40 to 150 deg F.

2.4 ANALOG CONTROLLERS

A. Step Controllers: 6- or 10-stage type, with heavy-duty switching rated to handle loads and operated by electric motor.

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B. Electric, Outdoor-Reset Controllers: Remote-bulb or bimetal rod-and-tube type, proportioning action with adjustable throttling range, adjustable set point, scale range minus 10 to plus 70 deg F, and single- or double-pole contacts.

C. Receiver Controllers: Single-or multiple input models with control point adjustment, direct or reverse acting with mechanical set point adjustment with locking device, proportional band adjustment, authority adjustment, and proportional control mode.

1. Remote-control-point adjustment shall be plus or minus 20 percent of sensor span, input signal of 3 to 13 psig.

2. Proportional band shall extend from 2 to 20 percent for 5 psig.

3. Authority shall be 20 to 200 percent.

4. Air supply pressures of 18 psig, input signal of 3 to 15 psig, and output signal of zero to supply pressure.

5. Gages: 2 1/2 inches in diameter, 2.5 percent wide scale accuracy, and range to match transmitter input or output pressure.

2.5 ELECTRONIC SENSORS

A. Description: Vibration and corrosion resistant; for wall, immersion, or duct mounting as required.

B. Thermistor or RTD Temperature Sensors and Transmittors:

1. Manufacturers:

a. Veris.

b. Johnson Controls.

c. Precon.

2. Accuracy: Plus or minus 0.5 percent at calibration point.

3. Wire: Twisted, shielded-pair cable.

4. Insertion Elements in Ducts: Single point, use where not affected by temperature stratification or where ducts are smaller than 9 sq. ft..

5. Averaging Elements in Ducts: Use where prone to temperature stratification or where ducts are larger than 9 sq. ft.

6. Insertion Elements for Liquids: Brass socket with minimum insertion length of 2-1/2 inches.

7. Room Sensor Cover Construction: Manufacturer's standard locking covers.

a. Set-Point Adjustment: Concealed.

b. Set-Point Indication: Exposed.

c. Thermometer: Exposed.

d. Color: White.

8. Outside-Air Sensors: Watertight inlet fitting, shielded from direct sunlight.

9. Room Security Sensors: Stainless-steel cover plate with insulated back and security screws.

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C. Pressure Transmitters/Transducers:

1. Manufacturers:

a. Veris.

b. Setra.

c. Rosemount.

2. Static-Pressure Transmitter: Nondirectional sensor with suitable range for expected input, and temperature compensated.

a. Accuracy: 2 percent of full scale with repeatability of 0.5 percent.

b. Output: 4 to 20 mA.

c. Building Static-Pressure Range: 0- to 0.25-inch wg.

d. Duct Static-Pressure Range: 0- to 5-inch wg.

3. Water Pressure Transducers: Stainless-steel diaphragm construction, suitable for service;

minimum 150-psig operating pressure; linear output 4 to 20 mA.

4. Water Differential-Pressure Transducers: Stainless-steel diaphragm construction, suitable for service; minimum 150-psig operating pressure and tested to 300-psig; linear output 4 to 20 mA.

5. Differential-Pressure Switch (Air or Water): Snap acting, with pilot-duty rating and with suitable scale range and differential.

6. Pressure Transmitters: Direct acting for gas or liquid service; range suitable for system;

linear output 4 to 20 mA.

2.6 STATUS SENSORS

A. Status Inputs for Fans: Differential-pressure switch with pilot-duty rating and with adjustable range of 0- to 5-inch wg.

B. Status Inputs for Pumps: Differential-pressure switch with pilot-duty rating and with adjustable pressure-differential range of 8 to 60 psig, piped across pump.

C. Status Inputs for Electric Motors: Comply with ISA 50.00.01, current-sensing fixed- or split-core transformers with self-powered transmitter, adjustable and suitable for 175 percent of rated motor current.

D. Voltage Transmitter (100- to 600-V ac): Comply with ISA 50.00.01, single-loop, self-powered transmitter, adjustable, with suitable range and 1 percent full-scale accuracy.

E. Power Monitor: 3-phase type with disconnect/shorting switch assembly, listed voltage and current transformers, with pulse kilowatt hour output and 4- to 20-mA kW output, with maximum 2 percent error at 1.0 power factor and 2.5 percent error at 0.5 power factor.

F. Current Switches: Self-powered, solid-state with adjustable trip current, selected to match current and system output requirements.

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G. Electronic Valve/Damper Position Indicator: Visual scale indicating percent of travel and 2- to 10-V dc, feedback signal.

H. Water-Flow Switches: Bellows-actuated mercury or snap-acting type with pilot-duty rating, stainless-steel or bronze paddle, with appropriate range and differential adjustment, in NEMA 250, Type 1 enclosure.

2.7 THERMOSTATS

A. Low-Voltage, On-Off Thermostats: NEMA DC 3, 24-V, bimetal-operated, mercury-switch type, with adjustable or fixed anticipation heater, concealed set-point adjustment, 55 to 85 deg F set-point range, and 2 deg F maximum differential.

B. Room thermostat accessories include the following:

1. Insulating Bases: For thermostats located on exterior walls.

2. Adjusting Key: As required for calibration and cover screws.

3. Set-Point Adjustment: 1/2-inch- diameter, adjustment knob.

C. Immersion Thermostat: Remote-bulb or bimetal rod-and-tube type, proportioning action with adjustable throttling range and adjustable set point.

D. Airstream Thermostats: Two-pipe, fully proportional, single-temperature type; with adjustable set point in middle of range, adjustable throttling range, plug-in test fitting or permanent pressure gage, remote bulb, bimetal rod and tube, or averaging element.

2.8 ACTUATORS

A. Electronic Actuators: Direct-coupled type designed for minimum 60,000 full-stroke cycles at rated torque.

1. Manufacturers:

a. Belimo Aircontrols (USA), Inc.

b. Johnson Controls.

c. Invensys.

2. Valves: Size for torque required for valve close off at maximum pump differential pressure.

3. Dampers: Size for running torque calculated as follows:

a. Parallel-Blade Damper with Edge Seals: 7 inch-lb/sq. ft. of damper.

b. Opposed-Blade Damper with Edge Seals: 5 inch-lb/sq. ft. of damper.

c. Parallel-Blade Damper without Edge Seals: 4 inch-lb/sq. ft of damper.

d. Opposed-Blade Damper without Edge Seals: 3 inch-lb/sq. ft. of damper.

e. Dampers with 2- to 3-Inch wg of Pressure Drop or Face Velocities of 1000 to 2500 fpm: Increase running torque by 1.5.

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f. Dampers with 3- to 4-Inch wg of Pressure Drop or Face Velocities of 2500 to 3000 fpm: Increase running torque by 2.0.

4. Coupling: V-bolt and V-shaped, toothed cradle.

5. Overload Protection: Electronic overload or digital rotation-sensing circuitry.

6. Fail-Safe Operation: Mechanical, spring-return mechanism. Provide external, manual gear release on nonspring-return actuators.

7. Power Requirements (Two-Position Spring Return): 24-V ac.

8. Power Requirements (Modulating): Maximum 10 VA at 24-V ac or 8 W at 24-V dc.

9. Proportional Signal: 2- to 10-V dc or 4 to 20 mA, and 2- to 10-V dc position feedback signal.

10. Temperature Rating: Minus 22 to plus 122 deg F.

11. Run Time: 12 seconds open, 5 seconds closed.

2.9 CONTROL VALVES

A. Control valves shall be sized and furnished by the ATC vendor. Installation by Mechanical Contractor.

B. Control Valves: Factory fabricated, of type, body material, and pressure class based on maximum pressure and temperature rating of piping system, unless otherwise indicated.

C. Hydronic system globe valves shall have the following characteristics:

1. NPS 2 and Smaller: Class 125 bronze body, bronze trim, rising stem, renewable composition disc, and screwed ends with backseating capacity repackable under pressure.

2. NPS 2-1/2 and Larger: Class 125 iron body, bronze trim, rising stem, plug-type disc, flanged ends, and renewable seat and disc.

3. Internal Construction: Replaceable plugs and stainless-steel or brass seats.

a. Single-Seated Valves: Cage trim provides seating and guiding surfaces for plug on top and bottom.

b. Double-Seated Valves: Balanced plug; cage trim provides seating and guiding surfaces for plugs on top and bottom.

4. Sizing: 5-psig maximum pressure drop at design flow rate or the following:

a. Two Position: Line size.

b. Two-Way Modulating: Either the value specified above or twice the load pressure drop, whichever is more.

c. Three-Way Modulating: Twice the load pressure drop, but not more than value specified above.

5. Flow Characteristics: Two-way valves shall have equal percentage characteristics; three-way valves shall have linear characteristics.

6. Close-Off (Differential) Pressure Rating: Combination of actuator and trim shall provide minimum close-off pressure rating of 150 percent of total system (pump) head for two-

INSTRUMENTATION AND CONTROL FOR HVAC 230900 - Page 8 of 11 way valves and 100 percent of pressure differential across valve or 100 percent of total system (pump) head.

D. Terminal Unit Control Valves: Bronze body, bronze trim, two or three ports as indicated, replaceable plugs and seats, and union and threaded ends.

1. Rating: Class 125 for service at 125 psig and 250 deg F operating conditions.

2. Sizing: 3-psig maximum pressure drop at design flow rate, to close against pump shutoff head.

3. Flow Characteristics: Two-way valves shall have equal percentage characteristics; three-way valves shall have linear characteristics.

E. Self-Contained Control Valves: Bronze body, bronze trim, two or three ports as indicated, replaceable plugs and seats, and union and threaded ends.

1. Rating: Class 125 for service at 125 psig and 250 deg F operating conditions.

2. Thermostatic Operator: Liquid-filled remote sensor with remote adjustable dial.

2.10 DAMPERS

A. Manufacturers:

1. Johnson Controls VD-1320.

2. Johnson Controls VD-1330.

3. Ruskin CD-40.

B. Dampers: AMCA-rated, opposed-blade design; 0.125-inch- minimum thick, extruded-aluminum frames with holes for duct mounting; damper blades shall not be less than 0.064-inch- thick galvanized steel with maximum blade width of 8 inches and length of 48 inches.

1. Secure blades to 1/2-inch- diameter, zinc-plated axles using zinc-plated hardware, with oil-impregnated sintered bronze blade bearings, blade-linkage hardware of zinc-plated steel and brass, ends sealed against spring-stainless-steel blade bearings, and thrust bearings at each end of every blade.

2. Operating Temperature Range: From minus 40 to plus 200 deg F.

3. Edge Seals, Standard Pressure Applications: Closed-cell neoprene.

4. Edge Seals, Low-Leakage Applications: Use inflatable blade edging or replaceable rubber blade seals and spring-loaded stainless-steel side seals, rated for leakage at less than 10 cfm per sq. ft. of damper area, at differential pressure of 4-inch wg when damper is held by torque of 50 in. x lbf; when tested according to AMCA 500D.

2.11 CONTROL CABLE

A. Electronic and fiber-optic cables for control wiring are specified in Division 27 Section "Communications Horizontal Cabling."

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PART 3 - EXECUTION

3.1 INSTALLATION

A. Verify location of thermostats, humidistats, and other exposed control sensors with Drawings and room details before installation. Install devices 60 inches above the floor.

1. Install averaging elements in ducts and plenums in crossing or zigzag pattern.

B. Install guards on thermostats in the following locations:

1. Entrances.

2. Public areas.

3. Where indicated.

C. Install automatic dampers according to Division 23 Section "Air Duct Accessories."

D. Install damper motors on outside of duct in warm areas, not in locations exposed to outdoor temperatures.

E. Install labels and nameplates to identify control components according to Division 23 Section "Identification for HVAC Piping and Equipment."

F. Install hydronic instrument wells, valves, and other accessories according to Division 23 Section "Hydronic Piping."

G. Install duct volume-control dampers according to Division 23 Sections specifying air ducts.

H. Install electronic and fiber-optic cables according to Division 27 Section "Communications Horizontal Cabling."

3.2 ELECTRICAL WIRING AND CONNECTION INSTALLATION

A. Install raceways, boxes, and cabinets according to Division 26 Section "Raceway and Boxes for Electrical Systems."

B. Install building wire and cable according to Division 26 Section "Low-Voltage Electrical Power Conductors and Cables."

C. Install signal and communication cable according to Division 27 Section "Communications Horizontal Cabling."

1. Conceal cable, except in mechanical rooms and areas where other conduit and piping are exposed.

2. Install exposed cable in raceway.

3. Install concealed cable in raceway.

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4. Bundle and harness multiconductor instrument cable in place of single cables where several cables follow a common path.

5. Fasten flexible conductors, bridging cabinets and doors, along hinge side; protect against abrasion. Tie and support conductors.

6. Number-code or color-code conductors for future identification and service of control system, except local individual room control cables.

7. Install wire and cable with sufficient slack and flexible connections to allow for vibration of piping and equipment.

D. Connect manual-reset limit controls independent of manual-control switch positions.

Automatic duct heater resets may be connected in interlock circuit of power controllers.

E. Connect hand-off-auto selector switches to override automatic interlock controls when switch is in hand position.

3.3 FIELD QUALITY CONTROL

A. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect, test, and adjust field-assembled components and equipment installation, including connections, and to assist in field testing. Report results in writing.

B. Perform the following field tests and inspections and prepare test reports:

1. Operational Test: After electrical circuitry has been energized, start units to confirm proper unit operation. Remove and replace malfunctioning units and retest.

2. Test and adjust controls and safeties.

3. Test calibration of controllers by disconnecting input sensors and stimulating operation with compatible signal generator.

4. Test each point through its full operating range to verify that safety and operating control set points are as required.

5. Test each control loop to verify stable mode of operation and compliance with sequence of operation. Adjust PID actions.

6. Test each system for compliance with sequence of operation.

7. Test software and hardware interlocks.

C. DDC Verification:

1. Verify that instruments are installed before calibration, testing, and loop or leak checks.

2. Check instruments for proper location and accessibility.

3. Check instrument installation for direction of flow, elevation, orientation, insertion depth, and other applicable considerations.

4. Check instrument tubing for proper fittings, slope, material, and support.

5. Check pressure instruments, piping slope, installation of valve manifold, and self-contained pressure regulators.

6. Check temperature instruments and material and length of sensing elements.

7. Check control valves. Verify that they are in correct direction.

8. Check air-operated dampers. Verify that pressure gages are provided and that proper blade alignment, either parallel or opposed, has been provided.

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9. Check DDC system as follows:

a. Verify that DDC controller power supply is from emergency power supply, if applicable.

b. Verify that wires at control panels are tagged with their service designation and approved tagging system.

c. Verify that spare I/O capacity has been provided.

d. Verify that DDC controllers are protected from power supply surges.

D. Replace damaged or malfunctioning controls and equipment and repeat testing procedures.

3.4 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain HVAC instrumentation and controls.

END OF SECTION 230900