AMD 05 - 40 95 00.pdf

DD#2 Complex Amendment 2021-04-05 Portsmouth Naval Shipyard, Kittery, ME

SECTION 40 95 00

INSTRUMENTATION AND CONTROLS

11/19

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C12.1 ((2014; Errata 2016) Electric Meters - Code for Electricity Metering

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C37.90.1 (2013) Standard for Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus

IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 61131-3 (2013) Programmable Controllers - Part 3:

Programming Languages

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2018) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005; Errata 2008) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 3 (2005; R 2010) Medium-Voltage Controllers Rated 2001 to 7200 V AC

NEMA ICS 4 (2015) Application Guideline for Terminal Blocks

NEMA ICS 5 (2017) Industrial Control and Systems:

Control Circuit and Pilot Devices

SECTION 40 95 00 Page 1

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14; TIA 17-15; TIA 17-16; TIA 17-17 )

National Electrical Code

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

NIST SP 250 (1991) Calibration Services Users Guide

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

47 CFR 15 Radio Frequency Devices

UNDERWRITERS LABORATORIES (UL)

UL 1059 (2001; Reprint Dec 2017) UL Standard for Safety Terminal Blocks

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Contractor Design Drawings; G, AE

Draft As-Built Drawings; G, AE

Station Control Panel; G, AE

Tower 6 Local Control Panel; G, AE

Tower 5 Local Control Panel; G, AE

Shipside Complex Local Control Panel; G, AE

Enclosure 8 Local Control Panel; G, AE

Enclosure 6 Ventilation Control Panel; G, AE

Station Control Panel Screen Layout; G, AE

Tower 5 Local Control Panel Screen Layout; G, AE

Tower 6 Local Control Panel Screen Layout; G, AE

Shipside Complex Local Control Panel Screen Layout; G, AE

Enclosure 8 Local Control Panel Screen Layout; G, AE

SECTION 40 95 00 Page 2

Enclosure 6 Ventilation Control Panel Screen Layout; G, AE

Remote Temperature Display Control Panel

SD-03 Product Data

Control Drawings; G, AE

Station Control Panel; G, AE

Local Control Panel; G, AE

Roof Control Panel; G, AE

Ventilation Control Panel; G, AE

Keyed Switches; G, AE

Push Buttons; G, AE

Battery Backup; G, AE

Touchscreen HMI; G, AE

Remote Temperature Display Screen

Remote Temperature Display Control Panel

Remote HMI Laptop; G, AE

Ethernet Switch; G, AE

Fiber Optic Media Converter; G, AE

Programmable Logic Controller (Plc); G, AE

Relays; G, AE

Terminal Blocks; G, AE

Limit Switches; G, AE

Zone Sensor; G, AE

SD-06 Test Reports

Enclosure 8 Testing, Adjusting And Commissioning; G, AE

Tower 6 Testing, Adjusting And Commissioning; G, AE

Tower 5 Testing, Adjusting And Commissioning; G, AE

Shipside Complex Testing, Adjusting And Commissioning; G, AE

Enclosure 6 Testing, Adjusting And Commissioning; G, AE

Enclosure 8 Performance Verification Test; G, AE

Tower 6 Performance Verification Test; G, AE

SECTION 40 95 00 Page 3

Tower 5 Performance Verification Test; G, AE

Shipside Complex Performance Verification Test; G, AE

Enclosure 6 Performance Verification Test; G, AE

SD-07 Certificates

Control and Sensor Wiring

Wiring

Installation

SD-10 Operation and Maintenance Data

Training Manual; G

Control System; G

SD-11 Closeout Submittals

Final As-Built Drawings; G

1.3 SITE ENVIRONMENTAL CONDITIONS

The expected site environmental conditions are a minimum of 40 degrees F and a maximum of 100 degrees F.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

The instrumentation and control system shall be used to monitor and control the operation of HVAC systems, lighting systems, and retractable roof systems as specified and in accordance with the sequence of control and control schematics shown on the drawings. The process control system must provide for operator interaction, overall process control system supervision, and process equipment control and monitoring. Provide hardware configured and sized to support expansion as specified and shown on the drawings.

The process control system must be complete including sensors, field preamplifiers, signal conditioners, offset and span adjustments, amplifiers, transducers, transmitters, control devices, engineering units conversions and algorithms for the applications; and must maintain the specified end-to-end process control loop accuracy from the sensor to display and final control element. Connecting conductors must be suitable for installed controls. Enclosures must be rated for NEMA 1.

When selecting the controls system manufacturer, consider performance, required support of all HVAC, roofing, lighting and other system control points, and PNSY personnel familiarity with the PLC system manufacturer.

2.1.1 General Requirements

The control system shall consist of a Station Control Panel, multiple Local Control Panels (LCP), and a Ventilation Control Panel. Each control

SECTION 40 95 00 Page 4 panel shall provide for basic monitoring and control of the HVAC equipment, lighting, and the retractable roof system motors and VFDs. Each control panel enclosure shall contain a PLC and all required accessories.

The PLC shall communicate via Ethernet/IP (Industrial Protocol) over Ethernet cable (CAT5e) between PLCs, VFD, and HMI Touch Screens. Note that when "Enclosure(s)" is capitalized within a sentence in the following sections it refers to the enclosures of the Complex, (Enclosure 4, Enclosure 5, Enclosure 6, Enclosure 7, Enclosure 8, Tower 5, Tower 6).

Otherwise, it refers to control panel enclosures.

2.1.2 Station Control Panel

A Station Control Panel shall be provided in Enclosure 4 as the central monitoring and control point of the entire complex. All functions and signals of the individual Enclosures shall be monitored and controllable from the Station Control Panel as if viewed/commanded from the individual Local Control Panel. The user will interact with the Station Control Panel through a Touch Screen HMI.

The control panel enclosure shall house all contactors and relays, and all necessary components for a fully functioning, UL508 control panel.

The control panel enclosure shall be surface mounted and as shown on the drawings. Dimensions shall be as required to house all the required components with the recommended spacing between components per UL 508 and the NEC Article 409.

2.1.3 Local Control Panel

A Local Control Panel (LCP) shall be provided to monitor and control the HVAC equipment, lighting, and retractable roof system of the enclosure in which it is located. The user will interact with the Local Control Panel through a Touch Screen HMI. A Local Control Panel (LCP) shall be provided in the following Enclosures:

Tower 6 Local Control Panel Tower 5 Local Control Panel Shipside Complex Local Control Panel Enclosure 8 Local Control Panel

The control panel enclosure shall house all contactors and relays, and all necessary components for a fully functioning, UL508 control panel.

The control panel enclosure shall be wall-recessed and as shown on the drawings. Dimensions shall be as required to house all the required components with the recommended spacing between components per UL 508 and the NEC Article 409.

2.1.4 Roof Control Panel

A remote control panel shall be provided to control the roof movement of the Shipside Complex and tower Enclosures, and shall be wired back to the Local Control Panel (LCP) and PLC. The roof controls for the Enclosure 8 shall be located integral to the Enclosure 8 Local Control Panel. The roof controls for the Enclosure 6 are existing to remain.

The control panel enclosure shall house all contactors and relays, and all necessary components for a fully functioning, UL508 control panel.

SECTION 40 95 00 Page 5

The control panel enclosure shall be wall-recessed and as shown on the drawings. Dimensions shall be as required to house all the required components with the recommended spacing between components per UL 508 and the NEC Article 409.

2.1.5 Ventilation Control Panel

Enclosure 6 Ventilation Control Panel shall be provided to monitor and control the HVAC equipment of Enclosure 6. The user will interact with the Local Control Panel through a Touch Screen HMI.

The control panel enclosure shall house all contactors and relays, and all necessary components for a fully functioning, UL508 control panel.

The control panel enclosure shall be surface mounted and as shown on the drawings. Dimensions shall be as required to house all the required components with the recommended spacing between components per UL 508 and the NEC Article 409.

2.1.6 Remote Temperature Display Control Panel

A remote control panel shall be provided to display the temperatures of the Complex's enclosures and shall be wired back to the Local Control Panel (LCP) and PLC.

The control panel enclosure shall house all necessary components for a fully functioning, UL508 control panel.

The control panel enclosure shall be outdoor rated NEMA 4x stainless steel and as shown on the drawings. Dimensions shall be as required to house all the required components the recommended spacing between components per UL508 and NEC Article 409.

The Remote Temperature Display located on Enclosure 4 shall display the temperature of Enclosure 5 when it is in its installed position in the dry dock.

The Remote Temperature Display located on the outside of Enclosure 7 shall display the temperature of Enclosure 5 in both positions (in dock and in the storage location).

The Remote Temperature Control panel shall have user interface restricted by having no functional touchscreen buttons.

2.1.7 Operation

The control system provided under this specification shall operate using PLC algorithms or ladder logic type and supervisory control to provide the required sequence of operation for the HVAC and retractable roof systems.

Input data to the controller shall be obtained by using instruments and controls interfaced to mechanical systems and other systems as shown and specified. All required setpoints, settings, alarm limits, and sequences of operation shall be as identified in the sequences of operation shown below. The number and location of control panels shown on drawings shall be provided as a minimum.

2.1.7.1 HVAC System Operation Description

The HVAC system for the Enclosure 8, Tower 5, Tower 6, and the Shipside

SECTION 40 95 00 Page 6

Complex Enclosures shall be controlled from the Local Control Panels (LCP) located in each of the Enclosures. The control panels shall provide control interface for setting supply airflow, discharge air temperature, space temperature, and Enclosure differential pressure via exhaust and supply dampers.

The enclosure space temperature shall be controlled with a split heat pump for heating and cooling, and a supplemental electric duct heater for the winter season. The heat pump control module shall communicate to the enclosure PLC via a BACnet MS/TP serial directly. The PLC shall enable the heat pump's internal controller which automatically controls internal processes of the heat pump operation, including self-diagnostic checks, defrost control, and heating/cooling cycles. The system shall automatically change to heat or cool in response to sufficient space temperature change.

A duct-mounted supply air temperature sensor and inside zone sensor shall be connected to the LCP and used as feedback to the heat pump. The space temperature setpoint shall be written from the PLC to the heat pump controller based on a seasonal schedule. Monitoring of the heat pump status shall be sent to PLC and displayed on the control panel HMI.

The heat pump shall be enabled whenever the recirculation fan is running, confirmed through the associated AFMS. The heat pump control module and auxiliary electric heat (when required) shall be interlocked with the supply air fan to ensure the heat pump shuts down when the fan is not running. The heat pump trouble indicator as shown on the HMI of the Enclosure's local control panel shall receive its signal from the heat pump controller via the PLC. This indicator shall automatically clear on the HMI when the alarm is cleared in the heat pump controller.

Control of the supply and exhaust air flows shall be from the HMI via fan speed and exhaust damper control. Arrangements allow the user to quickly modulate dampers and fan speed to pre-set configurations depending on their needs. In arrangement mode the supply fan speed Proportional-Integral (PI) controller in the PLC shall receive a flow setpoint from a numeric entry control on the HMI. The Process Variable, or Present Value (PV) for the supply air PI loop shall be the calculated difference between the return air flow station value and the exhaust air flow station value.

A supply air damper (on enclosure ductwork) shall be electrically actuated and modulated through the LCP to create back pressure as needed to exhaust recirculation airflow. The supply damper shall shut whenever the fan is off and return to its previous position upon restart.

Similar functionality shall be made available for the negative differential pressure control. In arrangement mode the Exhaust air flow control damper located downstream of the recirc fan shall allow for manual modulation to adjust negative differential pressure (dP) through the LCP.

The negative dP process value (PV) shall come from a differential pressure transmitter in the Enclosure with the High pressure port referenced to the outside of the enclosure and the low pressure port reference to the inside pressure. The Exhaust Air damper shall close when the recirculation fan is not running.

2.1.7.2 Engineered Ventilation

Engineered ventilation for Enclosure 5/7 shall be via flexible ducts that

SECTION 40 95 00 Page 7 connect directly to the recirculation fan return air assemblies. The engineered ventilation airflow shall be monitored and controlled in arrangement mode via a differential pressure transmitter and connected to the Enclosure PLC. The measured flow rates shall be inputs to PI loops which shall calculate airflow in CFM based on the differential pressure signal sent from the transmitter. This calculation also involves flow station (duct) free area and a K-factor determined during TAB testing.

Engineered ventilation airflows shall be displayed on the LCP HMI terminal. The HMI shall include a user defined minimumflow rate through each airflow measurement station that must be achieved before the HMI will display a value above 0 cfm. Each of the flex hose connections shall be equipped with an electrically actuated damper, with manual override, for flow control. The operator shall monitor the total air flow while adjusting the flow control damper via adjustments on the LCP screen. All dampers shall shut when the associated fan is off and open according to the parameters of the selected/active arrangement when the fan is cycled on.

Engineered ventilation for Tower 5, Tower 6, and Enclosure 8 shall be via flexible ducts that connect directly to the recirculation fan return air assemblies. The engineered ventilation airflow shall be monitored and controlled in arrangement mode via a differential pressure transmitter and connected to the Enclosure PLC. The measured flow rates shall be inputs to PI loops which shall calculate airflow in CFM based on the differential pressure signal sent from the transmitter. This calculation also involves flow station (duct) free area and a K-factor determined during TAB testing. Engineered ventilation airflows shall be displayed on the LCP HMI terminal. The HMI shall include a user defined minimumflow rate through each airflow measurement station that must be achieved before the HMI will display a value above 0 cfm. Each of the flex hose connections shall be equipped with an electrically actuated damper, with manual override, for flow control. The operator shall monitor the total air flow while adjusting the flow control damper via adjustments on the LCP screen. All dampers shall shut when the associated fan is off and open according to the parameters of the selected/active arrangement when the fan is cycled on.

2.1.7.3 Sequence of Operation

1. HVAC System, Recirculation And Exhaust Enclosures 5, 6, 7, 8 and Towers 5 and 6

a. Monitor and control operations of the recirculation fan, heat pump, supply and exhaust dampers, return airflow and exhaust fan airflow. Integrate the factory heat pump controls for remote operation of the heat pump and auxiliary heater.

b. Upon activation of the recirculation fan through the local control panel (LCP), fan shall start and operate at 15 Hz, or its minimum safe speed as determined at TAB, prior to the dampers opening. The APS valve shall open and the electronic flow meter shall show flow to prove the fan is working, prior to the dampers opening. The applicable dampers shall be commanded to open. A time delay shall be initiated, based on the damper actuation time, set during TAB. When the dampers are all positioned, based on the timer, the fan shall ramp up to set point. The air flow rates for Enclosures 5, 7, 8 and Towers 5 and 6 will be established during TAB as a permissive to enable the Heat Pump. The thermal flow switches on differential pressure switch for Enclosure 5&7 on the

SECTION 40 95 00 Page 8

Shipside and 6 on the dockside shall serve as the permissive to enable the Heat Pump and electric duct coil to operate. Heat Pump controller shall be enabled and control discharge air temperature in order to maintain space temperature setpoint as read by the zone sensor and current space temperature setpoint. The integral heat pump controller shall determine heating or cooling modes based on space temperature and outdoor air temperature.

Heating mode shall be enabled when the indoor air temperature falls below 68 degrees (ADJ).

Cooling mode shall be enabled when the space temperature rises above 75 degrees (ADJ).

Heating setpoint 68 DEG F (ADJ), Cooling Setpoint 75 DEG F (ADJ).

c. Recirculation fan speed shall be set by the user through the LCP as a constant volume. The return and exhaust airflow for Enclosures 5, 7 and 8 and Towers 5 and 6 shall be monitored and controlled in arrangement mode via air flow measuring stations, (AFMS) connected to the LCP. The measured flow rates shall be inputs to PI loops which shall calculate airflow in CFM based on the flow signal sent from the AFMS. This calculation also involves flow station (duct) free area and a K-factor determined during TAB testing. The return and exhaust airflow for Enclosure 6 shall be monitored and controlled in arrangement mode via differential pressure switches thermal flow switches connected to the LCP. The pressure thermal floww switch setpoints for Enclosure 6 will be determined during TAB as proof of flow. If the thermal flow switch differential pressure switch is not satisfied an alarm will be indicated, the heat pump will not be energized, and a signal will be send to the LCP.

High and low airflow limits shall be maintained by the user, as described below. Fan speed shall be manually modulated between these setpoints via local control panel in each work area by the user. An algorithm shall calculate supply flow by subtracting the exhaust flow from the fan inlet flow. The high limit shall be the flow which produces flow past the respective heat pump coil (air flow rate to be calculated based on approved coil size) and the low limit shall be set to the minimum safe operating point as dictated by the fan motor manufacturer to prevent overheating. In no case, however, shall the user allow the fan inlet flow to exceed the scheduled maximum filter housing flow.

d. The recirculation airflow meter located on the inlet of the fan and associated VFD shall signal "Recirc Fan On" at local control panel (LCP) and station control panel to prove system is running.

Similarly, a digital flow meter on the particulate sample probe tubing shall indicate positive flow. During normal operations, an alarm shall be generated when the fan is running but there is zero flow at the fan inlet flow station. The alarm shall not be generated when the fan is running and the dampers are closed.

e. Through an iterative process, the fan, exhaust and supply damper as needed, and engineered vent damper(s) are modulated through the LCP to achieve a negative differential pressure (dp) in the space of -0.1 to -0.2" w.g. while also satisfying a downward/supply air flow dependent on the user's needs.

SECTION 40 95 00 Page 9

f. Makeup air is normally provided by means of infiltration. If infiltrated airflow is not sufficient to provide the required exhaust airflow/velocity, introduction of outside air can be accomplished if required at the Level 1 Dockside Passage Way and Shipside Enclosure 7 East Stair. Enclosure 6 door mounted dampers on doors 004 and 006 shall be manually modulated open as needed.

g. Heating and cooling control through the heat pump and auxiliary electric heat shall modulate supply air temperature based on the signal from the associated space temperature sensor to maintain space temperature. Maximum heating supply temperature shall be 120 deg F and minimum cooling temperature shall be 52 deg F, set to the values indicated on the design documents. Upon fan proving, the PLC shall enable the heat pump's internal controller which automatically controls internal processes of the heat pump operation, including self-diagnostic checks, defrost control, and heating/cooling cycles which shall automatically change to heat or cool in response to sufficient space temperature change.

With a request for cooling, the internal control enables the heat pump cooling system.

When a request for heating occurs, the mechanical heat (compressors) turns on through 2-step heating process. Unit shall stage according to proportional/integral controls. Heat pump controls shall not turn off the fan when there are no heat requests. Auxiliary heat (electric duct heater) is enabled through the PLC if the zone temperature is below setpoint and not recovering at a rate of at least 6 degrees F per hour (0.1 degree F per min). A 9 minute stage-up delay is provided for each stage of heat to allow for recovery temperature to begin. Stages of electric heat are enabled and energized as necessary to meet heating demand and must be interlocked with the associated electric duct heater controller. The electric duct heater shall not be staged up to maximum power if the heat pump compressor is also running to avoid simultaneous full amperage draw on both pieces of equipment.

h. Electric duct heater shall be disabled when the supply airflow falls below 4,000 cfm (adj) or minimum flow as required by manufacturer. Airflow shall be determined by algorithm described in 2.1.6.3.1.c. For Enclosures 5&7 on the shipside and 6 on the dockside will have differential pressure thermal flow on switches between the inlet and outlet side s of the fan s and shall serve as the air flow interlock to enable/disable the electric duct heater, when the supply airflow falls below 4,000 cfm (adj) or minimum flow as required by manufacturer.

i. Fan speed and damper positions shall not modulate automatically.

j. Engineered ventilation dampers shall modulate through the local control panel by user input and display airflow accordingly based on coordinated damper tags.

k. Upon total power failure, the recirculation fan will restart per paragraph 2, "Power Failure Recovery", and Main screen of HMI shall display "HVAC System restart upon return from power loss?

Yes or No". "Yes" is selected. If this option is changed, a

SECTION 40 95 00 Page 10 pop-up confirmation should state: "CAUTION: Changing this option to NO will cause the system to NOT automatically restart upon power restoration following a power loss". If this is set to not restart, all dampers shall close upon loss of power and fan shall not restart upon restoration of power.

l. When the fan is instructed to turn off by the VFD (for example as a result of some fault detected by the VFD), the system shall go into the unplanned shutdown mode in which the dampers close after a user defined time delay.

m. For any planned shutdown of the fan, all dampers shall close.

n. For any planned startup, the dampers shall open to the selected arrangement positions.

o. For an unplanned shutdown of the fan for a short duration (for example, power loss followed by a diesel auto-start) the dampers shall not close and upon return of power the fan should return to pre-defined speed for currently selected arrangement with no time delay.

p. In the event of an unplanned shutdown of the fan for a longer duration, dampers shall close, and upon return of power, the system shall return to currently selected arrangement.

q. The determination of short duration vs long duration shall be a user defined "extended outage" time delay in the HMI.

2. Power Failure Recovery

a. In the event of a power loss to the HVAC systems the LCP shall retain all system setpoints.

b. Upon return of power the system shall check a automatic restart parameter (set through the HMI) If the automatic restart is enabled all systems shall be automatically restarted and shall operate according to the parameters of the selected/active arrangement when power is returned. When disabled all dampers shall close immediately upon a power loss. Upon return of power fan shall remain off and dampers remain closed. A manual restart of system will be required through HMI. In all cases ensure that the main supply and return dampers are not open at any time the fan is off.

c. Enclosures shall be restarted in the following order:

1. Shipside Complex

2. Tower 5

3. Tower 6

4. Enclosure 8

5. Enclosure 6

3. APS Valve

a. Particulate sampling flow in the exhaust duct shall be achieved by the V-port ball valve automatically adjusting flow through the sampling tube connected to the inlet of the fan. Reference the particulate sample duct probe, digital in-line flowmeter, variable area flow meter, and V-port ball valve on the design system

SECTION 40 95 00 Page 11 schematic drawings. The digital in-line flow meter shall read instantaneous flow rate, total flow since last reset, and grand total. Readings are displayed only at the meter's display. A signal from the meter's microprocessor shall be sent to the PLC to indicate sampling flow through an indicator light as follows:

Flashing light = no flow, solid light = flow. A signal is also sent to a remote mounted timer to totalize time of flow. Refer to Specification 23 74 00 PACKAGED, OUTDOOR, HEATING AND COOLING

SYSTEM

b. The motor-driven APS valve is a means to secure flow through the APS system when operating in Recirc-only mode is desired. In addition to having the ability to secure flow through the APS system, the motor-driven flow adjusting valve shall have the ability to adjust itself based on feedback from the sampling air flow meter. The PLC shall send a signal to the flow adjusting valve calling for it to adjust its position as necessary to maintain a certain flowrate or to stay within a certain flow range.

c. Three operational modes for the valve shall be provided:

1. Fully Closed

2. Fully Open

3. The valve shall hold a specific APS flowrate input by the user. A range may be used in lieu of a specific set point if it will keep the valve from constantly cycling itself trying to keep a specific flow rate.

d. Control Screens

The HMI will have a screen for monitoring and configuring the APS system.

Refer to Screen Layouts in the Contract Drawings for details on this screen.

2.1.7.4 Lighting Controls

Lighting for areas within the control boundaries will be controlled through the Enclosure's Local Control Panel (LCP) and the Station Control Panel. The PLC shall signal lighting contactors in order to switch the lighting circuit. Lighting circuits shall be as identified in the drawings.

2.1.7.5 Retractable Roof Operation

The roof retraction system shall be enabled from a key switch on the front door of the control panel. The enable key switch shall signal both the PLC and a magnetic motor contactor. Contactor shall switch the VFD load side of the traction motor circuit. The roof traction motors shall be physically disconnected from power when the key switch is disabled. A second contactor shall switch the circuit for the gearmotor brakes. The gearmotor brake circuit shall be sourced from the VFD line side of the traction motor circuit. The gearmotor brake contactor shall be signaled from the PLC such that the brakes are released only when both the enable key switch and a open/close push button is pushed. A programmable "coasting period" delay shall be included before re-enabling the brake after the push button is released. The traction motors shall be operated from momentary, non-illuminated pushbuttons on the control panel. Once enabled, one or both roof panels can be operated at any time. The roof panels shall be capable of changing direction in mid travel. The pushbuttons must be held in to operate the motors. Releasing the

SECTION 40 95 00 Page 12 pushbutton shall stop the motors and apply the gearmotor brake. Roof operation must respond to user action immediately.

The roof traction motors shall operate at two speeds utilizing variable frequency drives (VFDs), depending on the roof panel location along its travel. Initially the roofs open at a slow speed of 15 fpm (adjustable) and then shift to a faster speed of 30 fpm (maximum, adjustable) in between the end limits. The roofs slow to the slower speed when approaching either the open or closed position. Two limit switches located on each end of the roof travel limits shall be used for shifting the roof speed, and then stopping the panel at the end position.

Each moveable roof section will have two motors controlled by a single VFD. The VFD shall operate in Volts/Hertz mode. Each motor shall have an overload relay. In the event of an overload condition, both motors of the roof section should be stopped. Torque boosts shall be adjusted manually to allow for proper operation. Refer to section 26 20 00 INTERIOR DISTRIBUTION SYSTEM for more details on VFD specifications.

The roof VFDs shall be controlled by a PLC with hardwired input and outputs and monitored by the PLC over an Ethernet communication network using BACnet/IP protocol. The PLC shall receive hardwired inputs and outputs from the pushbuttons and roof position limit switches. A indicator shall be provided on the HMI of the Local Control Panel in the event of a VFD fault or COM error. The Trouble indicator shall automatically clear when the fault is cleared. Operation of the roof motors from the VFD operator interface terminal shall be disabled.

2.1.7.6 System Dependency

Each Local Control Panel system shall be independent of each other. No fault or failure of HVAC system shall prevent operation of roof system. No fault or failure of the roof system shall prevent operation of the HVAC system.

2.1.8 Points

Provide inputs to and outputs from the process control system in accordance with the Input/Output (I/O) shown in the wiring diagrams. Each connected analog output (AO), analog input (AI), binary output (BO), binary input (BI), pulse accumulator (PA) input and other input or output device connected to the control system must represent a "point" where referred to in this specification.

2.1.9 Building Telecommunications Cabling (BTC)

Provide data transmission systems for communication between PLCs and VFDs as specified in Section 27 10 00 BUILDING TELECOMMUNICATIONS CABLING SYSTEM and as indicated.

2.1.10 System Reliability

The system must be designed for maximum reliability, safety and integrity while maintaining an availability of 99.99% or better.

2.1.11 System Dependency

Each building system shall be independent of each other. No fault or failure of HVAC system shall prevent operation of roof system. No fault or

SECTION 40 95 00 Page 13 failure of the roof system shall prevent operation of the HVAC system.

2.2 MATERIALS AND EQUIPMENT

2.2.1 Product Certifications

Computing devices, as defined in FCC Part 15, supplied as part of the process control system must be certified to comply with the requirements of Class B computing devices.

2.2.2 Standard Products

Materials and equipment must be standard unmodified products of a manufacturer regularly engaged in the manufacturing of such products.

Units of the same type of equipment must be products of a single manufacturer. Items of the same type and purpose must be identical and supplied by the same manufacturer, unless replaced by a new version approved by the Government.

2.2.3 Nameplates

Each major component of equipment must have the manufacturer's name and address, and the model and serial number in a conspicuous place.

Laminated plastic nameplates must be provided for equipment devices and panels furnished. Each nameplate must identify the device, such as pump "P-1" or valve "VLV-402". Labels must be coordinate with the schedules and the process and instrumentation drawings. Laminated plastic must be 1/8 inch thick, white with black center core. Nameplates must be a minimum of 1 by 3 inches with minimum 1/4 inch high engraved block lettering. Nameplates for devices smaller than 1 by 3 inches must be attached by a nonferrous metal chain. All other nameplates must be attached to the device.

2.3 GENERAL REQUIREMENTS

Equipment located outdoors, not provided with climate controlled enclosure, must be capable of operating in the ambient temperature range.

Electrical equipment will conform to Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Equipment and wiring must be in accordance with NFPA 70 , with proper consideration given to environmental conditions such as moisture, dirt, corrosive agents, and hazardous area classification.

2.4 PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.4.1 PLC General Requirements

PLC shall be Delta Controls enteliBUS series controllers. PLCs must be micro-processor based, capable of receiving binary and analog inputs and, through programming, must be able to control binary and analog output functions, perform data handling operations and communicate with external devices. PLCs must meet the requirements of Class A computing devices, and must be labeled as set forth in 47 CFR 15 and must be able to withstand conducted susceptibility test as outlined in NEMA ICS 1 , NEMA ICS 2 , NEMA ICS 3 , or IEEE C37.90.1 . PLCs must function properly at temperatures between 32 and 122 degrees F at 5 to 95 percent relative humidity non-condensing and must tolerate storage temperatures between minus 40 and plus 140 degrees F at 5 to 95 percent relative humidity non-condensing.

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2.4.2 Modular PLC

PLCs must be based on a modular, field expandable design allowing the system to be tailored to the process control application. The system must be expandable through the use of additional hardware and/or user software. As a minimum, the PLC must include a mounting backplane, power supply module, central processing unit (CPU) module, communications module, and input/output (I/O) module. The modules must be grouped together in a mounting rack or cabinet. The mounting rack backplane must provide the communications mechanism to fully integrate the individual modules located within the rack. Modules other than I/O modules must plug directly into the backplane. The use of wire connectors between modules will not be allowed except for expansion of the system to include multiple backplanes. The rack size must be as needed to hold the equipment necessary while performing the required control functions. The system configuration must allow for the removal and/or installation of modules under power.

2.4.2.1 Central Processing Unit (CPU) Module

The CPU module must be a self contained, microprocessor based unit that provides time of day, scanning, application program execution, storage of application programs, storage of numerical values related to the application process and logic, I/O bus traffic control, peripheral and external device communications and self diagnostics. The scan time must be 250 milliseconds or better including spare I/O channels.

2.4.2.2 Communications Module

The communications module must allow peer-to-peer communication with other PLCs, HMI Screens, and VFDs. The communication module must utilize ethernet communication architecture and BACnet/IP protocol. The communication module must allow programming of the PLC to be done locally through the use of a laptop computer.

2.4.2.3 Power Supply Module

One or more power supply modules must be provided as necessary to power other modules installed in the same cabinet. Power supply modules must plug directly into the backplane. Auxiliary power supplies may be used to supply power to remote cabinets or modules.

a. Power supply modules must use AC power with a nominal voltage of 120 vac plus or minus 5 percent. The power supply module must monitor the incoming line voltage level and must provide over current and over voltage protection. If the voltage level is detected as being out of range the power supply module must continue to provide power for an adequate amount of time to allow for a safe and orderly shutdown.

Power supply modules must be capable of withstanding a power loss for a minimum of 20 milliseconds while still remaining in operation and providing adequate power to all connected modules.

b. Each power supply module must be provided with an on-off switch integral to the module. If the manufacturer's standard power supply module is not provided with an on-off switch, a miniature toggle type switch must be installed near the PLC and must be clearly labeled as to its function..

c. Provide power supply modules with an indicating light which must be

SECTION 40 95 00 Page 15 lit when the module is operating properly.

2.4.2.4 Input/Output (I/O) Modules

Modules must be self contained, microprocessor based units that provide an interface to field devices. The modules must be located in the same cabinet as the other PLC components. Each module must contain visual indication to display the on-off status of individual inputs or outputs.

Each I/O must be protected against reversal of polarity of the signal.

Analog inputs and analog outputs must have 'open, short and out of range circuit' detection. It must be configurable per channel.

2.4.3 Program Storage/Memory Requirements

The CPU must utilize the manufacturer's standard non-volatile memory for the operating system. The controller must have electronically readable and writeable non volatile memory (EPROM, EEPROM, or Flash PROM) for storage of user programs. The user programs must be loaded through the controller keypad, central station or through the use of a laptop computer. The CPU memory capacity must be based on the system's control requirements. The memory capacity must be sized such that, when the system is completely programmed and functional, no more than 50 percent of the memory allocated for these purposes is used.

2.4.4 Input/Output Characteristics

Each controller must allow for analog input, analog output, binary input and binary output. The number and type of inputs and outputs for the system must be as shown on the drawings and must comply with the sequence of control. The system capacity must include a minimum of 20 percent spare input and output points (no less than two points) for each point type provided. During normal operation, a malfunction in any input/output channel must affect the operation of that channel only and must not affect the operation of the CPU or any other channel. All input circuits must have a minimum optical isolation of 1500 VRMS and must be filtered to guard against high voltage transients from the externally connected devices. All output circuits must have a minimum optical isolation of 1500 VRMS and must be filtered to guard against high voltage transients from the externally connected devices.

2.4.4.1 Analog Inputs

Analog input circuits must be available in +/-10V +/-5V 0-10V 0-5V 4-20 mA.

2.4.4.2 Binary Inputs

Binary input circuits must be available in 5 volt TTL 10-30 vDc 18-26 vDc 79-132vDc 79-132 vAc.

2.4.4.3 Analog Outputs

Analog output circuits must be available in +/-10V 4-20 mA.

2.4.4.4 Binary Outputs

Binary output circuits must be available in 5 volt TTL 10-30 vDc 18-26 vDc 79-132 vAc.

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2.4.5 Wiring Connections

Wiring connections must be heavy duty, self lifting, pressure type screw terminals to provide easy wire insertion and secure connections. The terminals must accept two #14 AWG wires. A hinged protective cover must be provided over the wiring connections. The cover must have write-on areas for identification of the external circuits.

2.4.6 On-Off Switch

Each controller must be provided with an integral on-off power switch. If the controller is not provided with a manufacturer's standard on-off switch, a miniature toggle type switch must be installed in the control panel near the controller and must be clearly labeled as to its function.

2.4.7 Diagnostics

Each PLC must have diagnostic routines implemented in firmware. The CPU must continuously perform self-diagnostic routines that will provide information on the configuration and status of the CPU, memory, communications and input/output. The diagnostic routines must be regularly performed during normal system operation. A portion of the scan time of the controller must be dedicated to performing these housekeeping functions. In addition, a more extensive diagnostic routine must be performed at power up and during normal system shutdown. The CPU must log input/output and system faults in fault tables which must be accessible for display. When a fault affects input/output or communications modules the CPU must shut down only the hardware affected and continue operation by utilizing the healthy system components. All faults must be annunciated at the PLC. Diagnostic software must be useable in conjunction with the portable tester. The following diagnostics must be performed:

a. Analog Inputs: Sensor out of range, open or shorted loop, analog-to-digital converter check

b. Analog Outputs: Open or shorted loop

c. Configuration: Check compatibility and availability of selected I/O hardware and software

d. Memory: Checksum, parity check End-to End CPU memory

2.4.8 Accuracy

Controllers shall have an accuracy of plus or minus 0.25 percent of input span.

2.5 PLC SOFTWARE

All PLC software described in this specification shall be furnished as part of the complete control system.

2.5.1 Operating System

Each PLC must be provided with the manufacturer's standard operating system software package. The PLC must maintain a point database in its memory that includes all parameters, constraints and the latest value or status of all points connected to the PLC. Execution of the PLC

SECTION 40 95 00 Page 17 application programs must use the data in memory resident files. The operating system must support a full compliment of process control functions. It must be possible to define these functions using a mix of ladder logic diagrams, function blocks, sequential function charts and text programming. Programming methods and interactions must be based on IEC 61131-3 . A combination of the programming methods must be possible within a single controller. The operating system must allow loading of control logic locally and data files from the portable tester. It must also support data entry and diagnostics using an operator interface panel attached directly to the PLC. Each PLC must be capable of operating in stand alone mode.

2.5.1.1 Startup

The PLC must have startup software that causes automatic commencement of operation without human intervention, including startup of all connected I/O functions. A PLC restart program based on detection of power failure at the PLC must be included in the PLC software. The restart program must include start time delays between successive commands to prevent demand surges or overload trips.

2.5.1.2 Failure Mode

Upon failure for any reason, each PLC must perform an orderly shutdown.

Systems which are not Primary/Secondary must force all PLC outputs to a predetermined (failure mode) state, consistent with the failure modes shown and the associated control device. Primary/Secondary systems must transfer I/O scan and control to the PLC not currently failed.

2.5.2 Functions

The controller operating system must be able to scan inputs, control outputs, and read and write to its internal memory in order to perform the required control as indicated in the sequence of control on the drawings.

The controller must periodically perform self diagnostics to verify that it is functioning properly.

2.5.2.1 Analog Monitoring

The system shall measure and transmit all analog values including calculated analog points.

2.5.2.2 Logic (Virtual)

Logic (virtual) points must be software points entered in the point database which are not directly associated with a physical I/O function.

Logic (virtual) points must be analog or binary points created by calculation from any combination of binary and analog points, or other data having all the properties of real points, including alarms, without the associated hardware. Logic (virtual) points must be defined or calculated and entered into the database. The calculated analog point must have point identification in the same format as any other analog point.

2.5.2.3 State Variables

If an analog point represents more than two (up to 8) specific states, each state must be nameable. For example, a level sensor must be displayed at its measured engineering units plus a state variable with

SECTION 40 95 00 Page 18 named states usable in programs or for display such as low alarm/low/normal/high/high alarm.

2.5.2.4 Analog Totalization

Any analog point must be operator assignable to the totalization program.

Up to eight analog values must be totalized within a selectable time period.

2.5.3 Alarm Processing

Each PLC shall have alarm processing software for AI, DI, and PA alarms for all real and virtual points connected to that PLC.

2.5.3.1 Binary Alarms

Binary alarms are those abnormal conditions indicated by BIs as specified and shown. The system must automatically suppress analog alarm reporting associated with a binary point when that point is turned off.

2.5.3.2 Analog Alarms

Analog alarms are those conditions higher or lower than a defined value, as measured by an AI. Analog readings must be compared to predefined high and low limits, and alarmed each time a value enters or returns from a limit condition. Unique high and low limits must be assigned to each analog point in the system. In control point adjustment (CPA) applications, key the limit to a finite deviation traveling with the setpoint. The system must automatically suppress analog alarm reporting associated with an analog point when that analog point is turned off.

2.5.3.3 Pulse Accumulator (PA) Alarms

Pulse accumulator alarms are those conditions calculated from totalized values of accumulator inputs or PA input rates that are outside defined limits as specified and shown. PA totalized values must be compared to predefined limits and alarmed each time a value enters a limit condition.

Unique limits must be assigned to each PA point in the system.

2.5.4 Constraints

2.5.4.1 Equipment Constraints Definitions

Each control point in the database must have PLC resident constraints defined and entered by the Contractor, including as applicable: maximum starts (cycles) per hour; minimum off time; minimum on time; high limit (value in engineering units); and low limit (value in engineering units).

2.5.4.2 Constraints Checks

All control devices connected to the system must have the PLC constraints checked and passed before each command is issued. Each command point must have unique constraints assigned. High and low "reasonableness" values or one differential "rate-of-change" value must be assigned to each AI. Each individual point must be capable of being selectively disabled by the operator from the central station.

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2.5.5 Control Sequences and Control Loops

Specific functions to be implemented are defined in individual system control sequences and database tables shown on the drawings, and must include, as applicable, the following functions: PI control must provide proportional control and proportional plus integral control; two position control must provide control for a two state device by comparing a set point against a process variable and an established dead band; floating point control must exercise control when an error signal exceeds a selected dead band, and must maintain control until the error is within the dead band limits; signal selection must allow the selection of the highest or lowest analog value from a group of analog values as the basis of control and must include the ability to cascade analog values so that large numbers of inputs can be reduced to one or two outputs; signal averaging must allow the mathematical calculation of the average analog value from a group of analog values as the basis of control and must include the ability to "weight" the individual analog…