Specifications_Sliding_balancer_track_vehichle_exhaust_removal_system.doc

SPECIFICATIONS

SLIDING BALANCER TRACK VEHICLE EXHAUST REMOVAL SYSTEM

The following specifications are required for Aberdeen Proving ground Fire and Emergency Services. The unique mission of APG F&ES requires our organization to be flexible and dynamic. Units are exchanged regularly due to various situations. Mission requirement, out of service vehicles, fill in and/or standby are just a few of the mission related activities that require our fleet to be flexible. This requires an exhaust system that is capable of being adaptable to multiple units. The following specifications described below are required to ensure the system chosen will best meet the needs of our organization.

1.01

SUMMARY

A.

Provide all labor, materials, and equipment necessary to put in working operation a complete turnkey system to remove both diesel and automotive exhaust gases and particulate of operating vehicles within the confines of specified fire station(s). All necessary controls, motors, fittings, ductwork, blower(s), labor and all other equipment and materials specified shall be part of the work.

B.

Section Includes:

1.

Manufacturer

2. Sliding Track.

3.

Support Legs.

4.

Double Track Joiner Plate.

5.

Track Splicing Assembly.

6.

Riser Clamp Assembly.

7.

Trolley/Balancer Assembly.

8. Upper Flexible Hose

9.

Lower Hose Assembly

10.

Safety Disconnect Coupling.

11.

Collection Nozzle Assembly..

12.

Hose Saddle.

13.

Electrical Controllers.

14.

Electrical System.

15.

Air Moving Devices.

16.

Ductwork System.

C.

All items of equipment and materials described in these specifications are to be furnished installed and placed into proper operating condition in accordance with good practice and manufacturer’s written or published instructions.

1. The exhaust removal system shall provide virtually 100 percent complete evacuation of all diesel fumes at the source from start up to exit of the apparatus from the fire station. The diesel exhaust removal system shall be capable of delivering complete coverage for bays up to 60 feet (18.3M) in length. The system must be able to accommodate drive through and back-in bays to meet all the needs of the fire department.

2. System must be designed and installed to NIOSH recommendation, specifying that occupational exposures to carcinogens be limited to the lowest feasible concentration. Exposure in the human breathing zone should be limited to lowest feasible level, without any time delay required for the system to effectively capture the diesel fumes.

3. System must also be capable to provide virtually complete capture and evacuation of carbon monoxide emitted as part of the vehicle exhaust.

4. Systems that solely use filters, in which diesel particulate may accumulate, and that would potentially have to be treated as hazardous materials, will not be accepted.

5. System must meet the guidelines for the International Mechanical code for Source Capture Systems. Such system is defined as a mechanical exhaust system designed and constructed to capture air contaminants at their source and to exhaust such contaminants to the outdoor atmosphere.

6. The system shall not affect personnel boarding the apparatus. Hose loops shall not hang any lower then six feet from the bay floor. The hose assembly shall not come into contact with the vehicle other than one connection point to the vehicles tailpipe. The hose assembly shall not touch or drag on the bay floor.

7. The exhaust system shall not block doorways, exits, and aisles in the apparatus bay, which could endanger the welfare of fire personnel or visitors.

8. The exhaust system shall not need to be disconnected from the vehicle while shore lines are connected, during battery charging, or washing of the vehicle, as with other types of systems.

9. To protect the apparatus electrical system from possible damage, the system bid shall not incorporate any type of electromagnetic device that requires the apparatus to be utilized as an electrical ground for systems operation.

No exception or substitutions to the below requirement shall be allowed.

10. Due to the harmful effects of diesel exhaust, the system must be designed and capable of capturing virtually 100% of the exhaust gas and virtually 100% of the particulate even in the event of a complete power failure. The system shall not detach itself from the apparatus for any reason during a power failure other then normal exiting of the apparatus bay. System shall discharge exhaust outside the station even in the event of a power failure.

11. The system shall capture the exhaust gases and particulate directly from the tailpipe of the apparatus by a direct connected “visible” high temperature rated hose. Particulates emitted from the apparatus are known to be heavier than air and therefore must be captured by a directly connected hose with a tight seal, as loose nozzles or air filters cannot capture these heavy particulates. The particulates have been documented to be the main respirable carcinogen in diesel exhaust, and therefore are the primary concern of the fire department to capture virtually 100% of these particulates.

1.02

SUBMITTALS

A.

Product Data: Indicate manufacturer's model number, technical data including description of components and static pressure/air flow chart, and installation instructions.

Details of wiring for power differentiating between manufacturer-installed and field-installed wiring.

Closeout Submittals: Operation and Maintenance data manual including spare parts list.

1.03

QUALITY ASSURANCE

A. Engage a factory certified installer to perform work of this Section who has completed installations similar in design and extent to that indicated for this Project, and who has a record of successful in-service performance. No Exceptions.

B. The manufacturer must be a ISO 9001:2000 certified www.iso.org manufacturer with certification issued to a United States facility, this shows a commitment to delivering the highest quality service and products to the end user. Manufacturer shall be UL and CUL Certified www.ul.com/database/ and certified by the Air Movement and Control Association (AMCA) www.amca.org/search.htm to ensure quality, consistency and reliability of products. All certification documents shall be provided and attached to the bid proposal. No exceptions.

C. Engage a firm experienced in manufacturing vehicle exhaust systems similar to that indicated for this Project and with a record of successful in-service performance.

D. Conduct conference at Project site. Review methods and procedures related to vehicle exhaust system installation.

1. Review access requirements for equipment delivery.

2. Review equipment storage and security requirements.

3. Inspect condition of preparatory work performed by other trades.

4. Review structural loading limitations.

5. Review that all components specified in this Section and related components specified in other Sections are accounted for.

1.04

DELIVERY, STORAGE AND HANDLING

A.

Packing, Shipping, Handling and Unloading: Deliver components with protective packaging. Store in original protective crating and covering and in a dry location.

1.05

PROJECT/SITE CONDITIONS

Existing Conditions: Verify dimensions installation areas by field measurements.

1.06

COORDINATION

A. Coordinate layout and installation with other work, including light fixtures, fixed equipment and work stations, HVAC equipment, and fire-suppression system components.

B. Coordinate location and requirements of service-utility connections.

1.07

REFERENCES

Air Movement & Control Association International, Inc.

AMCA Standard 500-D-98, "Laboratory Methods of Testing Dampers for Rating".

ASTM International.

Stainless Steel:

a.

A240/A240M-04ae1 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications b.

Bright, Directional Polish: No. 4 finish.

2.

Aluminum:

B209/209M-04 Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate b.

Powder-Coated Finish: Immediately after cleaning and pretreating, electrostatically apply manufacturer's standard baked-polymer thermosetting powder finish. Comply with resin manufacturer's written instructions for application, baking, and minimum dry film thickness.

Galvanized Steel:

A653/A653M-04a Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

PART 2:

PRODUCTS

2.01

SLIDING TRACK

A one-piece continuous extruded aluminum track in a minimum length of 19 feet (5791.2 mm). Profile shall be of a Boxloc type profile, track height 3-1/8 inches (73.4 mm), track width 1-½ inches (38.1 mm), track thickness 1/8 inch (3.175 mm); aircraft aluminum alloy Type AA-6063 (ASTM B209/B209M). Track: Extruded design that shall incorporate three separate and functioning channels. Channels: Includes the mounting channel, the trolley channel and the Boxloc channel. Mounting Compartment: Designed to accept the slider bars (which shall be provided with factory supplied vertical support legs and riser clamp duct connection) and to allow positioning along the full length of the slotted track-mounting channel. Mounting Channel: Also accommodate the compressed airlines for the purposes of safe storage and appearance. Trolley Channel: Allow the trolley/balancer/ hose assembly to glide to the door threshold in a safe and effective manner. Boxloc Channel: Allow the whole track to remain rigid as it hangs from factory supplied leg supports and also shall provide an area to attach bolts for splicing additional tracks together for systems over 19 feet (5791.2 mm) long. The overall extruded track lengths shall be 19 foot standard and shall weigh no more than 35 pounds (15.88 KG). The track system shall be equipped with end stops that limit travel of flex hose as the vehicle exits the building. The end stop shall be fabricated of zinc plated steel in a U shape form with a rubber end stop on the impact end. It shall be attached by using a ¼ inch (6.35 mm) molded locking bolt. The end stop shall be secured to the track with no less than (2) ¼ inch (6.35 mm) bolts and locking nuts located on the underside of the track. For security, a ¼ inch 6.35 mm) bolt shall be drilled through the ends of each track system to ensure that the trolley/balancer assembly(s) roll no further than the end of the track system.

2.02

SUPPORT LEGS

Support Leg and Mounting Feet: Manufactured and provided by the supplier of primary exhaust removal system (Equipment Manufacturer). Leg Material: Aircraft aluminum alloy Type AA-6063 (ASTM B209/B209M). Supports shall come standard in 19 feet (5791.2 mm) lengths. A minimum of one support with appropriate bracing shall be provided for every 10 linear feet (3048 mm) of track profile. The support legs shall consist of a square tubular profile with dimensions no less than 2 inch (50.8 mm) OD X 0.1 inch (2.54 mm) with 0.4 inch (10mm) fastening hardware provided. Vertical Adjustable Mounting Foot: Capable of attaching the leg assembly to a ceiling with a 30 degree pitch, complete with a slider bar and 3/8 inch (9.5 mm) hardware necessary for mounting the horizontal track to the mounting channel system. Horizontal Adjustable Mounting Foot: Capable of attaching the leg assembly to a wall, complete with a slider bar and 3/8 inch (9.5 mm) hardware necessary for mounting the horizontal track to the mounting channel system. Support Leg: Equipped with round tubular zinc-plated steel knee brace with pressed ends in standard lengths of 20 inches (508 mm), 30 inches (762 mm) and 72 inches (1828.8 mm). Angle Completely adjustable to the leg support and mounted perpendicular and parallel to direction of the track. Typical Support Angle: 45 degrees from the centerline of the factory provided support leg. The standard leg shall be capable of meeting a Seismic 4 requirement. “Uni-strut”, all-thread rod, and/or chains may not be used in place of a leg assembly or to support the system.

2.03

DOUBLE TRACK JOINER PLATE

Joiner Plate: constructed from a minimum of ¼ inch (6.35 mm) thick zinc-plated material, designed to connect two parallel tracks to make a double track system to accommodate an apparatus bay over 40 feet (12192 mm) in length. Joiner Plate: 10 inch (254 mm) by 8 inch (203.2 mm) flat zinc-plated steel and designed to attach the two tracks to a single factory supplied support leg. The steel plate shall have (6) 3/8 inch (9.5 mm) holes drilled 6-7/8 inches (174.6 mm) apart to accommodate the slider bar provided with factory support legs. Joiner Plate: Have two slider bars attached to the plate, located on the outside edges of the plate. These slider bars shall fit into the Boxloc track mounting channel for a simple and secure attachment of the plate to the Boxloc track. The center portion of the joiner plate shall provide attachment for the factory supplied support leg.

2.04

TRACK SPLICING ASSEMBLY

Track Splice: Manufactured of galvanized steel (ASTM A653/A653M) in two parts and utilized as a clamping device. This clamp shall accurately secure both tracks together in a fashion, which shall eliminate any possibility of obstructing the trolley assembly as it passes through this connection point of track system. Connecting length of splice shall be a minimum of 15-3/4 inches(400 mm) long and fabricated of 14 gauge material. Four (4) 1/4 inch (6.35 mm) bolts with lock nuts shall pass directly through internal partition of the Boxloc track. The splicing sleeve shall fit externally around the outside dimension of extruded aluminum track profile.

2.05

RISER CLAMP ASSEMBLY

Riser Clamp: Fabricated as a one piece welded assembly, manufactured to create the transfer of the hard spiral pipe joined at the top and flexible duct connection at the bottom. A slider bar and associated hardware shall be provided with riser clamp assembly. Sizes of the riser clamp will range from 4 inches (101.6 mm) to 5 inches (127 mm) in diameter to match the output velocity of the vehicles that will park in that station.

2.06

TROLLEY/BALANCER ASSEMBLY

Trolley Assembly: Manufactured as a two piece galvanized steel assembly including bumper stops at each end. Fixed to the side of the trolley are solid steel pins, which shall be for load carrying bearings that are sealed and permanently lubricated. The load carrying bearings shall travel internally in track trolley channel. Two additional permanently lubricated trolley wheels shall be provided on bottom side of the track to reduce wobble of trolley as it conveys the hose assembly to the door threshold. Release Plate: Attached to the chassis of the trolley to smoothly energize the uncoupling release valve when the trolley-balancer assembly approaches the door threshold. System Balancer Assembly: Self-adjusting weight spring tension balancer with a lifting capacity of no less than 31 pounds (14 KG). The balancer shall have a minimum diameter stainless steel cable of .080 inch (2 mm), with a safety link connection.

2.07

UPPER FLEXIBLE HOSE

Upper Hose: Flexible exhaust hose manufactured for the sole purpose of venting high temperature exhaust gases. Flexible Hose: Designed strictly for the harsh environment of rapid response and auto-release of a vehicle exhaust tailpipe. Hose: Range from 4 inch (101.6 mm) to 5 inch (127 mm) diameters with varying lengths depending on the system length required ranging from 20 feet 6096 mm) to 43 feet (13106 mm) without joining or splicing connections. Hose Material: High temperature synthetic rubber impregnated into a high temperature laminated fabric with a minimum overlapping thickness of 2-7/16 inches (61.9 mm). This construction of hose must be capable of operating at continuous temperatures of 400 degrees F (204 degrees C) and intermittent temperatures of 500 degrees F (260 degrees C) such as are experienced when pump checks are performed inside the station. Wire Helix: Bound and protected in laminations of hose winding. This shall be accomplished in a fashion, which eliminates any possibility of personnel coming in contact with an exposed hot metal helix. The hose shall further protect the internal wire helix from heat buildup and in turn add increased visibility to personnel. Wear Strip: 9/16 inch (14.28 mm) wide and be provided as a safety yellow color. The bend radius of the high temperature hose shall be no less than 1.5 times the diameter of hose to ensure that hot gases are not restricted as they pass through the system. Hoses utilizing an exposed metal helix will not be acceptable due to potential burn hazard and/or shock hazard from being utilized as a grounded, grounding or current carrying conductor for electromagnet connections. No exceptions will be allowed.

2.08

LOWER HOSE ASSEMBLY

Lower Hose: Rigid 4 inch (101.6 mm) to 5 inch (127 mm) diameter by 2 foot (609.6 mm) long section of yellow and black hose identical in appearance to the upper hose assembly. Lower Hose: Support the connection nozzle and Stainless reducing elbow in a rigid fashion to allow for the operator to place hose collection nozzle onto the tailpipe without bending over. The lower hose is the only section of hose which shall disconnect from the upper hose assembly and act as a safety disconnect in the unlikely event the nozzle gets entangled. Hoses utilizing an exposed metal helix will not be acceptable due to potential burn hazard.

2.09

SAFETY DISCONNECT COUPLING /HANDLE

A. Safety Disconnect Coupling SDCH: An injection molded composite body with 360deg rubber bumper to protect the vehicle and disconnect from wear shall be incorporated in the design of the system. Coupling: Consists of two aluminum inner flange collars connected by a patented easy reconnect mechanism. The release tension of this device shall be preset at 99 pounds. And easily reconnected with only 33 pounds of force.

B. Manual Connection Fill Valve: Integrated into the SDCH body, sliding/push button type for manual or automatic release. In its design this valve shall be incorporated in its design into the handle which the operator may easily operate in a standing position. The attachment of the collection nozzle shall not position the operator's breathing zone closer than 36 inches (914.4 mm) from the exhaust tailpipe. The automatic release of the connection valve shall be no greater than 3 psi (2109 KG/m2). shift pressure to activate the automatic nozzle deflation. Primary Air Supply: Accomplished by means of a compression type fitting. The regulated air supply line to collection nozzle shall be designed to safely release from the upper hose at a pressure no greater than 80 lbs. (362.8 KG) 2.10

COLLECTION NOZZLE ASSEMBLY

Collection Nozzle Assembly: Provides a substantially air tight seal around exhaust tail pipe when connected thus allowing for virtually 100% source capture. The seal shall limit escape of life threatening exhaust gases

The Nozzle shall be engineered and designed with rare earth magnets that are strategically positioned on the face of the collection nozzle. The collection nozzle shall also incorporate a protective rubber safety cover to avoid damage to vehicle and surroundings. The tailpipe adapter shall be a conical design for aiding in the connection and release of the collection nozzle from the fire apparatus. The magnets shall only make contact with the face of the adapter located on the tailpipe. The reducing elbow that connects to the connection nozzle shall be fabricated using continuous welded construction and shall be made from stainless steel. The angle of transition shall be no less than or greater than 67 degrees from the centerline of the reducer. The stainless steel reducer shall incorporate a primary expanded metal debris screen, which is permanently affixed by welded seams to the inside opening of exhaust fitting. Since this item is a point of safety for both personnel and the system itself, no exception will be allowed 2.11

HOSE SADDLE

Hose Suspension Saddle: Fabricated of a rubber molded cushion specifically manufactured for the sole purpose of suspending high temperature exhaust ventilation hose in a rapid response and auto-release application. The design of the saddle shall smoothly transition the direction of the hose during its travel along the track. Securing clamps shall be provided including a link fastener, for the purpose of mounting it to the balancer safety link.

2.12

ELECTRICAL CONTROLLERS

Controller: Built and supplied by a UL recognized and listed exhaust system manufacturer. Controller shall carry the UL - CUL listing label as an “Enclosed Industrial Control Panel.” Individual components listed by UL - CUL shall not satisfy the above requirement. Manufacturer shall undergo monthly inspections by UL to verify all requirements and standards are met as outlined by UL. The controller shall be delivered as an Operating System Three series controller or an approved equal to the specifications to follow.

Electrical Controllers: Bear a visible UL listing label as proof of subscribership and shall be validated by UL www.ul.com/database/ as an “Enclosed Industrial Control Panel”. Certification documents shall accompany bid documents.

Manufacturer Name:

UL File No.:

Electrical controller and manufacturer shall be recognized and listed by UL. Controller shall be manufactured in accordance with Underwriters Laboratories standard UL-508 for “Enclosed Industrial Control Panels”. The electrical controller shall include a Class 1 limited energy control circuit. Enclosures shall be NEMA 12 rated and UL listed as Type 12. The electrical control components shall be provided and mounted in an electrical enclosure to restrict access to internal components of the controller by authorized personnel only.

Controller Performance: Designed to sense the output pressure and/or temperature change inside the ductwork system, which is normally generated by any internal combustion engine designed to propel a motor vehicle. The operating logic shall be designed to complete this cycle. At any point in time when a collection device is connected to a motor vehicle's exhaust tailpipe, as the operator starts the vehicle, the controller shall automatically sense the engine's output pressure or temperature of the exhaust and in turn energize the electrical contactor which will supply power to the AMCA certified spark resistant fan motor. Through the use of an adjustable timer the controller shall keep the contactors energized for up to six minutes in accordance with the stations response requirement. If the responding vehicle does not disconnect from the exhaust ventilation system in less than the designated setting, the temperature override switch shall override the time delay to ensure continuous system operation. This automated function will work for as long as the exhaust gas temperature is in excess of the setting on the heat sensor located in the ductwork system. This cycle shall not allow the electrical contactor, which energizes the exhaust fan, to short cycle or stop the fan while the system is connected to an operating vehicle.

D.

Motor Control Contactor: The contactor shall be UL - CUL listed as an approved component.

E.

Motor Control Overload Relay: Overload relay shall have an adjustable trip range to meet the proper full load amperage of the blower motor.

F.

Soft Touch Controls: Incorporated on the face or the access door of the controller by the use of an adhesive backed Lexan membrane type label to prevent water infiltration, which would void the NEMA 12R rating. Label: Provided and secured permanently to the exterior of the electrical controller. Label: Include the name of the manufacturer, address, telephone number, user instructions and any warnings or cautions required by Underwriters Laboratories.

Auto Start: This mode of operation shall be strictly for normal day to day use, as it would apply to receiving an emergency call and leaving the station. Any one or combination of the three devices listed below in Paragraph H shall activate the system. The system shall maintain itself in the Auto Start mode and always return there after the Stop sequence has been initiated. The controller shall not have a permanent off position due to the potential health hazards of diesel exhaust components.

Stop: This mode of operation shall be a system override to shut down the system manually. Upon activating this mode of operation the exhaust system blower shall shut down. After a period not to exceed three seconds the controller shall automatically return to the Auto Start ready mode. This shall be a safety feature to prevent a potential health hazard from carcinogenic diesel exhaust leakage from systems having an undesirable open nozzle.

Manual Run: This mode of operation shall be a system override to run the exhaust system blower continuously for the purpose of running the vehicles indoors for equipment checks during inclement weather. Upon activating this mode of operation the exhaust system blower shall start and run continuously until the Stop mode is activated at which point the system will automatically return to the Auto Start ready mode within a maximum three second time period.

G.

System Indicator LED’s: Show system status at all times.

Auto Start Indicator: Indicate the system is in the fully automatic mode of operation and that power is on to the controller.

Fan On Indicator: Indicate that power is being applied to the system blower and the controller is operating normally.

Filter Status Indicator: Indicates, if flashing, excessive pressure loss across the filter bank media. Consequently the filter must be serviced to maintain optimum efficiency of the system.

4.

Stop Indicator: Indicate the fan has been manually de-energized and will return to the Auto Start ready sequence in less than three seconds to prevent the system blower from being left in the Off mode.

5.

Manual Run Indicator: Indicate the fan is operating in a continuous run mode until interrupted by the stop mode activation.

H.

Controller Transformer: UL listed industrial control circuit transformer sized to properly supply all components so that only one transformer shall be required. Transformer shall be provided with multi-tap primary for 115, 208, 240, 277, 400, 480, and 600VAC, and 24, 120, 230VAC secondary operating on 50 or 60 hertz with a capacity of 90 volt amperes.

I.

Control Circuit Protection: By the use of primary and secondary fuses to meet UL requirements. The primary shall be protected by a pair of FLQ style fuses rated at 1.6 amps for voltages under 400V and a pair of .75 amp fuses for voltages over 400V. A single glass fuse rated at 3.15 amps at 250V shall protect the secondary side of the control circuit.

J.

Electronic Control Circuit Card: Solid state printed circuit board. The soft controls shall be an integral part of the control circuit card. The control circuit card shall utilize a potentiometer to adjust the length of the timing cycle from 7 to 360 seconds. It shall incorporate several different modes of operation and optional features.

K.

Activation Devices:

1. Engine Start Switch: An engine pressure sensing type, capable of recognizing the output pressure of any type of motor vehicle exhaust. The electrical contact shall be dry type or not to exceed 24V ac. There shall be one sensor per vehicle.

2. Thermal Start Switch: Temperature sensing switch of the snap disc type and adjustable from 90 degrees F (32 degrees C) to 130 degrees F (55 degrees C) to configure the system based on different exhaust temperatures. There shall be one sensor per vehicle.

3. Wireless Transmitter and Receiver System: Shall be an optional feature operating on a 900 Mhz spread spectrum frequency and FCC part 15 compliant. The receiver shall utilize 4 independent programmable channels of control and capable of supporting up to 16 transmitters. The receiver shall operate on 24 VAC and enclosed in a non metallic enclosure with a clear see through lid to view digital display for system supervisory functions. The transmitter shall be programmable and shall be powered by a 5 year 3 volt battery for ease of replacement and cost savings. The transmitter shall have an open field range of 2500 feet and shall be initiated by a NO contact closure such as from a pressure switch mounted on the exhaust system or a relay mounted on the vehicle.

L.

Clean Filter Indicator Alarm: Used in conjunction with the optional Unifilter for filtering diesel exhaust particulate before release to the atmosphere. The clean filter indicator shall monitor the pressure loss across the filter bank media. Once the useful life of the filter has been depleted the pressure differential switch will signal a high-pressure loss and flash the “Fan On” indicator while the exhaust blower is running.

M.

Optional System Monitor: Shall be an optional feature to monitor the system and advise when a preset number of emergency runs or run time on the system have accrued.

N.

Optional No Airflow Alarm: Shall be an optional feature to monitor the system and advise when the exhaust fan is not functioning properly.

O.

Optional Carbon Monoxide Alarm: Shall be an optional feature to monitor the carbon monoxide levels inside the apparatus bay area.

P.

Electrical Wiring: Run in wire channel to allow for easier identification of the wiring circuits and for a neat appearance. All wiring circuitry shall meet National Electric Code and UL standards for proper size, bending radiuses (NEC code ref. 300-34) and terminations.

Q.

Electrical Terminal Block: 600 V, UL rated and recognized. It shall provide individual connection points for remote controls, clean filter indicator and power connections. The primary and secondary control wiring fuses shall be incorporated into the terminal block as one unit.

R.

Product Manual: Shall be provided with each electrical control box supplied. The product manual shall include a description of components with part numbers inclusive to the controller. It shall include a wiring schematic showing all internal circuitry as well as all field installed wiring connections to the controller.

S.

Electrical Interference: To protect the apparatus and communications, designs that allow any possibility of electrical back-feed or induced current which may interfere with a central services communication or onboard vehicle computer logic or navigational equipment will not be accepted.

2.13

ELECTRICAL SYSTEM

Station Electric Supply Panel: The power circuit for the “Emergency Response Vehicle Exhaust Removal System” shall originate in a circuit breaker panel board of the appropriate size to handle the load. Fan circuit shall be supplied by a UL listed, HACR rated circuit breaker (HACR rating is specifically for motor type loads) of the same type as indicated by the manufacturer of the circuit breaker panel or a dual element time delay fuse for fuse style panels. The circuit shall be clearly marked on an engraved ledger plate or in ink on the panel schedule as “Emergency Response Vehicle Exhaust Removal System”.

OS-3 Automatic Controller: Built and supplied by a UL recognized and listed exhaust system manufacturer. Controller shall carry the UL - CUL listing label as an “Enclosed Industrial Control Panel”. Individual components listed by UL shall not satisfy the above requirement. Manufacturer must undergo monthly inspections by UL to verify all requirements and standards are met as outlined by UL. The controller shall be delivered as an Operating System Three series controller or an approved equal to the specifications in 2.17 Electrical Controllers. The controller shall be mounted 6 feet (1829 mm)to the top of the cabinet AFF (above finished floor). A safety disconnecting means must be within sight of the controller for servicing and for safety reasons. If the supply panel is not within sight, a separate disconnecting means is required beside the controller (per NEC Code 2008). Safety disconnect shall be capable of being locked in the off and on position to follow lockout, tag out procedures. See attached Table 1-1 for proper Square D part number of safety disconnect switch.

Power Wiring Conduit: Minimum of EMT utilizing fittings for damp locations such as apparatus wash down areas (per NEC Code 2008). Conduit shall be supported with a conduit strap every 10 feet and within 3 feet of each box or termination, (per NEC 2008).

Power Wiring from Supply Panel to OS-3: THHN stranded copper wire consisting of a flame retardant, heat-resistant thermoplastic insulation with a nylon jacket for abrasion, gas, and oil resistance and rated up to 600 volts.

Low Voltage Control Wiring: Minimum of a 16/2 multi-conductor cable to meet UL standards for the controller’s low voltage field wiring.

Low Voltage Control: Encased in a minimum of ½ inch (12.7 mm) EMT from the OS-3 Controller to the attic or building steel where it shall terminate with a EMT connector with a threaded plastic bushing. Conduit: Supported with a conduit strap every 10 feet and within 3 feet of each box or termination (per NEC Code 2008). The 16/2 multi-conductor cable shall be supported by the building structure and ran in a manner that the cable will not be damaged by normal building use (per NEC Code 2008), securely fastening it with nylon tie wraps every 24 inches (609.6 mm) to 36 inches (914.4 mm). Draping of the cable perpendicular to building steel or support members will be unacceptable.

G.

Power Wiring from OS-3 to Fan Motor: Minimum of EMT utilizing compression type fittings for damp locations such as apparatus wash down areas (per NEC Code 2008). Conduit shall be supported with a conduit strap every 10 feet (3048 mm) and within 3 feet 914.4 mm) of each box or termination (per NEC Code 2008). Conduit shall extend through the outside wall through a hole of the proper size and terminate directly into the back of the safety disconnect with the appropriate connector and sealed with a silicon sealer or cement mortar. (Using fan model number select appropriate wire and conduit size from Table 1-1).

H.

Fan Safety Disconnect: Square D, non-fusible, NEMA 3R rated for wet locations, mounted adjacent to the AMCA Certified blower. Safety disconnect shall be capable of being locked in the off and on position to follow lockout, tag out procedures. (Using fan model number select appropriate safety disconnect from attached Table 1-1).

I.

Liquid Tight Flexible Metal Conduit: UL listed liquidtight flexible metallic conduit (Sealtite). Conduit will encase the load wires and ground wire from the safety disconnect switch to the blower motor. Conduit length not to exceed 4 feet (1219.2 mm) from disconnect to blower motor. The appropriate listed terminal fittings shall be used (per NEC Code 2008). (Using fan model select appropriate conduit size from attached Table 1-1).

J.

Spark Resistant Blower: AMCA certified, designed and installed as a direct drive spark resistant blower (IMC code ref. 503.2) The motor shall meet current EPACT standards for energy savings. Fans utilizing steel impellers will not be accepted.

K.

Optional Temperature Switch: One for each apparatus connected to the system. The temperature switch shall be of the snap disc type and adjustable from 90 degrees F (32 degrees C) to 130 degrees F (54 degrees C). It shall be mounted on the ductwork 2 inches (50.8 mm) above the pressure switch by drilling a 1 inch (25.4 mm) hole, sealing the switch with silicon sealant and securing with 2 tek screws. Electrical connection shall be made with terminals provided or solder less type such as Thomas & Betts part no. 14RB-2577 or equivalent.

L. Pressure Switch: One for each apparatus connected to the system. The pressure switch shall operate at a maximum of 24VAC, pre-calibrated at .18 in. of water column. Mounting shall be accomplished by drilling a 3/8 inch (9.5 mm) hole 3 inches 76.2 mm) above the riser bracket and to the left of the regulator and threading the switch into the duct. The electrical connections shall be made with a 0.020 inch (.5 mm) by 0.187 inch (4.8 mm) female quick disconnect terminals, such as Thomas & Betts part no. 14RBD-18277 or equivalent.

2.14

AIR MOVING DEVICES

Centrifugal Fans: Direct drive centrifugal type, high pressure, single width, single inlet as required or indicated. Impeller Wheels: Radial design or backward incline for performance, spark resistant and made of a non ferrous material to prevent static electricity build up. The impeller shall be dynamically and statically balanced and of the non-overloading type to provide maximum efficiency while achieving quiet, vibration-free operation. The fan housing shall be manufactured from a epoxy powder coated galvanized steel or nonferrous material. The outlet configuration shall be top horizontal, bottom horizontal, or upblast. The housing shall be capable of field reconfiguration in the event the mounting position needs to be changed for unforeseen reasons. For aesthetic reasons the fan motor and assembly shall be mounted on a welded Type 304 stainless steel (ASTM A240/A240M) or epoxy powder coated steel mounting base to prevent rust stains on the exterior of the building. The fan housing and motor mounting hardware shall be Type 304 stainless steel (ASTM A240/A240M) for serviceability reasons.

Fan Motor and Bearing: All 1 horsepower (746 watts) to 15 horsepower (11190 watts) motors shall be totally enclosed fan cooled (TEFC) continuous duty rated. The motors shall be dual voltage where applicable. Motors built after October 27th, 1997 shall comply with the government mandated “Energy Policy and Conservation Act” (EPACT) as outlined by the Department of Energy. The bearings shall be self-aligned, ball bearing type permanently sealed and lubricated. The exhaust discharge outlet shall be in compliance with International Mechanical Code and ACGIH recommendations (min. of 36" above roofline). Air intakes, windows, cascade systems, prevailing currents, communication equipment and building aesthetics shall be considered in the final location of the fan.

Teflon Shaft Seal: The fan shaft shall be steel and rotate in a non-sparking TEFLON seal to prevent leakage and to prevent hot exhaust gases from coming into contact with the motor bearings.

Variable Speed Drive: The motor shall be compatible with a variable speed drive unit.

Performance: The delivered volume shall take into account all the static regain of vehicle engine exhaust (based on an airtight connection at the tailpipe), lengths of ductwork, elbows, branches, shut off, wyes, etc. which accumulate the static pressure at the field inlet. The manufacturer’s provided fan(s) shall be performance guaranteed.

Fan Capacity: The Fan Capacity shall be sized as such as to deliver the required CFM at each hose drop to which the vehicle is attached.

The 4 inch (101.6 mm) hose system shall be designed to deliver a minimum of 500 CFM (2.9 M/Second) at a velocity of 5800 FPM (33.6 M/Second) at the hose and nozzle connection.

b.

The 5 inch (127 mm) hose system shall be designed to deliver a minimum of 750 CFM (4.4 M/Second) at a velocity of 5800 FPM (33.6 M/Second) at the hose and nozzle connection.

c.

The 6 inch (152.4 mm) system shall be designed to deliver a minimum of 1100 CFM (6.4 M/Second) at a velocity of 5800 FPM (33.6 M/Second) at the hose and nozzle connection.

Location: The preferable fan location shall be on the outside of the fire station as far away from any living quarters as possible so that firefighters would not be disturbed by the system activation. No blower fans shall be mounted inside the fire station. Silencers shall be provided when fan sound pressure level exceeds 64 dB.

2.15

DUCTWORK SYSTEM

Ductwork Type and Materials: UMC Class 2 or SMACNA Class II product conveying duct, meet or exceed criteria for construction and performance as outlined in Round Industrial Duct Construction Standards, SMACNA. Materials of construction unless otherwise specified for all ductwork and fittings shall be a minimum G-90 galvanized sheet metal (ASTM A653/A653M). Only when specified, Type 304 stainless steel (ASTM A240/A240M) shall be provided.

B.

Ductwork Sizing and Gauges: Round pipe construction, with the range of available sizes not to exceed 10 inches (254 mm) in diameter. Duct gauge shall depend on diameter and a minimum operating pressure of 8 inches water gauge (1990 Pa). Acceptable Gauge and Reinforcement Requirements: Inner duct diameter 4 inches (101.6 mm) through 11 inches (279.4 mm) diameter shall be 22 gauge standard pipe (International Mechanical Code).

C.

Ductwork Fittings: Round and have a wall thickness 2 gauges (one even gauge number) heavier than the lightest allowable gauge of the downstream section of duct to which they are connected (International Mechanical Code). Air Duct Branch Entrances: Factory fabricated fittings or factory fabricated duct /tap assemblies. Fittings: Constructed so that air streams converge at angles no greater than 45 degree (International Mechanical Code). All Seams: Continuous stitch welded and if necessary internally sealed to ensure air tightness. Turning elbows shall be stitch-welded and used for all diameters and pressures. They shall be fabricated of 24 gauge galvanized steel and constructed as two piece with continuous welded seam construction fittings similar to those provided by Lindab Inc. Tapered Body Fittings: Used wherever particular fallout is anticipated and where air flow is introduced to the transport duct manifold.

D.

Ductwork Design Velocities: Minimum of 3500 FPM (20.3 M/Second) to 4000 FPM (23.2 M/Second) transport velocity. Capture Velocity: 5500 FPM (31.9 M/Second) to 6000 FPM (34.8 M/Second) to extract virtually 100 percent of the exhaust gases.

External Ductwork: Sized for the exact inlet and outlet of the exhaust fan blower. An exhaust rain cap shall be supplied and manufactured in accordance with EPA standard for free draft rain cap requirements. Included as an integral part of this rain cap shall be a back draft damper to provide protection from rain and other inclement weather.

Exhaust Penetrations: The core drilling shall be properly sized to reduce the diameter of the opening to the smallest possible size.

PART 3

EXECUTION

3.01

EXAMINATION

Examine areas and conditions, with Installer present, for compliance with requirements for installation tolerances, service-utility connections, and other conditions affecting installation and performance of equipment. Do not proceed with installation until unsatisfactory conditions have been corrected.

3.02

PREPARATION

A.

Provide surface/substrate preparation as required by the manufacturer's printed installation instructions. Do not proceed with installation is in proper condition to receive vehicle exhaust system installation.

3.03

INSTALLATION

Install vehicle exhaust system in accord with manufacturer’s written instructions, original design and referenced standards.

3.04

ADJUSTING

Adjust vehicle exhaust system for proper operation. Replace any parts that prevent the system from operating properly.

3.05

CLEANING

Remove all debris caused by installation of the vehicle exhaust system. Clean all exposed surfaces to as fabricated condition and appearance.

3.06

PROTECTION

A. Provide protection of the completed installation until completion of the project. Repair any damage at no additional cost to Owner.

3.07

TRAINING

Provide training to fire department personnel in the daily use and maintenance of the vehicle exhaust removal system that has been installed and specified herein. The fire department shall be notified at least 7 days prior to the date scheduled for the training course. Training shall be for all personnel involved with the operation of the exhaust removal system to include all shifts required to man the particular facility. The Training session shall be performed in person by a recognized representative of the manufacturer of the exhaust removal system, in addition a training video shall be provided to the fire department.

Provide training to all shifts during their normal shift period.

3.08

WARRANTY

A. Provide a written warrantee for a period of one (1) year from date of shipment for all components.