Miami University Cole Service Building Boiler Replacement · Cole Service Building Boiler...

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Miami University

Cole Service Building Boiler Replacement

Project Manual

Project No. G120270CD

BID SET


PROJECT MANUAL FOR

MIAMI UNIVERSITY

COLE SERVICE BUILDING BOILER REPLACEMENT

August 30, 2012 Project Number G120270CD

ENGINEER

FISHBECK, THOMPSON, CARR & HUBER, INC.

11353 Reed Hartman Highway, Suite 500 Cincinnati, Ohio 45241

(513) 469-2370

1515 Arboretum Drive, SE Grand Rapids, Michigan 49546

Phone: (616) 575-3824

Copyright 2012 Fishbeck, Thompson, Carr & Huber, Inc.

All rights reserved.

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Miami University Cole Service Building Boiler Replacement Project Number G120270CD

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Table of Contents

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SECTION 00 01 10 – TABLE OF CONTENTS Division/Section Nos. Section Name

DIVISION 01 GENERAL REQUIREMENTS 01 11 00 Summary of Work DIVISION 22 PLUMBING 22 05 00 General Plumbing Provisions 22 05 09 Copper Pipe and Fittings for Plumbing 22 05 23 General Duty Valves for Plumbing 22 05 29 Hangers and Supports for Plumbing Piping and Equipment 22 07 19 Plumbing Piping Insulation 22 10 19 Piping Specialties for Plumbing DIVISION 23 HEATING, VENTILATING, AND AIR CONDITIONING 23 01 00 Operation and Maintenance of HVAC Systems 23 05 00 General HVAC Provisions 23 05 23 General Duty Valves for HVAC 23 05 29 Hangers and Supports for HVAC Piping and Equipment 23 05 73 Testing and Cleaning of HVAC Systems 23 05 93 Testing, Adjusting and Balancing for HVAC 23 07 19 HVAC Piping Insulation 23 09 00 Instrumentation and Control for HVAC 23 09 93 Sequence of Operations for HVAC Controls 23 10 23 Natural Gas Piping System 23 20 19 Piping Specialties for HVAC 23 21 13 Hydronic Piping 23 21 23 Hydronic Pumps 23 25 00 HVAC Water Treatment 23 51 00 Breechings, Chimneys, and Stacks 23 52 16 Condensing Boilers 23 85 00 Variable Frequency Motor Controllers DIVISION 26 ELECTRICAL 26 00 10 Electrical General Provisions 26 05 00 Common Work Results for Electrical 26 05 20 Conductors and Cables - 600V and Below 26 05 27 Grounding and Bonding 26 05 29 Hangers and Supports for Electrical Systems 26 05 34 Raceways for Electrical Systems 26 05 35 Boxes for Electrical Systems 26 05 53 Identification for Electrical Systems 26 24 16 Panelboards 26 27 26 Wiring Devices 26 28 00 Low Voltage Circuit Protective Devices 26 28 20 Enclosed Switches 26 29 13 Enclosed Controllers

APPENDIX 1 AERCO International Submittal END OF TABLE OF CONTENTS


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Table of Contents

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Summary of Work

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SECTION 01 11 00 – SUMMARY OF WORK PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections apply to this Section.

1.2 WORK COVERED BY CONTRACT DOCUMENTS

A. The Work covered by the Contract Documents includes all labor, material and equipment necessary to provide general, mechanical and electrical construction in the Cole Service Building to replace the existing heating water boiler and associated pumps, piping, electrical wiring and conduit. The Contractor shall be responsible for equipment pads, cutting and patching of new wall or roof openings and modifications to existing systems and equipment. The work also includes demolition of 1 boiler and associated pumps and piping, electrical panels, disconnects, wiring and conduit. Associated DDC temperature control system will be provided by Siemens under state term. Work shall include coordination and installation of accessories and material furnished by Siemens.

B. Construction cost proposals will be received by Miami University for a single prime contract.

C. Miami University will have access to the Site.

D. The Contractor’s access to Cole Service Building outside the boiler room area shall be coordinated and scheduled in advance with the University’s Representative.

1.3 TYPE OF CONTRACT

A. Construct the Work of this Contract under a single prime lump sum Contract.

1.4 GENERAL

A. Imperative Language: 1. These Specifications (Divisions 01 through 26) are written in the imperative and abbreviated form.

This imperative language of the technical specifications is directed at the Contractor unless specifically noted otherwise. Incomplete sentences shall be completed by inserting "shall", "shall be" and similar mandatory phrases by inference in the same manner as they are applied to notes on the Drawings. The words "shall", "shall be" and similar mandatory phrases shall be supplied by inference where a colon (:) is used within sentences or phrases. Except as worded to the contrary, fulfill (perform) all indicated requirements whether stated in the imperative or otherwise.

B. Related Sections: 1. Some Sections of these Specifications (Divisions 01 through 26) may include a paragraph titled

"Related Sections". This paragraph is an aid to the Project Manual user and is not intended to include all Sections which may be related. It is the Contractor's obligation to coordinate all Sections whether indicated under "Related Sections" or not.

C. Reference to the General Conditions: 1. In Divisions 01 through 26, a reference to the General Conditions includes by inference all

amendments or supplements in the Supplementary Conditions.


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D. Furnish, Install, Perform, Provide: 1. The word “furnish,” when used in connection with services, materials, or equipment, shall mean to

supply and deliver said services, materials, or equipment to the site (or some other specified location) ready for use or installation and in usable or operable condition.

2. The word “install,” when used in connection with services, materials, or equipment, shall mean to put into use or place in final position said services, materials, or equipment complete and ready for intended use.

3. The words “perform” or “provide,” when used in connection with services, materials, or equipment, shall mean to furnish and install said services, materials, or equipment complete and ready for intended use.

4. When “furnish,” “install,” “perform,” or “provide” is not used in connection with services, materials, or equipment in a context clearly requiring an obligation of the Contractor, “provide” is implied.

1.5 OWNER FURNISHED MATERIAL

A. Products furnished and paid for by the Owner: 1. Two High Efficient Condensing Boilers B-1 and B-2 Aerco Model BMK 2.0 LN (refer appendix A)

B. Owner's Responsibilities: 1. Arrange for and deliver Shop Drawings, Product Data and Samples to the Contractor. 2. Arrange and pay for Product delivery to the Site. 3. On delivery, inspect Products jointly with the Contractor. 4. Submit claims for transportation damage. 5. Arrange for replacement of damaged, defective or missing items. 6. Arrange for Manufacturer's warranties, inspections and service.

C. Contractor's Responsibilities: 1. Coordinate delivery schedule of material to the site with the Owner and Supplier. 2. Review Shop Drawings, Product Data and Samples. 3. Receive and unload Products at site; inspect for completeness and damage jointly with the Owner. 4. Handle, store, install and finish Products. 5. Repair or replace items damaged by the Work of this Contract.

D. Information on Owner furnished material: 1. Is included in the following Sections:

a. Division 23 Section “Condensing Boilers.”

1.6 WORK UNDER OTHER CONTRACTS

A. The Owner will award a Contract for furnishing and installation of the following work: 1. Siemens DDC temperature control systems.

B. Coordinate the schedule of work under other contracts with the Owner and other contractors.

C. Cooperate with all contractors performing work on the Site.

D. Copies of Contract Documents for work under separate contracts are available for review at the Engineer's office.

1.7 CONTRACTOR USE OF PREMISES

A. Limit use of premises to allow for Owner occupancy and work by other contractors.

B. Coordinate use of premises under direction of the University Representative.


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1.8 OCCUPANCY REQUIREMENTS

A. Owner Occupancy During Construction: 1. The Owner will occupy or utilize the premises during the entire period of construction. Coordinate with

the University Representative to minimize conflict and to facilitate the Owner's operations. 2. Access to Abutting Properties: Provide at all times. 3. Access for Emergency Vehicles:

a. Provide at all times. b. Provide at least one clear lane during non-work periods.

4. Fire Hydrants: Provide access to at all times. 5. Do not block fire access routes from building. 6. Limit parking for construction vehicles to an area designated by the University Representative.

1.9 WORK SEQUENCE

A. Coordinate construction schedule and operations with the University Representative and Engineer. The work shall be started at the time stipulated in these documents and fully completed within time stated in written documents with the Miami University. Work will start after the Notice to Proceed is issued and will be completed within 65 days. For the purposes of this project, completion includes all work up to the issuance of the engineer’s punch list. Final acceptance will be achieved when all work is completed and accepted by the engineer and University Representative.

B. Each Contractor shall plan, schedule and coordinate his work and perform said work at such times in such a

manner, as to not delay completion of project within the stated time. C. Any work necessary to be done after regular working hours, or on weekends, or legal holidays, in order to

complete the work in the stipulated time; shall be done without additional cost to Miami University. Equitable allowance will be made for any written approval of time extension granted.

D. In order to establish "usual weather and other conditions prevailing in the locality of the Project", and to

provide a means by which to evaluate weather impact on the project, the following monthly anticipated adverse weather delay days (based on a 5-day work week) data from National Oceanic and Atmospheric Administration (NOAA) shall be used: January: 14, February: 10, March: 6, November: 5, December: 8. The Contractors days to complete the project will include these anticipated adverse weather delay days and the Contractor's schedule must reflect these anticipated delays in all weather dependent activities. The determination that unusually severe weather occurred does not automatically mean that the Contractor receives a time extension for the difference of days between the anticipated and actual adverse weather delays. Further analysis by the Engineer is necessary to determine if the unusually severe weather delayed Work activities critical to contract completion. The Contractor's daily log, request for adjustment, and progress schedule must be evaluated by the Engineer to make this determination. To determine if there were days in excess of "usual weather and other conditions prevailing in the locality of the Project", the number of adverse delay days will be compared to the NOAA data above. If the number of actual delay days is greater than noted above, then unusually severe weather occurred and the time for Contract Completion may be extended for such reasonable time as determined by the University. If the number of actual delay days is less than noted above, the time for Contract Completion may be reduced for such reasonable time as determined by the University.

E. Schedule of Construction and coordination with Miami University 's other Contractors working in the project

area: Per General Conditions, the Contractor shall schedule the overall work and shall coordinate the work of his subcontractors and material supplies, as well as coordinate his Work with the Work of the University's other contractors working in the area. The schedule shall be updated monthly and submitted to the Engineer and University Representative.

F. A shutdown of the heating water system in Cole Service Building for work in the boiler room shall be

scheduled with the University representative and be coordinated over a weekend when it is convenient for the University and shall start at 5:00 PM on a Friday and be complete by 11:59 PM on the following Sunday. Every hour in excess of 60 hours where the heating water system is not available to Cole Service Building is subject to the associated actual damages, including, without limitation, loss of revenues and essential functions relating to operations located within, intrinsic to and/or dependent upon Cole Service Building. All piping relocation work is to be completed prior to system shutdown.


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G. Submit a proposed sequence with appropriate times of starting and completion of tasks to the Engineer for review.

1.10 PUBLISHED STANDARDS

A. When manufacturers, societies and/or trade associations have published recognized standards or

specifications applying to the manufacture, quality, use and/or installation of materials, the latest issue of such publication on the date of advertisement for bids shall, where applicable, govern the use and installation of such materials unless otherwise specified.

B. Reference in the specifications to the standards and specifications of societies, associations, or other

recognized organizations shall make the applicable portions of such standards and specifications a part of the Contract Documents.

C. When published standards or specifications are in conflict with these specifications, the latter govern.

1.11 TAXES

A. The Contractor shall, in addition to procedures regarding taxes described in General Conditions, assume full responsibility for taking whatever steps are required to relieve Miami University from payment of excise tax and of any sales tax on materials, specialties, and equipment furnished for the project. Each Contractor shall notify Miami University of his need for exemption certificates or other forms to comply with this requirement. Failure of the Contractor to obtain such exemptions shall be no cause for Miami University to pay the Contractor for taxes paid.

1.12 PRE-CONSTRUCTION MEETING

A. The Engineer will schedule a pre-construction meeting at the project site with Prime Contractor, major subcontractors, major material suppliers and Miami University personnel. The agenda of the meeting will generally follow the guidelines below: 1. Introductions, Purposes, and Goals. 2. Communications/Status of Contracts, Permits, etc. 3. Project Meetings. 4. Temporary Facilities. 5. Access to Existing Building. 6. Vehicular Access and Parking. 7. Construction Administration Paperwork. 8. University Concerns.

1.13 WEEKLY CONSTRUCTION MEETINGS

A. The Miami University Project Manager (PM) and the Contractor identify a day and time for weekly construction meetings. These meetings will be held at the Cole Service Building.

B. The PM will prepare an agenda for the weekly construction meetings. The agenda will require a presentation

by the Lead Contractor including a review of the previous minutes, description of the work of the past week, work of the current week, and longer range planning and scheduling topics.

C. Attendance at the weekly construction meetings by the Lead Contractor is mandatory along with any

subcontractor that has work scheduled the following week. The person representing the Lead Contractor shall be familiar with both conditions at the project site and administrative paperwork in the Contractor's office. The person representing the Lead Contractor at weekly construction meetings shall have authority to make binding decisions for the Lead Contractor.

1.14 VEHICULAR ACCESS AND PARKING

A. The University Safety and Security Department shall be notified by the Contractor of any anticipated work that could affect existing traffic flow. This notification shall occur 2 weeks prior to the anticipated work.


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B. Employees of Contractors and subcontractors shall secure parking permits and regulations from the University Parking Services Office and must park cars in areas assigned to them. Parking in University maintained lots is prohibited unless permitted by the University representative. Permits may be obtained from the Parking services Office in Campus Avenue Building between the hours of 8:00 AM and 5:00 PM Monday through Friday.

1.15 TEMPORARY FACILITIES

A. The University will identify staging areas necessary for the delivery and storage of equipment and materials pertinent and relevant to completion of the Project. At completion of Contract, repair and restore site and any damaged paved surfaces to their original condition.

B. The Mechanical Contractor shall provide a dumpster for debris as a result of demolition and/or construction

work. The dumpster shall be placed and maintained as directed by the University. Debris may be removed from site daily in lieu of dumpster service. The use of University dumpsters is strictly forbidden.

1.16 MEASUREMENTS AND LAYOUT OF WORK

A. Each contractor shall be responsible for correctness and layout of their work and for proper fitting and fabrication of all materials and work. Take all necessary measurements for proper completion of work and field verify dimensions shown on drawings. Report any discrepancies to Engineer in writing and request instructions and adjustment before proceeding with work.

B. The exact location of the new work may be ascertained from Miami University, the Engineer or his

representative in the field. If Contractor fails to ascertain such locations, the work will be changed by the Contractor at his own expense when so ordered by the Engineer. The Engineer reserves the right to make minor changes in location up to the time of installing, without additional cost.

C. Verify layout information shown on Drawings before proceeding with layout of work.

1.17 CONTRACT CLOSE OUT

A. Submit written signed certification that Contract Documents have been reviewed, Work has been inspected, and that Work is complete in accordance with Contact Documents and ready for Engineer's inspection.

B. Submit final accounting to Miami University with final Application for Payment as follows:

1. Original Contract Sum 2. Additions and deductions resulting from; 3. Change Orders 4. Other adjustments 5. Total Contract Sum, as adjusted. 6. Previous payments 7. Sum Remaining Due

C. Evidence of Payment and Release of Liens: Per requirements of the General and Supplementary

Conditions. Contractor final affidavit, release and waiver of lien, acknowledgment of payment shall be complete for Prime Contractor’s own forces. Subcontractor final affidavit, release and waiver of lien, acknowledgment of payment shall be complete for each Subcontractor who has provided work. Material supplier final affidavit, release and waiver of lien, acknowledgment of payment shall be complete for each Material Supplier who has provided material.

D. Warranties and other close-out submittals listed in individual Specification sections and as noted below. E. Note that all items contained in this Section and other referenced Section shall be submitted by each

Contractor to the University PM prior to submission by the Contractor requesting final payment. Payment shall not be processed until all items are submitted in accordance with the Contract Documents.


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1.18 SAFEGUARDS DURING CONSTRUCTION

A. The following precautions shall be taken while the building is under construction. Note the following does not constitute any responsibility by the Engineer, the Engineer's Consultants, or the Miami University for safety procedures, means and methods of the Contractors. The construction documents shall not relieve the Contractors and any other entity of their obligations, duties and responsibilities, including, but not limited to, construction means, methods, sequence, techniques or procedures necessary for performing, superintending or coordination all portions of the work of construction in accordance with the contract document and nay health or safety precautions required by any regulatory agency having jurisdiction.

B. Approved portable fire extinguisher shall be provided in accordance with the Provisions of N.F.P.A. No. 10

(Portable Fire Extinguisher). C. Access to the project site and surrounding areas shall be provided for heavy firefighting equipment at the

start of construction and continuously maintained thereafter. D. Cutting and welding operations on the project site shall be properly supervised. E. Only the following types of temporary heating equipment are recommended: Steam Heaters and approved

electric heaters subject to the approval of the Miami University, Building Authority and Local Fire Department having jurisdiction. Whichever type is chosen, it should be properly supervised and maintained.

F. Smoking anywhere on the campus outside of personal vehicles shall be prohibited at all times. G. Waste material and rubbish shall not be stored nor allowed to accumulate within the building or in the

immediate vicinity but shall be removed from the premises daily. H. Scrap fires shall not be permitted on the Project Site. I. Flammable liquids and other hazardous materials such as bottled gasses, paints, flammable thinners. Fuels

and gasoline shall be stored in locked detached structures. They shall be dispensed and carried only in Underwriter's Laboratory approved safety cans.

J. Construction offices and sheds for the storage of tools and materials shall not be located within the building. K. Follow all local, state and OSHA regulations for construction sites. Comply with OSHA Act of 1970 (P.L. 91-

596). END OF SECTION 01 11 00


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General Plumbing Provisions

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SECTION 22 05 00 – GENERAL PLUMBING PROVISIONS PART 1 - GENERAL


A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes specifying the general requirements for execution of that portion of the Work defined in Division 22 of these Specifications and as indicated on the Drawings: 1. Major items include, but are not necessarily limited to:

a. Piping, fittings and valves. b. Piping and equipment insulation. c. Plumbing equipment. d. Demolition of existing plumbing work. e. Labor, materials, equipment, tools, supervision and start-up services. f. Instructions to Owner regarding operation. g. Incidental and related items necessary to a complete and functionally operational installation of

the Work. 1) General requirements. 2) Drawings. 3) Supervision. 4) Unacceptable work and observation reports. 5) Final inspection. 6) Guarantee. 7) Test and adjustments. 8) Manufacturer’s drawings. 9) Protection and cleaning. 10) Remodeling.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of Division 22 shall comply with the following: 1. ANSI: A13.1 - Standard for the Identification of Piping Systems. 2. ASME - American Society of Mechanical Engineers: B31.1 – Pressure Piping Code. 3. ASME - American Society of Mechanical Engineers: Boiler and Pressure Vessel Code - Section IV -

Heating Boilers, Section VIII - Unfired Pressure Vessels. 4. Ohio Building Code. 5. State of Ohio Code for Energy Conservation. 6. Local Building Code.

B. Contractor shall file all Drawings, pay all necessary charges and fees, and obtain all necessary permits and certificates of inspection relative to their work.

C. Nothing contained in the Drawings and Specifications shall be construed to conflict with these laws, codes and ordinances and they are hereby made a part of these Specifications.

1.4 GENERAL REQUIREMENTS

A. Include any minor details essential to successful operation and any other items indicated on the Drawings.

B. If the Contractor has any questions concerning the Drawings and Specifications or notices any discrepancies or omissions in either Drawings or Specifications, contact the Engineer for clarification before Bids, to fully understand the extent and responsibilities of their work.


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C. Contractor shall visit the Site and fully inform themselves concerning all conditions affecting the scope of their work. Failure to visit the Site shall not relieve the Contractor from any responsibility in the performance of their Contract.

D. Other than minor adjustments shall be submitted to the Engineer for approval before proceeding with the work.

E. Coordinate and scheduling work performed by this Contractor with the University’s Representative.

F. All connections to, or revisions in, existing piping or facilities shall be done at such time as agreed to by the Engineer and University’s Representative and all work shall be scheduled as required under "General Conditions". Revisions to the existing piping systems must be done with the minimum of shutdown time. All piping shall be run to the point of new connections and new equipment installed and ready to operate before any connections are to be made.

G. At the completion of the project, this Contractor shall promptly clean up and remove from the Site, all debris and excess materials.

1.5 DESIGN AND PERFORMANCE REQUIREMENTS

A. Construction details, components, accessories, sizes and model numbers indicated on the Drawings or in these specifications are used to indicate minimum levels of quality and coordination requirements.

B. Equipment supplied, whether as scheduled or selected from list of acceptable Manufacturers, must meet minimum requirements listed in specifications or on Drawings, be compatible with facility and intended use, and meet requirements for a functional system.

C. Drawings: 1. Are diagrammatic and indicate general arrangement of systems and work included. 2. Do not necessarily indicate every required valve, fitting, trap, thermometer, gage, duct, elbow,

transition, turning vane, mounting support and access panel. 3. Shall not be scaled for measurement or installation location. 4. Shall not serve as Shop Drawings. 5. Consult all Contract Drawings which may affect the locations of any equipment, apparatus and piping

and make minor adjustments in location to secure coordination. 6. Piping layout is schematic and exact locations shall be determined by structural and other conditions

and verified in the field. This shall not be construed to mean that the design of the system may be changed, it refers only to the exact location of piping to fit into the building as constructed, and to coordination of all work with piping and equipment included under other Divisions of the Specifications.

7. Where certain grades and/or elevations are given on the Drawings, they have been obtained from the best information available; however, they are not guaranteed. This Contractor MUST assume the full responsibility of verifying present elevations in the field and making any adjustments as may be necessary, all of which must be included in their Bid Price.

8. Install all work as close as possible to walls, structural, members, etc., consistent with the proper space for covering, access, etc., so as to occupy the minimum of space and allow as much space as possible between ductwork, piping, etc. and the ceiling.

D. Schedules and model numbers shall not be used to: 1. Serve as final, definitive quantity requirements. Contractor shall make own count as indicated on

Drawings. 2. Determine proper type or model with arrangement, mounting and accessories applicable.

E. Coordinate installation work of Division 22 with work of other trades to provide a complete and functional system.

1.6 SUPERVISION

A. The Contractor shall have in charge of the work, on the Site as required, during construction, a competent superintendent experienced in the work installed under this Contract.


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1.7 UNACCEPTABLE WORK AND OBSERVATION REPORTS

A. Work shall be unacceptable when found to be defective or contrary to the Drawings, Specifications, Codes specified or accepted standards of good workmanship.

B. The Contractor shall promptly correct all work found unacceptable by the Engineer whether observed before or after Substantial Completion and whether or not fabricated, installed or completed. The Contractor shall bear all costs of correcting such unacceptable work, including compensation for the Engineer's additional services made necessary thereby.

C. During the course of construction, the Engineer will prepare "Observation Reports" with a list of items found to be in need of correction. All items listed shall be corrected by the Contractor. A space is provided on the form for the Contractor to note the completion of each item. All prior "Observation Report" items must be completed, the lists signed and returned to the Engineer prior to making the final inspection. After the final list is issued, the same procedure will apply.

1.8 FINAL INSPECTION

A. When the Contractor determines all work is completed and working properly per the Contract Documents, they shall request a "final" inspection by the Engineer in writing. If more than one reinspection is required after this final inspection, the Contractor shall bear all additional costs including compensation for the Engineer's additional services made necessary thereby. A final inspection will not be made until all prior "Observation Report" punch lists completed, signed and returned to the Engineer.

1.9 WARRANTY (GUARANTEE)

A. This Contractor is responsible for all defects, repairs and replacements in materials and workmanship, for a period of 1 year after approval of the Certificate of Contract Completion.

1.10 INSTALLATION OF PIPING

A. Refer to Part 3 – Execution, for general piping installation requirements that apply to all interior piping systems installed under this Contract, except where otherwise indicated on the Drawings or elsewhere in the Specifications.

1.11 TESTS AND ADJUSTMENTS

A. After work has been completed but before pipe covering has been applied, the Contractor shall test and adjust the systems they have installed.

B. The Engineer shall be notified of all scheduled tests at least 48 hours before they are scheduled so that they may witness same. If the Contractor performs any test without the Engineer present or without properly notifying the, Engineer, the Contractor will be required to perform the test a second time in the presence of the Engineer.

C. Concealed lines shall be tested before being concealed. If this is not done and a leak appears during the final test, this Contractor shall repair leak and all damage resulting there from.


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1.12 MANUFACTURER’S DRAWINGS

A. The Contractor shall submit to the Engineer for review, within 6 weeks after date of contract, the required number of copies in accordance with Division 01 requirements of manufacturer’s drawings, wiring diagrams, pump curves or data. The Engineer will review Contractor’s Shop Drawings and related submittals (as indicated below) with respect to the ability of the detailed work, when complete, to be a properly functioning integral element of the overall system designed by the Engineer. Before submitting a Shop Drawing or any related material to the Engineer, Contractor shall: Review each such submission for conformance with the means, methods, techniques, sequences, and operations of construction, and safety precautions and programs incidental thereto, all of which are the sole responsibility of Contractor; approve each such submission before submitting it; and so stamp each such submission before submitting it. The Engineer shall assume that no Shop Drawing or related submittal comprises a variation unless Contractor advises Engineer otherwise via a written instrument which is acknowledged by Engineer in writing. The Shop Drawings and related material (if any) called for are indicated in the appropriate specification section.

B. The Engineer shall return Shop Drawings and related materials with comments provided that each submission has been called for and is stamped by Contractor as indicated above. The Engineer shall return without comment material not called for or which has not been approved by the Contractor.

C. This Contractor shall furnish equipment Shop Drawings which will indicate power hook up and control connections as required for mechanical equipment. “Stock” wiring diagrams are NOT ACCEPTABLE.

D. Engineer's review of manufacturer's drawings or schedules shall not relieve the Contractor from compliance with the requirements of the Drawings and Specifications.

E. Items may be referred to in singular or plural on Drawings and Specifications. Contractor is responsible for determining quantity of each item.

1.13 PROTECTION AND CLEANING

A. Protect all plumbing equipment against damage from any cause whatsoever and pay the cost of replacing and repairing equipment made necessary by failure to provide suitable protection.

B. Cover all existing plumbing fixtures, equipment and open pipes, etc., to keep out dirt, water and weather during construction.

C. This Contractor shall clean up and remove all debris from the site and shall at all times keep the premises in a neat and orderly condition.

1.14 REMODELING

A. Contractor shall include the remodeling of and additions to all plumbing work in the present building in the areas indicated on the Drawings and in all areas affected by the above. All necessary or required remodeling or additions to the present plumbing work shall be included in this Contract, as indicated or required, to the end that the work will result in the complete system indicated on the Drawings.

B. All unused piping, etc., throughout the facility shall be removed unless otherwise indicated on the Drawings. No abandoned piping shall remain in any part of the renovated area.

C. In all of the remodeling work the plumbing work shall follow the intent of the Plumbing Specification insofar as possible with regard to material and workmanship.

1.15 PRODUCT UNLOADING AND HANDLING

A. Unload equipment and materials required for completion of the Work.

B. Handle and store equipment and materials carefully to prevent damage. Method of rigging and handling shall be subject to the approval of an authorized representative of the equipment Manufacturer whose equipment is being handled.


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1.16 TROUBLESHOOTING

A. By Contractor: If, during the start-up or warranty period, mechanical systems operational problems occur for which the root cause is not readily apparent, Contractor shall promptly, through a Subcontractor or other resource designated by Subcontractor, provide diagnostic and investigative services to determine the cause or causes.

B. By Engineer: 1. At Contractor's request, Engineer will provide the services necessary to determine the cause or

causes of the operational problems. 2. Under the provisions of the General Conditions, Engineer will also provide these services if Contractor

fails to respond satisfactorily to operational problems within a reasonable time after written notice from Engineer.

3. If while working at Contractor's request or under the provisions of the General Conditions, Engineer determines that the problems are due to failure of the Work to comply with the requirements of the Contract Documents, Owner will compensate Engineer for additional services and deduct the amount paid from payment or payments to Contractor.

1.17 MAINTENANCE

A. Special Tools: Where special tools are required for operation, furnish these to Owner.

B. Loose and Detachable Parts: 1. Retain loose and small detachable parts of the apparatus and equipment furnished until the

completion of the Work. 2. Turn over these parts to Owner.

PART 2 - PRODUCTS

Not Used.

PART 3 - EXECUTION


A. All piping shall be arranged in accordance with the best standards of the trade with vertical pipes plumb and horizontal runs parallel or perpendicular to the building wall.

B. Provide valves and specialties where indicated on the Drawings.

C. Provide 3/4-inch drain valves in piping at low points to provide complete drainage of all systems and as indicated on the Drawings.

D. Ream ends of pipe and clean before installing.

E. Copper joints: Copper piping in plumbing systems less than 2 inches shall be soldered using 95/5 tin/antimony solder. Copper piping in plumbing systems 2 inches and larger shall be brazed using a 6% silver alloy with a 1,000 degrees F solidus minimum. Solders and fluxes containing lead are prohibited. For solder to threaded adapter nipples, the contractor shall use either a 95/5 tin/copper solder similar to “Taramet Sterling” or a 96/4 tin/silver solder similar to “Tarasil 964” in lieu of brazing.

F. Valves to be installed with handwheel at or above center of pipe. Valves outdoors exposed to weather shall be installed with handwheel in the horizontal.

G. Make all changes of direction with fittings, rather than bending.

H. Provide dielectric unions or insulating flanges between dissimilar metals, i.e., copper to steel.


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Section 22 05 00


I. Bull head connections in any piping service are expressly prohibited.

J. At the end of each day's work and otherwise as required or directed, provide caps and/or plugs at all openings in piping for protection. Particular attention must be given to avoid the possibility of any foreign materials entering the pipes, whether it be inadvertent or with malicious intent.

3.2 TEST AND ADJUSTMENTS

A. After work has been completed but before pipe covering has been applied, the Contractor shall test the systems as follows. At these pressures, the circulation shall be free and the piping free of leaks.

System Test Medium Pressure – Not Less Than

Time – Not Less than:

Notes

Water Lines Water 125 Pounds 6 hours No Drop

B. This Contractor shall adjust all equipment in the Plumbing system to obtain proper operation and shall demonstrate to the Owner and Engineer that the entire system will function properly.

3.3 INSTALLATION - GENERAL

A. Character of Work: Installation shall be executed in a workmanlike manner and shall present a neat mechanical appearance when completed.

B. Laying Out of Work: 1. Layout piping, equipment and components in accordance with the Contract Documents and the

Manufacturer’s recommended practice, including provision of adequate space for maintenance. Review layout with Engineer prior to installation.

2. Check drawings of other trades to verify spaces in which work will be installed. Maintain maximum head room and space conditions at all points. Where head room or space conditions appear inadequate, notify Engineer before proceeding with installation.

3. If directed by Engineer, Contractor shall make reasonable modifications in the layout as required to permit proper execution of the Work and to prevent conflict with work of other trades.

4. Work shall be installed so as to be ready for operation, maintenance and repair. Minor deviations from Drawings may be made to accomplish this. Changes shall not be made without approval of Engineer.

3.4 CODING AND TAGGING

A. Piping: 1. Applied to new piping after installation and insulation. 2. Conform to University’s existing standards or conventions. 3. Markings:

a. Painted on, 1-inch high black letters. b. Color coded band, conforming to ANSI A13.1. c. Directional arrow.

4. Place markers at 20-foot centers with at least 1 in each room. 5. Plastic coated "Set Mark-Snap-Around" pipe markers manufactured by Seton Name Plate Corp., New

Haven, Connecticut; or approved equal, may be used in lieu of painted markers and bands.

B. Valves: 1. Provide brass or minimum 1/16-inch thick laminated plastic tags indicating assigned valve number on

valves. 2. Furnish schedule(s) of tagged valves with number, location and purpose of each valve. 3. Place a copy of each schedule in the Maintenance Instructions.


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Section 22 05 00


3.5 START-UP

A. Coordinate the start-up, testing and shutdown of the new equipment and systems involved.

B. Inspection: 1. Verify that Project conditions comply with requirements. 2. Verify that status of Work meets requirements for starting of systems.

3.6 ADJUSTING

A. The work of installation shall be executed in conformity with the best practice, so as to contribute to efficiency of operation, minimum noise or vibration, minimum maintenance, accessibility and sightliness.

END OF SECTION 22 05 00


/3

Copper Pipe and Fittings for Plumbing

Section 22 05 09


SECTION 22 05 09 – COPPER PIPE AND FITTINGS FOR PLUMBING PART 1 - GENERAL 1.1 RELATED DOCUMENTS


1.2 SUMMARY

A. This section includes pipe and fitting materials, joining methods, special duty valves, and specialties for the domestic cold water piping.

B. Related Sections include Division 22 Section “General Plumbing Provisions” for description on the Tests and Adjustments.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ASTM Specifications:

a. B75 - Copper Fittings. b. B88 - Seamless Copper Water Tube.

2. ANSI Publications: A13.1 - Scheme for the Identification of Piping Systems.

1.4 QUALITY ASSURANCE

A. Fabrication and Installation Personnel Qualifications: 1. Trained and experienced in the fabrication and installation of the materials and equipment. 2. Knowledgeable of the design and the reviewed Shop Drawings.

B. Testing of Copper Piping: In accordance with Division 22 Section “General Plumbing Provisions.”

1.5 DELIVERY, STORAGE AND HANDLING

A. Deliver materials in original, unbroken, brand marked containers or wrapping as applicable.

B. Handle and store materials in a manner which will prevent deterioration and contamination with foreign matter.

C. Reject damaged, deteriorated or contaminated material and immediately remove from the Site. Replace removed materials at no additional cost to University.


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Section 22 05 09


PART 2 - PRODUCTS

2.1 PIPING MATERIALS

A. Seamless Copper Tubing: 1. Factory coded and marked. 2. Conform to the following schedule:

a. Aboveground: ASTM B88, Type L hard drawn. 3. Pipe Markings:

a. All piping longer than 2'-0" shall have a permanent marking in accordance with ASTM or ANSI specifications.

b. This identification shall include the following: 1) Manufacturer's name. 2) Pipe pressure rating. 3) Pipe size.

B. Solder type shall conform to the following schedule: 1. Hot and cold water and recirculation lines: 95% tin, bismuth, copper and 5% silver similar to Taramet

Sterling or a 96/4 tin/silver solder similar to Tarasail 964. a. IAPMO listed lead free.

C. Fittings: 1. General Service:

a. Sweat type, wrought copper, long radius elbows. b. Cast bronze fittings shall only be allowed with written permission from the Engineer.

2. Drainage: a. Sweat type, wrought copper, drainage pattern. b. Specialty items, such as closet elbows, may be cast brass.

PART 3 - EXECUTION

3.1 PREPARATION

A. During Freezing Weather: 1. Protect all materials in such a manner that no harm can be done to:

a. Installations already made. b. Materials and equipment on the Site.

2. Furnish all necessary protection for such installations and equipment as may be required.

3.2 ERECTION

A. General: 1. All Piping: Follow approved paths as indicated on the Drawings. 2. Connect to existing lines where required in an approved manner. 3. Locate Pipes, Valves and Equipment to Provide:

a. Access for maintenance. b. Minimum obstruction of passageways and working space.

4. Normally, all pipe runs shall be plumb, parallel with the building and level, except for drain slope. 5. Be responsible for establishing and maintaining drain slope of piping in order to ensure drainage. 6. As Piping Material is Erected:

a. Thoroughly clean the inside of all piping. b. Remove foreign material such as scale, sand, weld spatter, particles and cutting chips.

7. Provide caps or plugs in all openings at the end of each day's work and as otherwise directed for the protection of the piping.

B. Pipe Joints: 1. Cut ends of copper tubing squarely using only sharp tube cutters. 2. Ream pipe to full I.D. before preparing the joint.


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Section 22 05 09


3. Soldering: a. Solder or braze joints by cleaning outside ends of all copper tubings and inside of fittings

immediately before joining and soldering. b. Apply solder flux to both tube and fitting. c. Insert tube full depth into fitting, apply heat and solder in such a manner as to draw solder into

and completely around the joint. 4. Joining Valves:

a. When joining copper lines to valves follow Manufacturer's instructions. b. In general:

1) Valve shall be in the fully open position. 2) Solenoid and expansion valves shall be broken down.

3.3 FIELD QUALITY CONTROL

A. Clean and test piping in accordance with Division 22 Section “General Plumbing Provisions.”

B. Manufacturer’s Field Service: Arrange and pay for Manufacturer’s engineer to provide the installation direction for a minimum onsite time of 1 day. 1. Submit written approval of installation.



/1

General Duty Valves for Plumbing

Section 22 05 23


SECTION 22 05 23 – GENERAL DUTY VALVES FOR PLUMBING PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all valves.

1.3 REFERENCES

A. Except as specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. General: Provide valves with features indicated and, where not otherwise indicated, provide proper

valve features as determined by Installer for installation requirements. Comply with ASME B31.9 for building services piping, and ASME B31.1 for power piping.

2. Solder-Joint: Valve ends complying with ANSI B16.18.


A. General: 1. This Section is provided as a guide in the application and specification of specific valves intended for

use in this Project. This Section does not instruct where to install these valves unless specifically noted. Refer to other specific Plumbing Specification Sections and Drawing details for instruction for location and use.

2. As indicated on the Drawings. 3. As called out in the Piping Systems Schedules.

B. Valves not specifically indicated on the Drawings: Size and class of valve to agree with line in which installed.

C. Valves shall have Manufacturer's name, trademark and working pressure rating cast into the valve body.

1.5 SUBMITTALS

A. Shop Drawings for all valves.

B. Manufacturer's Literature: For All Valves: 1. Manufacturer's name. 2. Details of construction. 3. Performance characteristics.


A. Made in USA: 1. Unless specifically noted otherwise, all valves shall comply with the Federal Trade Commission Made

in USA standard. 2. Supplier shall furnish documentation of USA content if requested by Engineer.

B. Fabrication and Installation Personnel Qualifications: 1. Trained and experienced in the fabrication and installation of the material and equipment. 2. Knowledgeable of the design and the reviewed Shop Drawings.


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Section 22 05 23


PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Valves shall be manufactured by one Manufacturer for each type of valve. Where valve Manufacturers are not specifically indicated, they shall be one of the following: 1. Nibco. 2. Milwaukee. 3. Keystone. 4. Stockham. 5. Grinnell. 6. Mueller. 7. Jamesbury. 8. Apollo.

2.2 MATERIALS

A. Bronze Valves: 1. All brass alloys used in valves shall contain no more than 15% zinc. 2. Alloys must comply with ASTM B61, B62 or B584.

2.3 HAND VALVES

A. General: 1. Provide extended stem handles with a minimum clearance of 1-1/2-inch on insulated service. 2. All valves used for throttling/balancing shall have adjustable memory stops. 3. Pressure ratings are at service indicated by application.

B. Ball Valves: 1. Ball valves used in connection with piping 2 inches in size and smaller shall have screwed or sweat

ends, 2 piece bronze body, standard port with stainless steel and a like stem. VA rated for 150 pound SWP and 600 WOG. Seats and seals shall be virgin teflon for standard duty cycle. Provide reinforced teflon for applications identified for extended duty cycle.

2. Based on Jamesbury Series 300 or “Eliminator” Series.

C. Drain Valves: Furnish at each low point 3/4-inch ball valves as specified above. Install nipple with cap at valve outlet.

2.4 CHECK VALVES

A. Swing Check Valve: 1. 2-Inch and Smaller: 125 psi valves for domestic hot and cold water.

a. MSS SP-80; Class 125, cast-bronze body and cap conforming to ASTM B62; with horizontal swing, Y-pattern, and bronze disc; and having threaded or solder ends.

b. Provide valves capable of being reground while the valve remains in the line. c. Provide Class 150 valves meeting the above specifications, with threaded end connections,

where system pressure requires or where Class 125 valves are not available.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install valves in conformance with: 1. The Shop Drawings reviewed by Engineer. 2. The Manufacturer's recommendations.


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Section 22 05 23


B. Install Valves: 1. At all branch piping connection to mains. 2. At all connections to equipment. 3. As required for complete control or isolation of any piece of equipment or service to branch lines. 4. In accessible locations. 5. Equal in flow area to connecting piping, unless otherwise indicated.

C. No valve shall be installed with its stem below the horizontal. END OF SECTION 22 05 23


/2

Hangers and Supports for Plumbing Piping and Equipment

Section 22 05 29


SECTION 22 05 29 – HANGERS AND SUPPORTS FOR PLUMBING PIPING AND EQUIPMENT PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all pipe hanging and support systems.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ASME - American Society of Mechanical Engineers:

a. B31.5 - Building Services Piping. 2. MSS - Manufacturers Standardization Society:

a. SP-58 - Pipe Hangers and Supports - Materials, Design and Manufacture. b. SP-69 - Pipe Hangers and Supports - Selection and Application - 1996. c. SP-90 - Guidelines on Terminology for Pipe Hangers and Supports.


A. Unless otherwise indicated on Drawings or in these Specifications, this Contractor shall be responsible to design and provide all pipe hangers, supports, framing, etc., as required to comply with all applicable building codes, ASME B31 and MSS SP-69.

1.5 SUBMITTALS

A. Submit Shop Drawings for all engineered hanger, restraints and support assemblies.

PART 2 - PRODUCTS


A. The materials of all pipe hanging and supporting elements shall be in accordance with the latest requirements of the ASME Code for Pressure Piping B31.1 and MSS Standard Practice MSS SP-58 and MSS SP-69 except as supplemented or modified by the requirements of these Specifications.

B. The material in contact with the pipe shall be compatible with the piping material so that neither shall have a deteriorating action on the other.

2.2 MANUFACTURERS

A. Elcon.

B. Anvil.

C. Bergen.

D. Hilti.

E. Lindapter.


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Section 22 05 29


2.3 PIPE HANGERS AND SUPPORTS

A. Horizontal Piping Hangers: Unless otherwise indicated and except as specified in piping system Specification sections, install the following types: 1. Adjustable Steel Clevis Hangers (MSS Type 1): For suspension of noninsulated or insulated

stationary pipes, NPS 1/2 to NPS 30 (DN15 to DN750). 2. Pipe Hangers (MSS Type 5): For suspension of pipes, NPS 1/2 to NPS 4 (DN15 to DN100), to allow

off-center closure for hanger installation before pipe erection. 3. Clips (MSS Type 26): For support of insulated pipes not subject to expansion or contraction.

2.4 HANGER RODS

A. Minimum rod diameters for rigid rod hangers shall be as shown in MSS SP-69 Table 4 (Minimum Rod Diameter for Single Rigid Rod Hangers) and as indicated in Part 3 of these Specifications.

B. Hanger rods shall be subject to tensile loading only. At hanger locations where lateral or axial movement is anticipated, suitable linkage shall be provided to permit swing.

C. Rod material must be compatible with hanger and comply with above. Do not field cut thread on galvanized rod.

D. Do not use perforated strap.

2.5 SADDLES AND SHIELDS

A. All Piping: 1. Saddle: MSS Type 39 (Grinnell #160-164), or Anvil Figure 162 or 165. 2. Shield: MSS Type 40 (Grinnell #167), provide and install in accordance with Manufacturer's shield size

selection tables. 3. The contour of the saddle shall match the radius of the pipe insulation.

PART 3 - EXECUTION

3.1 HANGER AND SUPPORT APPLICATIONS

A. General Requirements: 1. The selection of pipe hangers and supports shall be based on the overall design concept of the piping

system and any special requirements which may be called for in these Specifications or as indicated on the Drawings. The support systems shall provide for, and control, the free or intended movement of the piping including its movement in relation to that of the connected equipment. They shall prevent excess stress resulting from the transfer of weight being introduced into the pipe or connected equipment.

2. The selection of hangers and supports shall be made to provide the piping system with the degree of control that its operating characteristics require.

3. The selection of hangers or supports will take into consideration the combined weight of the supported systems, including system contents and test water.

4. Select and install hangers and supports to allow controlled thermal and seismic movement of piping system, to permit freedom of movement between pipe anchors, and facilitate action of expansion joints, expansion loops, expansion bends and similar units.

5. Select all hangers and supports rated for the maximum potential loading with pipe full.

3.2 HANGER AND SUPPORT INSTALLATION

A. Pipe Hanger and Support Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from building structure.


/2


Section 22 05 29


B. General: 1. Adjust all components as required for proper operation and required pipe slope. 2. Location and Routing:

a. Install Piping as Indicated: 1) On the Drawings. 2) On the reviewed Shop Drawings.

b. Secure Engineer's approval for all pipe routing changes. 3. Install all items in accordance with Manufacturer's instructions.

C. Horizontal Runs: 1. General:

a. Provide adequate supports for the loads with a factor of safety of at least 5 (400 pounds minimum).

b. Provide protective shield at all hangers and rollers supporting plastic pipe and coated pipe. c. Support spacing not to exceed MSS SP-69 Table 3, or the requirements for seismic restraint,

whichever is more stringent. d. Hanger rod diameter shall not be less than the requirements of MSS SP-69 Table 4, or the

requirements for seismic restraint, whichever is more stringent.

3.3 INSULATION PROTECTION

A. Provide Protection Saddle: 1. Equal to insulation thickness. 2. At each hanger. 3. For all insulated piping systems where longitudinal expansion exceeds 1-inch per 100 feet.



/2

Plumbing Piping Insulation

Section 22 07 19


SECTION 22 07 19 – PLUMBING PIPING INSULATION PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of piping insulation.

1.3 REFERENCES:


a. C552 - Cellular Glass Block and Pipe Thermal Insulation. 2. ASTM Standard Test Methods: E84 - Surface Burning Characteristics of Building Materials. 3. National Fire Protection Association (NFPA) publications: NFPA 255 - Surface Burning

Characteristics of Building Materials: 25, 50, 50 flame spread, fuel, smoke. 4. ASHRAE: 90A - Energy Conservation in New Building Design, current edition.

1.4 SUBMITTALS

A. Manufacturer's Literature: For piping insulation. 1. For Each Type Used:

a. Name of Manufacturer. b. Details of construction and installation. c. Manufacturer's data (density, K-factor).

2. For Each Application: a. Thickness. b. Total "R" value. c. Jacket material.




A. Deliver materials in original, unbroken, brand marked containers or wrapping as applicable. Handle and store materials in a manner which will prevent deterioration and contamination with foreign matter.

B. Reject damaged, deteriorated, or contaminated material and immediately remove from the Site. Replace removed materials at no additional cost to Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Insulation: 1. Owens-Corning. 2. Certainteed. 3. Armacell.


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Section 22 07 19


4. Rubatex. 5. Knauf. 6. Johns Manville.

B. Jacketing: 1. Ceel-Co. 2. O'Brien. 3. Zeston. 4. Childers. 5. Pabco.

C. Adhesives: 1. Benjamin Foster. 2. Childers. 3. Vimasco. 4. B.E.H. 5. Or equal.

2.2 TYPES OF INSULATION MATERIALS

A. Rigid Molded Glass Fiber - High Density (HFG): 1. All-service jacket (ASJ), factory-applied jacketing. 2. 6 lbs/cu ft minimum density. 3. k factor of 0.31 maximum at 200 degrees F mean. 4. 850 degree F service temperature. 5. Owens-Corning Type SSLII; or equal. 6. Typical for applications on pipes below 16 inches (normal).

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install piping insulation:

a. In conformance with the Drawings. these Specifications, and the Manufacturer's recommendations.

b. After piping system has been satisfactorily tested. c. Over clean, dry piping system. d. To the following thickness:

1) As specified herein or as indicated on the Drawings. 2) If not specified herein or indicated on the Drawings, in accordance with Manufacturer's

recommendations for the specific application. e. Continuous through walls, ceilings and sleeves except at fire stops.

2. Fill all cracks and voids with insulating cement carefully troweled to leave a smooth finish. 3. Repair or replace insulation damaged by:

a. Demolition. b. Making connections to piping or equipment. c. Water or mildew.

B. Joints and Fittings: 1. Block insulate valves and flanges with reusable insulation system. 2. Insulate elbows, tube turns, sweeps and bends with mitered sections or premolded fittings. Match

pipe covering material where used. 3. Fit joints tightly together. 4. Seal joints with sealing compound and preformed aluminum bands.


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Section 22 07 19


3.2 JACKETS AND FINISH

A. General: 1. Provide moisture barrier between the insulation and the jacketing in a continuous, unbroken seal. 2. Hold jacketing in place by a continuous sealed joint, providing a positive weatherproof seal along the

entire length of the jacket. 3. Cap off ends with caps. 4. On cold lines, cut caps to the exact size of the pipe and seal with a recommended silicone calking. 5. Locate longitudinal jacket seams on indoor exposed piping out of view.

B. Attachment: Vapor seal laps using self-sealing lap, lap seal tape gun or adhesive such as Benjamin Foster 520.

C. Taper and seal insulation ends regardless of service.

3.3 PIPING INSULATION APPLICATION SCHEDULE

A. Basis of Thickness Chart: 1. Thicknesses shown are based on products having a maximum "k" factor of 0.26 at a mean

temperature of 75 degrees F. 2. These Thicknesses:

a. Can be reduced for products having significantly lower "k" values. b. Shall be increased for products having higher "k" values in order to produce equivalent or

greater thermal resistance.

B. Flame/Smoke Ratings: Local requirements for flame and smoke ratings must be met and may exclude some options listed herein.

C. Thickness Chart (In Inches): 1. Key: Insulation Type (Refer to Paragraph 2.2 of this Section):

a. HFG = High Density Rigid Fiberglass.

PIPE SIZE

Piping Systems Type Temp (F)

Range Less

Than 1″ 1″ to

1-1/4″ 1-1/2″ to 3″ 4″ to 6″ 8″ & Up

Type of Insulation *

1.

Domestic Cold Water 40-80 0.5 0.5 1.0 1.0 1.0 HFG

* See PART 2 – PRODUCTS Article 2.2 TYPES for types of insulation.



/2

Piping Specialties for Plumbing

Section 22 10 19


SECTION 22 10 19 – PIPING SPECIALTIES FOR PLUMBING PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of piping specialties.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ASME American Society of Mechanical Engineers:

a. B31.5 - Building Services Piping.

1.4 SUBMITTALS

A. Manufacturer's Literature: For all items listed in PART 2 – PRODUCTS. Include dimensions, details of construction and installation, name of Manufacturer, and model.



PART 2 - PRODUCTS

2.1 STRAINERS

A. Manufacturer: Armstrong, Mueller.

B. Type: "Y".

C. Screen: 20 mesh brass, removable.

D. Area: 5 times pipe diameter.

E. Pressure Rating: Match piping.

F. Install where indicated on the Drawings.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install all piping specialties in conformance with: 1. The Shop Drawings reviewed by Engineer. 2. The Manufacturer's recommendation.



/1

Operation and Maintenance of HVAC Systems

Section 23 01 00


SECTION 23 01 00 – OPERATION AND MAINTENANCE OF HVAC SYSTEMS PART 1 - GENERAL



B. Refer to individual Division 23 sections for additional equipment specific Operations and Maintenance Manual requirements.

1.2 SUMMARY

A. This Section includes preparing and furnishing an operating and maintenance manual for mechanical equipment.

1.3 DESCRIPTION

A. Compile an Operating and Maintenance Manual: 1. For all building mechanical systems and major equipment items. 2. Including, but not necessarily limited to:

a. Installing company's name, address, telephone number and name of job supervisor. b. Maintenance and operating booklets (as supplied by the equipment Manufacturer) for each item

or representative type item installed. c. Valve tag schedule. d. A complete set of Shop Drawings. e. Temperature control drawings. f. Equipment information forms for each equipment piece.

3. Each equipment information form include all applicable items of the following: a. Type of unit. b. Manufacturer's name. c. Equipment service area. d. Motor and Drive Information:

1) Belt type and quantity. 2) Belt size. 3) HP. 4) Voltage. 5) Phase.

e. Lubrication Information: 1) Recommended service interval. 2) Lubricant application points. 3) Recommended lubricant type.

f. Recommended cleaning procedures and intervals.

B. Prepare Information Packets: 1. Attach to each major piece of equipment in a string tie envelope labeled with the equipment's

designation in large print. 2. Information Required:

a. A copy of the equipment information form as defined above. b. A temperature control written operation sequence. c. A maintenance checklist form with equipment identification information and listing all relevant

maintenance procedures in a column format to accommodate date entries.

1.4 SUBMITTALS

A. Three copies of Operating and Maintenance Manual.


/1

Operation and Maintenance of HVAC Systems

Section 23 01 00


PART 2 - PRODUCTS

Not used.

PART 3 - EXECUTION

Not used. END OF SECTION 23 01 00


/2

General HVAC Provisions

Section 23 05 00


SECTION 23 05 00 – GENERAL HVAC PROVISIONS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes specifying the general requirements for execution of that portion of the Work defined in Division 23 of these Specifications and as indicated on the Drawings: 1. Major items include, but are not necessarily limited to:

a. Cutting and patching. b. Concrete foundations c. Piping, fittings and valves. d. Piping, ductwork and equipment insulation. e. Temperature and pressure gages. f. HVAC equipment. g. Temperature control systems. h. Demolition of existing mechanical work. i. Labor, materials, equipment, tools, supervision and start-up services. j. Mechanical systems testing, adjusting and balancing. k. Mechanical systems commissioning. l. Instructions to Owner regarding operation. m. Incidental and related items necessary to a complete and functionally operational installation of

the Work. 1) General requirements. 2) Drawings. 3) Supervision. 4) Unacceptable work and observation reports. 5) Final inspection. 6) Guarantee. 7) Test and adjustments. 8) Painting. 9) Electrical Work. 10) Manufacturer’s drawings. 11) Protection and cleaning. 12) Equipment furnished by Owner. 13) Remodeling.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of Division 23 shall comply with the following: 1. ANSI: A13.1 - Standard for the Identification of Piping Systems. 2. ASME - American Society of Mechanical Engineers:

a. B31.1 - Pressure Piping. b. B31.9 - Building Services Piping. c. Boiler and Pressure Vessel Code:

1) Section IV. 2) Section VIII.

3. Ohio Building Code. 4. State of Ohio Code for Energy Conservation. 5. Local Building Code.

B. Contractor shall file all Drawings, pay all necessary charges and fees, and obtain all necessary permits and certificates of inspection relative to their work.


/2


Section 23 05 00


C. Nothing contained in the Drawings and Specifications shall be construed to conflict with these laws, codes and ordinances and they are hereby made a part of these Specifications.


A. Include any minor details essential to successful operation and any other items specified or indicated on the Drawings.

B. If the Contractor has any questions concerning the Drawings and Specifications or notices any discrepancies or omissions in either Drawings or Specifications, they shall contact the Engineer for clarification before Bids, to fully understand the extent and responsibilities of their work.

C. The Contractor is required to visit the Site and fully inform themselves concerning all conditions affecting the scope of their work. Failure to visit the Site shall not relieve the Contractor from any responsibility in the performance of their Contract.

D. Other than minor adjustments shall be submitted to the Engineer for approval before proceeding with the work.

E. Scheduling of all work performed by this Contractor shall be completely coordinated with the University’s Representative.

F. Connections to, or revisions in, existing piping or facilities shall be done at such time as agreed to by the Engineer and University’s Representative and all work shall be scheduled as required under "General Conditions". Revisions to the existing piping systems must be done with the minimum of shutdown time. All piping shall be run to the point of new connections and new equipment installed and ready to operate before any connections are to be made.

G. At the completion of the project, this Contractor shall promptly clean up and remove from the Site, all debris and excess materials.


A. Construction details, components, accessories, sizes and model numbers indicated on the Drawings or in these specifications are used to indicate minimum levels of quality and coordination requirements.

B. Equipment supplied, whether as scheduled or selected from list of acceptable Manufacturers, must meet minimum requirements listed in specifications or on Drawings, be compatible with facility and intended use, and meet requirements for a functional system.

C. Drawings: 1. Are diagrammatic and indicate general arrangement of systems and work included. 2. Do not necessarily indicate every required valve, fitting, trap, thermometer, gage, duct, elbow,

transition, turning vane, mounting support and access panel. 3. Shall not be scaled for measurement or installation location. 4. Shall not serve as Shop Drawings. 5. Consult all Contract Drawings which may affect the locations of any equipment, apparatus and piping

and make minor adjustments in location to secure coordination. 6. Piping layout is schematic and exact locations shall be determined by structural and other conditions

and verified in the field. This shall not be construed to mean that the design of the system may be changed, it refers only to the exact location of piping to fit into the building as constructed, and to coordination of all work with piping and equipment included under other Divisions of the Specifications.

7. Where certain grades and/or elevations are given on the Drawings, they have been obtained from the best information available; however, they are not guaranteed. This Contractor MUST assume the full responsibility of verifying present elevations in the field and making any adjustments as may be necessary, all of which must be included in their Bid Price.

8. Install all work as close as possible to walls, structural, members, etc., consistent with the proper space for covering, access, etc., so as to occupy the minimum of space and allow as much space as possible between ductwork, piping, etc. and the ceiling.


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Section 23 05 00


D. Schedules and model numbers shall not be used to: 1. Serve as final, definitive quantity requirements. Contractor shall make own count as indicated on

Drawings. 2. Determine proper type or model with arrangement, mounting and accessories applicable.

E. Coordinate installation work of Division 23 with work of other trades to provide a complete and functional system.

1.6 SUPERVISION

A. Contractor shall have in charge of the work, on the Site as required, during construction, a competent superintendent experienced in the work installed under this Contract.

1.7 UNACCEPTABLE WORK AND OBSERVATION REPORTS

A. Work shall be unacceptable when found to be defective or contrary to the Drawings, Specifications, Codes specified or accepted standards of good workmanship.

B. The Contractor shall promptly correct all work found unacceptable by the Engineer whether observed before or after substantial completion and whether or not fabricated, installed or completed. The Contractor shall bear all costs of correcting such unacceptable work, including compensation for the Engineer's additional services made necessary thereby.

C. During the course of construction, the Engineer will prepare "Observation Reports" with a list of items found to be in need of correction. All items listed shall be corrected by the Contractor. A space is provided on the form for the Contractor to note the completion of each item. All prior "Observation Report" items must be completed, the lists signed and returned to the Engineer prior to making the final inspection. After the final list is issued, the same procedure will apply.

1.8 FINAL INSPECTION

A. When the Contractor determines all work is completed and working properly in accordance with the Contract Documents, they shall request a "final" inspection by the Engineer in writing. If more than one reinspection is required after this final inspection, the Contractor shall bear all additional costs including compensation for the Engineer's additional services made necessary thereby. A final inspection will not be made until all prior "Observation Report" punch lists completed, signed and returned to the Engineer.

1.9 WARRANTY/GUARANTEE

A. This Contractor is responsible for all defects, repairs and replacements in materials and workmanship, for a period of 1 year after approval of the Certificate of Contract Completion.


A. Refer to Part 3 – Execution, for general piping installation requirements that apply to all interior piping systems installed under this Contract, except where otherwise noted on the Drawings or elsewhere in the Specifications.

1.11 CUTTING AND PATCHING

A. All holes in existing walls shall be cut by use of core drills, using water to keep down the dust, and a method for catching water shall be provided.

B. Fill space in all areas where core drilled with packing where required to maintain fire rating. Openings shall be temporarily fire-stopped until permanent fire stopping is done. This includes holes left due to removal of piping.


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C. All holes cut for the installation of piping, ductwork and equipment shall be neatly patched and refinished with the same materials as, and to match, adjacent surfaces, and damages thereto shall be repaired in kind and to match existing conditions by this Contractor. This includes patching existing holes left by removal of existing piping, ductwork, equipment, etc.

D. No structural member will be cut into without the expressed permission of the University.

1.12 ELECTRICAL WORK

A. Work Included – Contractor: 1. Furnish to the Electrical Subcontractor information, drawings, schedules, locations of rough-ins,

electric loads, sizes and characteristics for motors and equipment furnished by Contractor requiring electric services. "Stock" wiring diagrams are not acceptable.

2. Starters which are specified to be provided as a part of the HVAC equipment shall be furnished by Contractor. Wiring by the Electrical Subcontractor.

3. All alarm, control or interlocking wiring for motors and equipment furnished by Contractor unless otherwise specified.

4. 120 volt wiring required for equipment furnished by Contractor when not indicated or specified elsewhere.

5. Final connections to boilers from wired junction boxes. 6. All interconnecting control wiring between temperature control panels and control devices shall be the

responsibility of the Temperature Control Subcontractor.

B. Work Included - Electrical Subcontractor: 1. Electrical Subcontractor shall provide all power services for motors and equipment furnished by other

contractors, including safety disconnect switches (unless specified with HVAC equipment), if required by code, and final connection to motors and equipment.

2. All starters installed in motor control centers and loose starters shall be provided by the Electrical Subcontractor and shall be as specified in Division 26 except where specifically specified to be furnished with certain HVAC equipment.

3. All power wiring between any adjustable speed controller or other unit controller and the motor being controlled.

C. Temperature Control Wiring Responsibility: 1. Electrical Subcontractor to include the following:

a. Necessary wiring between temperature control panels and motor controllers, to extent indicated on the Electrical Drawings. Final termination of the wiring inside the temperature control cabinets by the Temperature Control Subcontractor.

b. Electrical Subcontractor shall provide 120 volt power to a wired junction box near each Temperature Control Cabinet or panel. Final connections to be made by the Temperature Control Subcontractor.

2. Temperature Control Subcontractor wiring to include the following: a. Wiring of devices provided by the HVAC Contractor or the Temperature Control Subcontractor

and wired in series or parallel with the control circuit of the motor controller to the extent indicated on the control diagrams on the Electrical Drawings. These devices will normally include but not be limited to flow switches, low limit thermostats, DDC contacts, etc.

b. Changes from or additions to wiring indicated on the Electrical Drawings which are required by the HVAC Specifications to provide a complete and workable temperature control system.

c. Temperature Control Subcontractor to furnish a complete set of approved Shop Drawings to Electrical Subcontractor prior to system installation. Drawings shall include terminal designations on control items and equipment. Wiring diagrams to be compatible with those shown on the Electrical Drawings (Construction Documents).

d. All equipment and wiring furnished by the Temperature Control Subcontractor shall meet the requirements of Division 26.

e. All wiring to sensors, etc., which are part of the DDC control system and not indicated on any of the Electrical Control Diagrams, shall be by the Temperature Control Subcontractor.

f. All terminations inside of Temperature Control Panels shall be by the Temperature Control Subcontractor.


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1.13 TESTS AND ADJUSTMENTS

A. After work has been completed but before pipe covering has been applied, the Contractor shall test and adjust the systems they have installed.

B. The Engineer shall be notified of all scheduled tests at least 48 hours before they are scheduled so that they may witness same. If the Contractor performs any test without the Engineer present or without properly notifying the, Engineer, the Contractor will be required to perform the test a second time in the presence of the Engineer.

C. Concealed lines shall be tested before being concealed. If this is not done and a leak appears during the final test, this Contractor shall repair leak and all damage resulting there from.

1.14 MANUFACTURER’S DRAWINGS

A. The Contractor shall submit to the Engineer for review, within 6 weeks after date of contract, the required number of copies in accordance with Division 01 of manufacturer’s drawings, wiring diagrams, pump curves or data. The Engineer will review Contractor’s Shop Drawings and related submittals (as indicated below) with respect to the ability of the detailed work, when complete, to be a properly functioning integral element of the overall system designed by the Engineer. Before submitting a Shop Drawing or any related material to the Engineer, Contractor shall: review each such submission for conformance with the means, methods, techniques, sequences, and operations of construction, and safety precautions and programs incidental thereto, all of which are the sole responsibility of Contractor; approve each such submission before submitting it; and so stamp each such submission before submitting it. The Engineer shall assume that no Shop Drawing or related submittal comprises a variation unless Contractor advises Engineer otherwise via a written instrument which is acknowledged by Engineer in writing. The Shop Drawings and related material (if any) called for are indicated in the appropriate specification section.

B. The Engineer shall return Shop Drawings and related materials with comments provided that each submission has been called for and is stamped by Contractor as indicated above. The Engineer shall return without comment material not called for or which has not been approved by the Contractor.

C. This Contractor shall furnish equipment Shop Drawings which will indicate power hook up and control connections as required for mechanical equipment. “Stock” wiring diagrams are NOT ACCEPTABLE.

D. Engineer's review of manufacturer's drawings or schedules shall not relieve the Contractor from compliance with the requirements of the plans and specifications.

E. Items may be referred to in singular or plural on Drawings and Specifications. Contractor is responsible for determining quantity of each item.

1.15 PROTECTION AND CLEANING

A. Protect all plumbing equipment against damage from any cause whatsoever and pay the cost of replacing and repairing equipment made necessary by failure to provide suitable protection.

B. Repair all dents and scratches in factory prime or finish coats on all equipment to the satisfaction of the Engineer. If damage is excessive, replacement may be required.

C. Flush out all piping systems to remove all dirt and grease from pipes and equipment before systems are placed in operation. Clean strainers after each flushing until the strainer remains clean.

D. The HVAC Subcontractor shall clean all water piping systems under this Contract. Refer to Division 23 Section “HVAC Water Treatment” for the chemicals and procedure to be followed.

E. Contractor shall clean up and remove all debris from the Site and shall at all times keep the premises in a neat and orderly condition.


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1.16 EQUIPMENT FURNISHED BY OWNER

A. The following equipment will be furnished by the Owner at the Site. This Contractor is to furnish all labor and material required to assemble, set the equipment in place, with all miscellaneous supports, hangers and materials to install equipment ready to operate. 1. Equipment Consists of: Condensing Boilers B-1 and B-2.

B. Equipment shall be installed in accordance with manufacturer's instructions. Contractor shall obtain these instructions from each manufacturer, or from the Owner, and these instructions shall be considered part of these Specifications.

C. Any defects or differences in Owner furnished equipment shall be reported to the Owner for consideration before proceeding with the work. All equipment shall be received and unloaded, stored in a location designated by the Owner, and protected from the weather by this Contractor. This Contractor shall be responsible for and pay particular attention to coordination of delivery of equipment.

D. This Contractor shall assume Warranty responsibilities.

1.17 REMODELING

A. Contractor shall include the remodeling of and additions to all HVAC work in the present building in the areas indicated on the Drawings and in all areas affected by the above. All necessary or required remodeling or additions to the present HVAC work shall be included in this Contract, as indicated or required, to the end that the work will result in the complete system indicated on the Drawings.

B. All unused piping, etc., throughout the facility shall be removed unless otherwise indicated on Drawings. No abandoned piping shall remain in any part of the renovated area.

1.18 PRODUCT UNLOADING AND HANDLING

A. Unload equipment and materials required for completion of the Work.

B. Handle and store equipment and materials carefully to prevent damage. Method of rigging and handling shall be subject to the approval of an authorized representative of the equipment Manufacturer whose equipment is being handled.

1.19 TROUBLESHOOTING

A. By Contractor: If, during the start-up or warranty period, mechanical systems operational problems occur for which the root cause is not readily apparent, Contractor shall promptly, through a Subcontractor or other resource designated by Subcontractor, provide diagnostic and investigative services to determine the cause or causes.

B. By Engineer: 1. At Contractor's request, Engineer will provide the services necessary to determine the cause or

causes of the operational problems. 2. Under the provisions of the General Conditions, Engineer will also provide these services if Contractor

fails to respond satisfactorily to operational problems within a reasonable time after written notice from Engineer.

1.20 MAINTENANCE

A. Special Tools: Where special tools are required for operation, furnish these to University.

B. Loose and Detachable Parts: 1. Retain loose and small detachable parts of the apparatus and equipment furnished until the

completion of the Work. 2. Turn over these parts to University.


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PART 2 - PRODUCTS

2.1 ELECTRICAL WORK

A. Refer to Division 26 - ELECTRICAL.

B. All single-phase motors provided by Contractor to have built-in thermal overload protection.

C. All motors furnished shall have copper windings and all motors 5 horsepower and greater shall have factory installed lifting eyebolts. All motors shall conform to ANSI and NEMA standards.

D. Motor starters, contactors, and disconnects are provided and installed by the Electrical Subcontractor, unless part of packaged equipment furnished by this Contractor, or otherwise specified.

E. All motors 1 HP or more shall be “premium efficient” motors meeting all requirements of ASHRAE Standard 90.1 – 2007 and latest version of EPA Act by the federal government.

F. All motors served by Adjustable Frequency A/C Drives shall be inverter duty rated.

PART 3 - EXECUTION

3.1 SEALING AROUND PIPE OPENINGS

A. The openings around all pipes that penetrate full height walls (defined as walls that extend from the floor to the structure above) unless otherwise required to be firestopped shall be sealed to maintain the acoustic integrity of the wall. This applies to all full height walls regardless of whether the wall has a fire rating.

B. Gaps less than 1/2-inch between the pipe and the wall opening or sleeve shall be packed with batt insulation and the exposure calked on both sides of the wall.

C. Gaps 1/2-inch and larger between the pipe and the wall opening or sleeve shall be packed with batt insulation and a sheet metal collar installed around the entire pipe on both sides of the wall. The sheet metal collar shall extend from the surface of the pipe to a minimum 2 inches on the wall and be secured to the wall.


A. All piping systems shall be installed with adequate provisions made for expansion and contraction to prevent stresses on piping, valves and equipment. Anchor and guide piping at all points indicated and/or as required. Type and method of anchoring, guiding and attachments to sustaining members to suit job requirements and conditions and shall be approved by the Engineer.

B. Provide unions or flanges at each final connection, and at each piece of equipment. Branches from mains to equipment stubs, risers, etc., to have swing joints with at least one change of direction in the horizontal plane, and one change of direction in the vertical plane, before connecting to equipment or fixtures. Piping shall be arranged and unions and flanges located to permit easy removal of parts and equipment for inspection and cleaning without disconnecting any part except unions or flanges. No welded connections shall be made to valves or equipment. Use bronze unions in copper lines. Unions to be downstream of valves.

C. Make proper connections to all items of equipment in the Contract as recommended by the Manufacturer or as indicated on the Drawings.

D. All piping shall be arranged in accordance with the best standards of the trade with vertical pipes plumb and horizontal runs parallel or perpendicular to the building wall.

E. Provide valves and specialties where indicated on the Drawings.


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F. Provide 3/4-inch drain valves in piping at low points to provide complete drainage of all systems and as indicated on the Drawings.

G. Ream ends of pipe and clean before installing.

H. Copper joints: Copper piping in plumbing systems less than 2 inches shall be soldered using 95/5 tin/antimony solder. Copper piping in plumbing systems 2 inches and larger shall be brazed using a 6% silver alloy with a 1,000 degrees F solidus minimum. Solders and fluxes containing lead are prohibited. For solder to threaded adapter nipples, the Contractor shall use either a 95/5 tin/copper solder similar to “Taramet Sterling” or a 96/4 tin/silver solder similar to “Tarasil 964” in lieu of brazing.

I. Use pipe dope on male threads of screwed pipe only. Teflon pipe joint tape may be used at the Contractor's option.

J. Valves to be installed with handwheel at or above center of pipe. Valves outdoors exposed to weather shall be installed with handwheel in the horizontal.

K. Make all changes of direction with fittings, rather than bending.

L. Provide dielectric unions or insulating flanges between dissimilar metals, i.e., copper to steel. In closed loop HVAC systems which have provisions for regular water treatment and little or no make-up water, bronze valves can serve as the dielectric.

M. Properly support all relief valve discharge piping and provide no more than one 90° ell.

N. Bull head connections in any piping service are expressly prohibited.

O. At the end of each day's work and otherwise as required or directed, provide caps and/or plugs at all openings in piping for protection. Particular attention must be given to avoid the possibility of any foreign materials entering the pipes, whether it be inadvertent or with malicious intent.

P. All piping connected to reciprocating or rotating equipment shall be isolated with flexible connectors within 5 feet of the equipment.

3.3 ELECTRICAL WORK

A. All wiring, conduits, etc., shall be in strict accordance with the requirements of the latest edition of the National Electrical Code and Division 26, Electrical specification.

B. All wiring, including low voltage wiring, shall be run in conduit.

C. Low voltage wiring may be size and type recommended by the Manufacturer and/or Temperature Control Subcontractor.

3.4 TEST AND ADJUSTMENTS

A. After work has been completed but before pipe covering has been applied, the Contractor shall test the systems as follows. At these pressures, the circulation shall be free and the piping free of leaks.

System Test Medium Pressure – Not Less Than

Time – Not Less than:

Notes

Water Lines Water 125 Pounds 6 hours No Drop

B. Purge Gas System to Outdoors. Purge and test to be witnessed by Gas Company and Engineer. Test gas piping as specified in Division 23 Section “Natural Gas Piping System”.


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Section 23 05 00


C. Before starting any pumping unit with pump and driver mounted on a common base plate with a flexible couplings, the Contractor shall check the unit for proper alignment.

D. Contractor shall adjust all equipment in the HVAC system to obtain proper operation and shall demonstrate to the Owner and Engineer that the entire system will function properly.

3.5 INSTALLATION - GENERAL

A. Character of Work: Installation shall be executed in a workmanlike manner and shall present a neat mechanical appearance when completed.

B. Laying Out of Work: 1. Layout piping, ductwork, equipment and components in accordance with the Contract Documents and

the Manufacturer’s recommended practice, including provision of adequate space for maintenance. Review layout with Engineer prior to installation.

2. Check drawings of other trades to verify spaces in which work will be installed. Maintain maximum head room and space conditions at all points. Where head room or space conditions appear inadequate, notify Engineer before proceeding with installation.

3. If directed by Engineer, Contractor shall make reasonable modifications in the layout as required to permit proper execution of the Work and to prevent conflict with work of other trades.

4. Work shall be installed so as to be ready for operation, maintenance and repair. Minor deviations from Drawings may be made to accomplish this. Changes shall not be made without approval of Engineer.

3.6 CODING AND TAGGING

A. Piping: 1. Applied to new piping after installation and insulation. 2. Conform to University’s existing standards or conventions. 3. Markings:

a. Painted on, 1-inch high black letters. b. Color coded band, conforming to ANSI A13.1. c. Directional arrow.

4. Place markers at 20-foot centers with at least 1 in each room. 5. Plastic coated "Set Mark-Snap-Around" pipe markers manufactured by Seton Name Plate Corp., New

Haven, Connecticut; or approved equal, may be used in lieu of painted markers and bands.

B. Valves: 1. Provide brass or minimum 1/16-inch thick laminated plastic tags indicating assigned valve number on

valves. 2. Furnish schedule(s) of tagged valves with number, location and purpose of each valve.

a. Place a copy of each schedule in the Maintenance Instructions.

C. Provide record documentation of all hydronic system air vent locations on record drawings (as-builts) or other method as approved by Engineer.

D. Equipment: 1. Provide for:

a. Each boiler exhaust fan and pump. b. Labeled with its tag name/number as given on the Drawings. c. Use 2-inch high stenciled painted lettering.

2. Similarly label control components associated with the above named equipment items.

3.7 START-UP

A. Coordinate the start-up, testing and shutdown of the new equipment and systems involved.

B. Operating personnel, fuel, water, power and other utilities necessary for equipment start-up, will be furnished by University. Instructions shall be provided to the operators by the equipment vendor's personnel.


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C. Inspection: 1. Verify that Project conditions comply with requirements. 2. Verify that status of Work meets requirements for starting of systems.

D. Preparation: 1. Coordinate sequence for start-up of various systems. 2. Notify University’s Representative and the Engineer 7 days prior to start-up of each system. 3. Have at hand during entire start-up process:

a. Contract Documents. b. Shop Drawings. c. Product data. d. Operation and maintenance data.

4. Verify that each piece of equipment has been checked for: a. Proper lubrication. b. Drive rotation. c. Control sequence. d. Other conditions which may cause damage.

5. Verify control systems are fully operational in automatic mode. 6. Verify that tests, meter readings and specific electrical characteristics agree with those specified by

electrical equipment Manufacturer. 7. Bearings:

a. Inspect for cleanliness, clean and remove foreign materials. b. Verify alignment. c. Replace defective bearings and those which run rough or are noisy. d. Grease as necessary and in accordance with Manufacturer's recommendations.

8. Motors: a. Check each motor for amperage comparison to nameplate value. b. Correct conditions which produce excessive current flow and which exist due to equipment

malfunction. c. 3-phase Motors: Measure voltage imbalance between legs. Notify Engineer if imbalance

exceeds 2%. 9. Pumps:

a. Check mechanical seals for cleanliness and adjustment before running pump. b. Inspect shaft sleeves for scoring. c. Inspect mechanical faces, chambers and seal rings; replace if defective. d. Verify that piping system is free of dirt and scale before circulating liquid through the pump. e. Check Pump Performance:

1) Install a pressure gage on the discharge side of the check valve following pump. 2) Operate the pump at all system operating heads:

a) Verify pump operation with the Manufacturer's pump curve. b) Report deviations to Engineer.

3) Operate the pump through several cycles while observing the pressure gage: a) Watch pressure gage for several minutes after pump shut down. b) Report significant pressure variations to Engineer.

4) Remove pressure gage and plug tap. f. Trim impellers as directed by Engineer.

10. Flanges: a. Tighten flanges after system has been placed in operation. b. Replace flange gaskets which show any sign of leakage after tightening.

11. Screwed Joints: a. Inspect screwed joints for leakage. b. Promptly remake each joint which appears to be faulty; do not wait for rust to form. c. Clean threads on both parts, apply compound and remake joints.

12. Cleaning: a. After system has been placed in operation, clean strainers, dirt pockets, orifices, valve seats and

headers in fluid systems, to ensure being free of foreign materials. b. Open steam traps and air vents; remove operating elements. Clean thoroughly, replace internal

parts, and put back into operation. c. Remove rust, scale and foreign materials from equipment and renew defaced surfaces.

13. Control Circuits: Check each electrical control circuit to ensure that operation complies with Specifications and requirements to provide desired performance.


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3.8 ADJUSTING

A. Adjust and align equipment for smooth operation: 1. Plumb true and with parts in proper position and alignment. 2. Rotating parts shall turn freely and in the correct direction. 3. Flexible couplings shall be checked for alignment subject to University's approval. 4. Follow Manufacturer's instructions.

B. The work of installation shall be executed in conformity with the best practice, so as to contribute to efficiency of operation, minimum noise or vibration, minimum maintenance, accessibility and sightliness.


A. Manufacturer's Field Services: 1. Provide when required by individual Section. 2. Provide the following services except where indicated otherwise in individual Sections:

a. Inspect, check and approve system installation. b. Supervise system start-up. c. Provide written report indicating that system:

1) Has been properly installed and lubricated. 2) Is in accurate alignment. 3) Is free from undue stress imposed by connecting lines or anchor bolts. 4) Has been satisfactorily operated under full load conditions.

d. Demonstrate operation of system to Owner's personnel. e. Instruct University's personnel on operation and maintenance of system.

B. Preparation: 1. Verify That System:

a. Has been inspected and put in service. b. Is fully operational.

2. Operation and Maintenance Manuals: a. Completed. b. Sufficient copies available for use in demonstrations and instructions.

3. System balancing shall have been completed.

3.10 CLEANING AND FINISHING

A. Entire installation shall be free from surface oil and grease before work will be considered for final payment.

B. After tests have been made and the system pronounced tight: 1. Clean piping and equipment. 2. Lubricate bearings.

C. Final cleaning includes but is not limited to the following: 1. Equipment with Factory Finishes:

a. Wash factory-finished equipment with mild soap and water and leave in first-class condition, entirely free of stains or streaks.

b. Do not use abrasive materials. Touch up scratches or other violations of the factory finish paint with matching paint from the equipment Manufacturer prior to cleaning.



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General Duty Valves for HVAC

Section 23 05 23


SECTION 23 05 23 – GENERAL DUTY VALVES FOR HVAC PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all valves.

1.3 REFERENCES

A. Except as specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. General: Provide valves with features indicated and, where not otherwise indicated, provide proper

valve features as determined by Installer for installation requirements. Comply with ASME B31.9 for building services piping, and ASME B31.1 for power piping.

2. Flanged: Valve flanges complying with ANSI B16.1 (cast iron), ANSI B16.5 (steel), or ANSI B16.24 (bronze).

3. Threaded: Valve ends complying with ANSI B2.1.


A. General: 1. This Section is provided as a guide in the application and specification of specific valves intended for

use in this Project. This Section does not instruct where to install these valves unless specifically noted. Refer to other specific Mechanical Specification Sections and Drawing details for instruction for location and use.

2. As indicated on the Drawings. 3. As called out in the Piping Systems Schedules.

B. Valves not specifically indicated on the Drawings: 1. Size and class of valve and pipe schedule to agree with line in which installed. 2. All valves 2-1/2-inch and larger shall be flanged unless noted otherwise.

C. Valves shall have Manufacturer's name, trademark and working pressure rating cast into the valve body.

1.5 SUBMITTALS

A. Shop Drawings for all valves.

B. Manufacturer's Literature: For All Valves: 1. Manufacturer's name. 2. Details of construction. 3. Performance characteristics. 4. Pressure and temperature ratings. 5. Close-off pressure.


A. Made in USA: 1. Unless specifically noted otherwise, all valves shall comply with the Federal Trade Commission Made

in USA standard. 2. Supplier shall furnish documentation of USA content if requested by Engineer.


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B. Fabrication and Installation Personnel Qualifications: 1. Trained and experienced in the fabrication and installation of the material and equipment. 2. Knowledgeable of the design and the reviewed Shop Drawings.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Valves shall be manufactured by one Manufacturer for each type of valve. Where valve Manufacturers are not specifically indicated, they shall be one of the following: 1. Nibco. 2. Crane. 3. Milwaukee. 4. Keystone. 5. Stockham. 6. Mueller. 7. Jamesbury. 8. DeZurik. 9. Hammond. 10. Apollo. 11. Powell.

2.2 MATERIALS

A. Bronze Valves: 1. All brass alloys used in valves shall contain no more than 15% zinc. 2. Alloys must comply with ASTM B61, B62 or B584.

2.3 HAND VALVES

A. General: 1. Provide extended stem handles and necks with a minimum clearance of 1-1/2-inch on insulated

service. 2. All valves used for throttling/balancing shall have adjustable memory stops. 3. Pressure ratings are at service indicated by application.

B. Ball Valves: 1. Ball valves used in connection with piping 2 inches in size and smaller shall have screwed or sweat

ends, 2 piece bronze body, standard port with stainless steel ball and a like stem. VA rated for 150 pound SWP and 600 WOG. Seats and seals shall be virgin teflon for standard duty cycle. Provide reinforced teflon for applications identified for extended duty cycle.

2. Based on Jamesbury Series 300 or “Eliminator” Series. 3. 3 inches and larger shall be flanged or butt welded.

C. Standard Duty Butterfly Valves: 1. Iron body rated for 175 psig and 250 degrees F, bubble-tight shutoff. 2. Lug body for use with ANSI flanges. Wafer style is not acceptable, except where specifically approved. 3. Aluminum Bronze disk, 416 stainless steel shaft, EPDM seat. 4. Provide neck extended 2 inches beyond flange diameter. 5. DeZurik Figure BOS-US; or equal.

D. Drain Valves: Furnish at each low point 3/4-inch ball valves as specified above. Install nipple with cap at valve outlet.

E. Plug Valves: 1. Plug valves shall be nonlubricated eccentric plug type rated for 175 pound WOG with semi-steel body

neoprene coated plug and epoxy coated seat; equal to DeZurik Series 100 or Homestead Ballcentric. Furnish with compatible wrench. All valves used for throttling/balancing to have adjustable memory stop.


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Section 23 05 23


2. Plug valves (gas cock) for natural gas shutoff applications shall be lubricated type equal to Homestead Figure 611 or 612 or Rockwell Figure 114 or 115.

2.4 CHECK VALVES

A. Silent Check Valve: 1. Install silent check valves in all pump discharge. 2. Piping less than 2-inch: 300 pounds, bronze body, renewable bronze disc screwed or sweat ends,

bronze trim, Mueller, #203 BP; or equal. 3. Piping 2-inch and larger: 125 pounds, globe type, iron body, bronze trim, renewable seat and disc,

SS springs, Mueller #105-AP; or equal.

B. Swing Check Valve: 1. 2-Inch and Smaller: 150 psi valves for heating hot water:

a. MSS SP-80; Class 125, cast-bronze body and cap conforming to ASTM B62; with horizontal swing, Y-pattern, and bronze disc; and having threaded or solder ends.

b. Provide valves capable of being reground while the valve remains in the line. c. Provide Class 150 valves meeting the above specifications, with threaded end connections,

where system pressure requires or where Class 125 valves are not available. 2. 2-1/2-Inch and Larger for Heating Hot Water:

a. MSS SP-71; Class 125 cast iron body and bolted cap conforming to ASTM A126, Class B; horizontal swing, and bronze disc or cast-iron disc with bronze disc ring; and flanged ends.

b. Provide valves capable of being refitted while the valve remains in the line.

C. Combination Balance And Stop Valves: 1. Based on Bell & Gossett: By the following manufacturers of the same size, type, capacity and meeting

other requirements may be furnished at the Contractor’s option and shall all be by the same manufacturer. a. Taco. b. Griswold. c. Tour & Andersson/Victaulic. d. Flow Design.

2. Based on Bell & Gossett Circuit Plus, Model CB, bronze body, brass ball or globe, positive shut-off, memory stop, differential pressure readout ports, drain port. Valves on piping systems operating below 100 degrees F shall be furnished with pre-formed insulation cover.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install valves in conformance with: 1. The Shop Drawings reviewed by Engineer. 2. The Manufacturer's recommendations.

B. Install Valves: 1. At all branch piping connection to mains. 2. At all connections to equipment. 3. As required for complete control or isolation of any piece of equipment or service to branch lines. 4. In accessible locations. 5. Equal in flow area to connecting piping, unless otherwise indicated.

C. No valve shall be installed with its stem below the horizontal.

D. Install flanged valves at equipment in a manner which allows equipment side of valve to be opened up without draining piping system.



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Hangers and Supports for HVAC Piping and Equipment

Section 23 05 29


SECTION 23 05 29 – HANGERS AND SUPPORTS FOR HVAC PIPING AND EQUIPMENT PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all pipe hanging and support systems.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ASME - American Society of Mechanical Engineers:

a. B31.1 - Power Piping. b. B31.8 - Gas Transmission and Distribution Piping Systems.

2. MSS - Manufacturers Standardization Society: a. SP-58 - Pipe Hangers and Supports - Materials, Design and Manufacture. b. SP-69 - Pipe Hangers and Supports - Selection and Application - 1996. c. SP-90 - Guidelines on Terminology for Pipe Hangers and Supports.


A. Unless otherwise indicated on Drawings or in these Specifications, this Contractor shall be responsible to design and provide all pipe hangers, supports, framing, etc., as required to comply with all applicable building codes, ASME B31 and MSS SP-69.

B. Comply with the requirements of ASME B31.8 for pipe hangers and support of natural gas piping systems.

1.5 SUBMITTALS

A. Submit Shop Drawings for all engineered hanger, restraints and support assemblies. 1. For Metal Framing Pipe Supports: Include locations, dimensions, lengths, Manufacturer, material,

cross-section number or type, finish, pipe sizes, and pipe locations.

PART 2 - PRODUCTS


A. The materials of all pipe hanging and supporting elements shall be in accordance with the latest requirements of the ASME Code for Pressure Piping B31.1 and MSS Standard Practice MSS SP-58 and MSS SP-69 except as supplemented or modified by the requirements of these Specifications.

B. The material in contact with the pipe shall be compatible with the piping material so that neither shall have a deteriorating action on the other.

2.2 MANUFACTURERS

A. Elcon.

B. Anvil.

C. Bergen.


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Section 23 05 29


D. Hilti.

E. Lindapter.

2.3 PIPE HANGERS AND SUPPORTS

A. Horizontal Piping Hangers: Unless otherwise indicated and except as specified in piping system Specification sections, install the following types: 1. Adjustable Steel Clevis Hangers (MSS Type 1): For suspension of noninsulated or insulated

stationary pipes, NPS 1/2 to NPS 30 (DN15 to DN750). 2. Steel Pipe Clamps (MSS Type 4): For suspension of cold and hot pipes, NPS 1/2 to NPS 24 (DN15 to

DN600), if little or no insulation is required. 3. Pipe Hangers (MSS Type 5): For suspension of pipes, NPS 1/2 to NPS 4 (DN15 to DN100), to allow

off-center closure for hanger installation before pipe erection. 4. Clips (MSS Type 26): For support of insulated pipes not subject to expansion or contraction.

2.4 HANGER RODS

A. Minimum rod diameters for rigid rod hangers shall be as shown in MSS SP-69 Table 4 (Minimum Rod Diameter for Single Rigid Rod Hangers) and as indicated in Part 3 of these Specifications.

B. Hanger rods shall be subject to tensile loading only. At hanger locations where lateral or axial movement is anticipated, suitable linkage shall be provided to permit swing.

C. Rod material must be compatible with hanger and comply with above. Do not field cut thread on galvanized rod.

D. Do not use perforated strap.

E. Multiple Supports: 1. Horizontal banks of pipe may be supported on a common base member without regard to the pipe

centerline elevation. 2. In the supporting of multiple pipe runs, provisions shall be made to keep the lines in their relative

lateral positions, using clamps or clips as required. Lines subject to thermal expansion shall be free to roll axially or slide.

2.5 SADDLES AND SHIELDS

A. All Piping: 1. Saddle: MSS Type 39 (Grinnell #160-164), or Anvil Figure 162 or 165. 2. Shield: MSS Type 40 (Grinnell #167), provide and install in accordance with Manufacturer's shield size

selection tables. 3. The contour of the saddle shall match the radius of the pipe insulation.

PART 3 - EXECUTION

3.1 HANGER AND SUPPORT APPLICATIONS

A. General Requirements: 1. The selection of pipe hangers and supports shall be based on the overall design concept of the piping

system and any special requirements which may be called for in these Specifications or as indicated on the Drawings. The support systems shall provide for, and control, the free or intended movement of the piping including its movement in relation to that of the connected equipment. They shall prevent excess stress resulting from the transfer of weight being introduced into the pipe or connected equipment.

2. The selection of hangers and supports shall be made to provide the piping system with the degree of control that its operating characteristics require.

3. The selection of hangers or supports will take into consideration the combined weight of the supported systems, including system contents and test water.


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Section 23 05 29


4. Select and install hangers and supports to allow controlled thermal and seismic movement of piping system, to permit freedom of movement between pipe anchors, and facilitate action of expansion joints, expansion loops, expansion bends and similar units.

5. Select all hangers and supports rated for the maximum potential loading with pipe full.

3.2 HANGER AND SUPPORT INSTALLATION

A. Pipe Hanger and Support Installation: Comply with MSS SP-69 and MSS SP-89. Install hangers, supports, clamps, and attachments as required to properly support piping from building structure.

B. General: 1. Adjust all components as required for proper operation and required pipe slope. 2. Location and Routing:

a. Install Piping as Indicated: 1) On the Drawings. 2) On the reviewed Shop Drawings.

b. Secure Engineer's approval for all pipe routing changes. 3. Install all items in accordance with Manufacturer's instructions.

C. Support at Valves: Provide additional supports at all valves in piping 4-inch and larger.

D. Horizontal Runs: 1. General:

a. Provide adequate supports for the loads with a factor of safety of at least 5 (400 pounds minimum).

b. Provide protective shield at all hangers and rollers supporting plastic pipe and coated pipe. c. Support spacing not to exceed MSS SP-69 Table 3, or the requirements for seismic restraint,

whichever is more stringent. d. Hanger rod diameter shall not be less than the requirements of MSS SP-69 Table 4, or the

requirements for seismic restraint, whichever is more stringent.

3.3 INSULATION PROTECTION

A. Provide Protection Saddle: 1. Equal to insulation thickness. 2. At each hanger. 3. For all insulated piping systems where longitudinal expansion exceeds 1-inch per 100 feet.

B. Provide insulation protection shield: 1. At each hanger for all "cold" (less than 50 degrees F) piping services. 2. In accordance with the following table:

Pipe Size (IPS) Shield Gage Length 5" and Smaller 16 12"



/1

Testing and Cleaning of HVAC Systems

Section 23 05 73


SECTION 23 05 73 – TESTING AND CLEANING OF HVAC SYSTEMS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes providing testing and cleaning services and the major items listed below: 1. Provide all pumps, gages, valves and other equipment and material necessary to properly conduct

tests and perform cleaning. 2. Arrange and pay for all costs of utilities and chemicals required for the Work. 3. Repair and Restore All Work Damaged:

a. By tests. b. By cutting required in connection with the tests.

1.3 SUBMITTALS

A. Flushing and Cleaning: 1. Submit certificates for all code-required inspections. 2. Submit all water Sample analysis reports as required in Part 3 of these Specifications.

B. Pressure Test Reports: 1. Submit within 1 week after each system pressure test. 2. List time, date and persons present for the following for each system:

a. Initial tests. b. Final test.

3. Include report indicating: a. Test type and duration. b. Initial pressure. c. Final pressure.

4. Indicate that necessary repairs and final tests were satisfactorily completed.


A. Comply with all applicable codes.

B. Testing and Cleaning Agency: 1. Minimum 15 years experience in providing cleaning chemicals for water systems use. 2. Provide regional laboratory support services.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Cleaning Agents: 1. Aqua-Chem. 2. Aquatrol. 3. Enerco. 4. Nalco.


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Section 23 05 73


PART 3 - EXECUTION

3.1 PIPING SYSTEM PRESSURE TEST

A. General: 1. Perform all tests before piping is painted, covered, concealed or backfilled. 2. Before testing, remove or otherwise protect from damage, control devices, air vents, fixtures, meters,

or other parts which are not designated to withstand test pressures.

B. Test Procedures: 1. Air Test:

a. Charge with air to the test pressure specified. b. When possible, perform test when ambient air temperature is constant.

2. Water Test: a. Charge with water to the pressure specified. b. Exterior Surface of Pipe and Fittings:

1) Show no cracks or other form of leaks. 2) Completely drip dry.

C. Pressure Test Criteria: 1. Test criteria below are minimum requirements. In addition, the requirements of State and Local Codes

having jurisdiction shall be met:

Piping System

Type Test

Pressure

Allowable Pressure Drop

Minimum Test Duration

Hydronic Water 100 psig 2 psi 8 Hours Gas * * * * * * See below for natural gas piping pressure tests.

2. Natural Gas Piping: a. Natural gas piping shall be tested in accordance with NFPA 54, Sections 8.1.4.2 and 8.1.4.3. b. Test pressure to be used shall be no less than 1-1/2 times the proposed maximum working

pressure, but not less than 3 psi. c. Where the test pressure exceeds 125 psi (862 kPa), the test pressure shall not exceed a value

that produces a hoop stress in the piping greater than 50 percent of the specified minimum yield strength of the pipe.

d. Test duration shall be not less than 1/2 hour for each 500 cubic feet (14 cubic meter) of pipe volume or fraction thereof. When testing a system having a volume less than 10 cubic feet, the test duration shall be a minimum of 10 minutes. The duration of the test shall not be required to exceed 24 hours.

3.2 FLUSHING AND CLEANING PROCEDURES

A. Hydronic Piping Systems: 1. Thoroughly flush with water to remove pipe dope, slushing compounds, oils, welding slag, loose mill

scale and other extraneous materials. Open all valves to ensure cleaning of entire system. 2. Apply detergent and operate system in accordance with water treatment service organizations

recommendations, circulating for a minimum of 8 hours: a. Use only equipment and chemicals furnished by a qualified water treatment service

organization. b. Determine loop capacity by metering fill with all air bled out. c. Isolate alkaline cleaners from cooling towers and aluminum and galvanized surfaces. d. Place all control valves in open position for filling and venting. e. Flush thoroughly with clean water and introduce corrosion inhibitors if system is not to be

immediately started and/or filled with glycol. 3. After the system has been cleaned:

a. Test water Sample and submit analysis to Engineer. b. Water Sample shall exhibit neutral pH and no turbidity.


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Section 23 05 73


B. Natural Gas Piping Systems: 1. Blow clear using oil-free compressed air. 2. Prior to pressure testing and final equipment connection.

C. Remove and clean all strainers after flushing is complete.

D. Drain completely and refill after flushing. END OF SECTION 23 05 73


/2

Testing, Adjusting and Balancing for HVAC

Section 23 05 93


SECTION 23 05 93 – TESTING, ADJUSTING AND BALANCING FOR HVAC PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes a description of the mechanical system testing, adjusting and balancing (TAB) scope of services. The following systems shall be included in the testing, adjusting, and balancing process: 1. Hydronic distribution systems. 2. Exhaust systems. 3. Variable frequency drives. 4. Boilers.

B. Division of Work: 1. In accordance with the General Conditions, Contractor shall be responsible for dividing the Work

among the Subcontractors and Suppliers and for delineating the work to be performed by specific trades.

2. The following are suggestions as to how the Work may be divided. This is not a complete list of all the work: a. Mechanical Subcontractor:

1) Provide related work as specified herein to support the mechanical systems TAB work. 2) Provide replacement fan sheaves on the existing exhaust fan serving the space:

a) At no additional cost to Owner. b) As required to achieve design performance for mechanical equipment.

3) Perform system start-up functions including, but not necessarily limited to: a) Venting air from all hydronic system piping and components. b) Complete and submit pre-test and balance checklist to Engineer prior to start of TAB

work. 4) Perform preliminary balance of heating water flow rates, prior to start of construction, in all

branch piping as indicated on the Drawings. Upon completion of installation of new equipment, Contractor shall rebalance each heating water branch to flow rates measured prior to starting construction.

5) Correct all mechanical system deficiencies identified during the TAB process. 6) Test, adjust and balance all air and hydronic systems and prepare final report.

b. Temperature Control (TCS) Subcontractor: 1) Provide related work as specified herein to support the mechanical systems TAB work

being performed by Mechanical Subcontractor. 2) Operate all temperature control devices to support TAB work that is dependent on various

control operating modes. 3) Correct all TCC system deficiencies identified by Mechanical Subcontractor.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. Sheet Metal and Air Conditioning Contractor's Association (SMACNA) publications:

a. Procedural Standards for Testing, Adjusting, and Balancing of environmental systems. b. c. Testing, Adjusting, Balancing Manual for Technicians.

2. Associated Air Balance Council (AABC): National Standards for Total System Balance, 2002 Edition. 3. National Environmental Balancing Bureau (NEBB): Procedural standards for testing, adjusting, and

balancing of environmental systems.


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Section 23 05 93


1.4 DEFINITIONS

A. Proper Performance Characteristics: 1. In accordance with design intent, acceptable energy efficiency and Manufacturer's recommendations. 2. Providing acceptable thermal and acoustical performance in all service areas. 3. As directed by Engineer.

1.5 SUBMITTALS

A. Submit Pre Test and Balance Checklist and mechanical systems TAB report in accordance with Division 01 Section for Submittal Procedures.

B. Submit Pre Test and Balance Checklist at least 2 weeks prior to scheduled start of TAB work as scheduled by Contractor and approved by University.

C. Preliminary TAB Submittal: 1. Prior to final inspection. 2. 1 copy to Engineer.

D. Final Submittal: 1 copy to Engineer.

E. The TAB report shall include, but not necessarily be limited to, the following general items: 1. Summary remarks regarding problems. 2. Initial, interim and final performance test data. 3. Description of test procedures and equipment used. 4. Systems' Drawings and/or schematics clearly marked to identify location of equipment tested, duct

traverse location(s), location of system static pressure sensor, etc. 5. Systems performance data sheets shall include design conditions, installed equipment information,

and field test data for: a. Air Systems:

1) Design Conditions: a) Air capacity. b) System total static pressure drops and profiles of all air handling systems, including

filters, coils, etc. c) Motor horsepowers and design brake horsepowers. d) Fan speeds. e) Fan curves or fan rating tables showing design conditions.

2) Field Test Data - Initial and Final Test Readings For: a) Air capacities. b) Static pressures through units and unit components. c) Equipment speeds. d) Motor operating voltages and amperages. e) Brake horsepower.

b. Hydronic Systems: 1) Design Conditions:

a) Water flow rates. b) Pump TDH and speed. c) Motor horsepowers and design brake horsepowers. d) Pump curves showing design conditions.

2) Installed Equipment: a) Equipment Manufacturer(s). b) Equipment model numbers, sizes, types, etc. c) Motor types, sizes and characteristics. d) Heater and starter types, sizes and characteristics. e) Equipment ratings if different than design.

3) Field Test Data - Initial and Final Test Reading For: a) Pump pressures at full flow and at shut-off. b) Pump motor operating voltages and amperages. c) Flow rates through all flow indicators. d) Positions of balancing valves.


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Section 23 05 93


e) Inlet pressure, outlet pressure and pressure drops through all heating (and cooling) equipment pieces.

f) Brake horsepower. g) Operating performance plotted on pump curves.


A. Qualifications: 1. TAB Field Technician Personnel:

a. Trained and experienced in the operation of the test and balance equipment. b. Knowledgeable of the design of all systems scheduled for testing and balancing.

2. The mechanical contractor serving as the TAB Engineer: a. A certified member of either the following organizations:

1) AABC. 2) NEBB.

B. Report Forms: 1. The report forms included in the appendix of the AABC Standard are incorporated in the work of this

Section for the purpose of identifying the level of detail required for testing and reporting. 2. Mechanical Subcontractor may use the AABC forms or other similar forms which present equivalent

information in a logical format.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Patching Materials: 1. Comply with requirements as specified in other Sections where applicable to provide materials

essentially and functionally identical to original installation before testing and balancing work. 2. Maintain the integrity of systems for air tightness, water tightness, and durability of finish.

2.2 INSTRUMENTS

A. Instruments used for TAB work shall be as indicated in the referenced standards.

B. Calibration: 1. Instruments to have been calibrated within one year of start of TAB work. 2. Appropriate documentation shall be made available to the Engineer on request.

PART 3 - EXECUTION

3.1 PROCEDURES

A. General: 1. Determine what actual performance characteristics are deemed proper during system tests. 2. During heating season of the first year of operation, at times when directed, make final adjustments

until all occupants are reasonably satisfied and all equipment is operating at peak efficiency. 3. Confirmation of proper equipment operation must be through actual observation. Computer simulation

and sensor readouts are not acceptable proof.

B. Air Systems: 1. General:

a. Adjust and set all belted fan speeds as required to attain proper total air flow. 2. TAB Procedures for Air Systems:

a. Check all motorized dampers for proper position. b. Inspect fans for cleanliness. c. "Bump" motor to check for proper fan rotation.


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Section 23 05 93


d. Check unit performance including: 1) Fan speed. 2) Amperage and voltage. 3) Suction, discharge and total static pressures at fan.

e. See that necessary adjustments or changes are made to achieve design airflow capacities or consult Engineer if change(s) required are beyond the scope of the TAB contract.

C. TAB Procedures for Water Systems: 1. Adjust and set all applicable balancing valves to achieve proper water distribution to all components of

the hydronic heating and cooling systems. 2. When valves are in final balance position, permanently mark final location. 3. Verify pump performance by means of system flow meter and/or pump head measurements in

conjunction with shutoff head measurement. 4. Proportionally set all primary cross-over bridge circuits. Set 3-way valve for full flow through bridge, by-

passing the secondary circuit, and measure flow by means of bridge flow meter. 5. Remeasure pump delivery after system is proportionally balanced. 6. Test and balance secondary pumping circuits as required by system type. 7. Immediately after system balance report pump throttling required to Engineer.


A. Preliminary Review and Analysis: 1. If after standard balancing procedures have been carried out and readjustments attempted, the

system does not perform as specified, Engineer shall be notified at once. 2. All "as is" field data shall be submitted in a preliminary report for review and analysis. 3. Manipulation of system to achieve air flow and balance without meeting intended and specified total

system air flow will not be accepted in a balance report. Should this occur, rebalance shall be at the Contractor's expense.

B. Final Inspection: Prior to final acceptance, all systems shall be operated to test performance as directed to the satisfaction of the Engineer: 1. Water shall circulate throughout entire system without noise, evidence of leaks and trapping or air-

binding. 2. Motors, fans and other equipment shall operate without excessive noise or vibration. 3. Systems shall be balanced to operate within stated tolerances. If any heating unit, chilled water

cooling coil, or air outlet does not operate within the stated tolerances, then the entire system shall be considered out of balance and shall be readjusted until all units are within the stated tolerances.

3.3 PRE TEST AND BALANCE CHECKLIST

A. Contractor shall copy the following Pre Test and Balance Checklist (Exhibit A, attached) and submit one completed checklist for each pump, boiler, and fan.


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Section 23 05 93


EXHIBIT A

PRE TEST AND BALANCE CHECKLIST Equipment Tag No. _______________ Date: ____________________ As an aid to properly interface work between trades and prevent unnecessary return visits for everyone concerned, the TAB engineer requires that the following list of items be completed by the Mechanical Subcontractor prior to any testing and balancing of air and hydronic systems. Work required is as follows: Item No. Description 1. All air shall be bled from hot water system. 2. Memory devices shall be installed on all specified balancing valves 3. Installation of all temperature wells and gage cocks.

4. Pressure taps shall be installed across body of pump and inlet and outlet of coils. Location of

pressure taps shall be between isolation and check valves, etc., associated with coils.

5. Hydronic systems shall have been cleaned and flushed and construction strainers removed from

equipment. 6. Pump rotation shall be correct. 7. Verify that pump is running within motor nameplate amp draw at initial installed impeller size. 8. All exhaust fans shall be wired, operable and in correct rotation. 9. All relief air or backdraft dampers shall be set for proper operation, i.e., just closing.



/1

HVAC Piping Insulation

Section 23 07 19


SECTION 23 07 19 – HVAC PIPING INSULATION PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of piping insulation.

1.3 REFERENCES


a. C534 - Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form. b. C552 - Cellular Glass Block and Pipe Thermal Insulation.

2. ASTM Standard Test Methods: E84 - Surface Burning Characteristics of Building Materials. 3. National Fire Protection Association (NFPA) publications: NFPA 255 - Surface Burning

Characteristics of Building Materials: 25, 50, 50 flame spread, fuel, smoke. 4. ASHRAE: 90A - Energy Conservation in New Building Design, current edition.

1.4 SUBMITTALS

A. Manufacturer's Literature: For piping insulation. 1. For Each Type Used:

a. Name of Manufacturer. b. Details of construction and installation. c. Manufacturer's data (density, K-factor).

2. For Each Application: a. Thickness. b. Total "R" value. c. Jacket material.




A. Deliver materials in original, unbroken, brand marked containers or wrapping as applicable. Handle and store materials in a manner which will prevent deterioration and contamination with foreign matter.

B. Reject damaged, deteriorated, or contaminated material and immediately remove from the Site. Replace removed materials at no additional cost to Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Insulation: 1. Owens-Corning. 2. Certainteed.


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Section 23 07 19


3. Armacell. 4. Rubatex. 5. Knauf. 6. Johns Manville.

B. Jacketing: 1. Ceel-Co. 2. O'Brien. 3. Zeston. 4. Childers. 5. Pabco.

C. Adhesives: 1. Benjamin Foster. 2. Childers. 3. Vimasco. 4. B.E.H. 5. Or equal.

2.2 TYPES OF INSULATION MATERIALS

A. Rigid Molded Glass Fiber - High Density (HFG): 1. All-service jacket (ASJ), factory-applied jacketing. 2. 6 lbs/cu ft minimum density. 3. k factor of 0.31 maximum at 200 degrees F mean. 4. 850 degree F service temperature. 5. Owens-Corning Type SSLII; or equal. 6. Typical for applications on pipes below 16 inches (normal).

B. Flexible Elastomeric Thermal Pipe Insulation (E): 1. Density of 5.0 lbs/cubic foot. 2. k factor of 0.27 at 75 degrees F mean. 3. Maximum water vapor transmission of 0.17 per inch. 4. Must be listed for 25/50 flame/smoke spread for thickness used. 5. Armacell Armaflex AP; or equal.

2.3 INSULATION INSERTS

A. Insulation inserts shall be made of calcium silicate treated with water repellant.

B. Inserts shall be preformed for the pipe size, same thickness as adjoining pipe insulation, same length as shield, and 180 degree-minimum segments.

C. Insulation inserts shall not be less than the following lengths: 1. 2-1/2-Inch Pipe Size and Less: 10 inches long. 2. 3-Inch to 6-Inch Pipe Size: 12 inches long.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install piping insulation:

a. In conformance with the Drawings. these Specifications, and the Manufacturer's recommendations.

b. Over clean, dry piping system.


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Section 23 07 19


c. To the following thickness: 1) As specified herein or as indicated on the Drawings. 2) If not specified herein or indicated on the Drawings, in accordance with Manufacturer's

recommendations for the specific application. d. Continuous through walls, ceilings and sleeves except at fire stops.

2. Fill all cracks and voids with insulating cement carefully troweled to leave a smooth finish. 3. Repair or replace insulation damaged by:

a. Demolition. b. Making connections to piping or equipment. c. Water or mildew.

4. Verify that piping has been tested and cycled before applying insulation materials. 5. All sectional pipe covering shall be neatly and tightly applied with unbroken lengths and with the ends

of the sections firmly butted together. Longitudinal joints shall be on the least conspicuous side of the pipe and slightly staggered. Fiberglass cloth or other coating shall be lapped over all joints and well pasted or cemented down in a neat and inconspicuous manner.

6. The insulation on piping shall be extended through all sleeves, anchor points and supports in order to produce a continuous application, and same shall be installed to conform to a uniform diameter.

7. All fittings, flanges, end caps, etc. on all lines, except where otherwise noted, shall be covered with insulated fitting covers. Thickness of insulation, jackets and finishes shall also match adjacent piping.

8. Insulation for piping shall be continuous through hangers and supports. 9. Provide insulation inserts and insulation protection shields at hanger or support locations. 10. Valve bodies to the bonnet flange or union, drip legs, and pipes at anchor points shall be insulated.

Terminate insulation into a finished end. 11. Terminate insulation into a finished end.

B. Joints and Fittings: 1. Block insulate valves and flanges with reusable insulation system. 2. Insulate elbows, tube turns, sweeps and bends with mitered sections or premolded fittings. Match

pipe covering material where used. 3. Fit joints tightly together. 4. Seal joints with sealing compound and preformed aluminum bands.

3.2 JACKETS AND FINISH

A. General: 1. Provide moisture barrier between the insulation and the jacketing in a continuous, unbroken seal. 2. Hold jacketing in place by a continuous sealed joint, providing a positive weatherproof seal along the

entire length of the jacket. 3. Cap off ends with caps. 4. Locate longitudinal jacket seams on indoor exposed piping out of view. 5. Vapor seal laps using self-sealing lap, lap seal tape gun or adhesive such as Benjamin Foster 520.

B. Taper and seal insulation ends regardless of service.

C. Fitting and pipe jackets to have matching finishes ready for painting.

3.3 PIPING INSULATION APPLICATION SCHEDULE

A. Basis of Thickness Chart: 1. Thicknesses shown are based on products having a maximum "k" factor of 0.26 at a mean

temperature of 75 degrees F. 2. These Thicknesses:

a. Can be reduced for products having significantly lower "k" values. b. Shall be increased for products having higher "k" values in order to produce equivalent or

greater thermal resistance.

B. Flame/Smoke Ratings: Local requirements for flame and smoke ratings must be met and may exclude some options listed herein.


/1


Section 23 07 19


C. Thickness Chart (In Inches): 1. Key: Insulation Type (Refer to Paragraph 2.2 of this Section):

a. HFG = High Density Rigid Fiberglass. b. E = Flexible Elastomeric.

PIPE SIZE

Piping Systems Type Temp (F)

Range Less

Than 1″ 1″ to

1-1/4″ 1-1/2″ to 3″ 4″ to 6″ 8″ & Up

Type of Insulation *

1. Heating Water 180-250 1.5 1.5 2.0 2.0 2.0 HFG

2. Boiler Condensate Drain -- 0.5 0.5 0.5 1.0 -- HFG, E



/2 Z:\2012\120270CD\WORK\SPECS\BID SET\23_09_00_MIAMI CONV.DOCX

Instrumentation and Control for HVAC

Section 23 09 00

23 09 00 – 1

SECTION 23 09 00 – INSTRUMENTATION AND CONTROL FOR HVAC PART 1 - GENERAL



B. Refer to Electrical Drawings for specific requirements as they relate to Control Diagrams.

1.2 SUMMARY

A. Siemens, Inc. will be the basis of design for this project. This system shall be engineered, programmed, and installed by personnel trained by the manufacturer and regularly employed by the manufacturer's recognized, approved, certified, and authorized agent. The agent shall have complete responsibility for proper installation and operation including checkout, test, calibration, commissioning, and warranty of the equipment and the entire system. The system shall be installed in strict compliance with the specifications. Supplier shall have an in-place support facility within 50 miles of the site with technical staff, spare parts inventory and all necessary test and diagnostic equipment.

B. This section includes equipment and configuration requirements for the HVAC controls system as follows: 1. General: The control system shall consist of a high-speed, peer-to-peer network of DDC controllers

and a web-based operator interface. A web server with a network interface card shall gather data from this system and generate web pages accessible through a conventional web browser on each PC connected to the network. Operators shall be able to perform all normal operator functions through the web browser interface.

2. The system shall directly control HVAC equipment as specified in Division 23 “Sequence of Operations for HVAC Controls.” Each zone controller shall provide occupied and unoccupied modes of operation by individual zone. Furnish energy conservation features such as optimal start and stop, night setback, request-based logic, and demand level adjustment of setpoints as specified in Division 23 “Sequence of Operations for HVAC Controls.”

3. Provide for future system expansion to include monitoring of occupant card access, fire alarm, and lighting control systems.

4. System shall use the Miami University RPMS system for BAS communication. This system shall fully integrate into the MU-Remote Powers Management System (RPS) systems for complete communication to the campus operator workstations or web servers and for communication between DDC panels and modules. I/O points, schedules, setpoints, trends and alarms as specified in Division 23 Section “Sequences of Operations for HVAC Controls shall be included as specified.

C. Related sections include the following: 1. HVAC:

a. Division 23 Section “General HVAC Provisions.” b. Division 23 Section “Testing, Adjusting and Balancing for HVAC.” c. Division 23 Section “Sequence of Operations for HVAC Controls.” d. Division 23 Section “Hydronic Pumping.” e. Division 23 Section “Condensing Boiler.” f. Division 26 Section “Variable Frequency Motor Controllers.”

2. Electric: a. Division 26 Electrical Specifications.

1.3 SCOPE

A. Install a new Siemens DDC temperature control system in the building as shown on the Drawings and as specified herein. System shall communicate with the campus DDC control system. Failure to mention any specific item or device does not relieve the Contractor of the responsibility for installing such device or item in order to comply with the intent of the drawings or this Specification. 1. Install DDC controls for the HVAC system. 2. Install monitoring for the HVAC system and electrical systems.




Section 23 09 00

23 09 00 – 2

3. This specification is a performance type specification. Detailed design, conduit routing, programming, graphics generation, etc., is the responsibility of the Temperature Control Contractor. The materials and equipment specified are set up as a standard, and the Base Bid must be submitted on this basis.

4. Temperature Control Contractor shall provide: a. Necessary conduit, wiring, enclosures, and panels, for all DDC temperature control equipment

and devices. Installation shall comply with applicable local and national codes. b. All components and control devices necessary to provide a complete and operable DDC system

as specified herein. c. All final electrical connections to each DDC panel. Connect to 120 VAC power provided by the

Division 26 Contractor. d. Temperature Control Contractor shall be responsible for all electrical work associated with the

temperature control system and as called for on the Drawings. This temperature control wiring shall be furnished and installed in accordance with the electrical requirements as specified in Division 26, the National Electric Code and all applicable local codes.

e. Surge transient protection shall be incorporated in design of system to protect electrical components in all DDC Controllers, Application Specific Controllers and operator’s workstations. Provide an external protection device listed under UL 1449 with maximum clamping voltage of 400 volts and surge current capability of 26,000 amps.

f. All 120V and low voltage electrical control wiring throughout the building shall be run in conduit in accordance with the Electrical requirements as specified in Division 26, the National Electric Code, and all applicable local codes.

g. All 24V power required for operation of the DDC system shall be by the Temperature Control Contractor.

h. Temperature Control Contractor shall provide programming modifications necessary to fine tune sequences during commissioning and through warranty period of systems at no additional cost to the University.

5. HVAC Contractor provides: a. All wells and openings required for water monitoring devices, flow switches and alarms.

6. Electrical Contractor provides: a. Power circuit near temperature control equipment and devices and final connections to those

devices called for on the electrical drawings. b. Additional 120 volt power circuits for power to terminal boxes as shown on Electrical Drawings.

Any quantity of circuits required over and above those shown on electrical drawings shall be at the Temperature Control Contractors expense. Power wiring from transformers for these boxes and all control wiring shall be by the Temperature Control Contractor.

c. 120 volt, 20 amp breaker for each DDC Control Processor. 7. Programming:

a. This Contractor will be responsible for complete programming and checkout for the systems controlled. Control systems to perform according to Division 23 “Sequence of Operations for HVAC Controls.”

b. All sensors provided shall be dynamically updated. c. Temperature Control Contractor shall provide programming modifications necessary to fine tune

sequences during commissioning of systems at no additional cost to the University. B. General Architecture of the Temperature Control System:

1. The system shall incorporate Direct Digital Control (DDC), equipment monitoring, and control consisting of a PC based Operator Work Station (OWS) with colorgraphic data displays; microcomputer based DDC Control Processors (DDCs) interfacing directly with sensors, actuators and environmental delivery systems (i.e., HVAC units, pumps, etc.); electronic and electric controls and mechanical devices for all items indicated on drawings described herein including dampers, valves, panels, and devices; a primary communication network to allow data exchange from DDC to DDC control processors; microcomputer based Terminal Equipment Controllers (TECs) interfacing with sensors, actuators, and terminal equipment control devices; and a secondary communication networks interfacing TECs to DDC network devices.

2. The quantity and location of temperature control panels and devices shown on the drawings are for coordination purposes only, and in no way indicate the extent of the equipment. Additional panels or devices required to accomplish the sequence of operations in accordance with Division 23 “Sequence of Operations for HVAC Controls” shall be the responsibility of the Temperature Control Contractor. This includes any electrical power wiring or additional circuits over and above that shown on the electrical contract drawings.

3. The system shall be modular in nature and shall permit expansion of both capacity and functionality through the addition of sensors, actuators, DDC control processors, TEC's, and operator devices.




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4. System architectural design shall eliminate dependence upon any single device for alarm reporting and control execution. Each DDC control processor shall operate independently by performing its own specified control, alarm management, operator I/O and data collection. The failure of any single component or network connection shall not interrupt the execution of control strategies at other operational devices.

5. DDC control processors shall be able to access any data from, or send control commands and alarm reports directly to, any other DDC control processor or combination of controllers on the network without dependence upon a central processing device. DDC control processors shall also be able to send alarm reports to multiple operator workstations without dependence upon a central processing device.


A. Materials and equipment shall be the catalogued products of manufacturers regularly engaged in production and installation of Building Automation Systems and shall be manufacturer's latest standard design that complies with the specification requirements.

B. The installer shall be employees of the temperature control system manufacturer or shall be recognized as an approved installer of temperature control system for the manufacturer.

C. Install system using competent workmen who are fully trained in the installation of temperature control equipment.

D. Single source responsibility of supplier shall be the complete installation and proper operation of the DDC temperature control system and shall include debugging and proper calibration of each component in the entire system.

E. Supplier shall have an in-place support facility at bid day within 50 miles of the site with technical staff, spare parts inventory and all necessary test and diagnostic equipment.

F. All electronic equipment shall conform to the requirements of FCC Regulation, Part 15, Section 15, Governing Radio Frequency Electromagnetic Interference and be so labeled.

G. The system shall comply with NFPA 90A Air Conditioning and 90B Warm Air Heating, Air conditioning. System shall be designed and manufactured to ISO 99001 quality standard, and all electronic equipment shall conform to the requirements of FCC regulation Part 15, Section 15 governing radio frequency electromatic interference and be so labeled.

H. Design and build all system components to be fault-tolerant. 1. Satisfactory operation without damage at 110% and 85% of rated voltage and at plus 3 Hertz variation

in line frequency. 2. Static, transient and short-circuit protection on all inputs and outputs. 3. Protect communication lines against incorrect wiring, static transients and induced magnetic

interference. 4. Network-connected devices to be A.C. coupled or equivalent so that any single device failure will not

disrupt or halt network communication. 5. All real time clocks and data file RAM to be battery-backed for a minimum 72 hours and include local

and system low battery indication. 6. All programs shall retain their memory for a minimum of 7 days upon loss of power.

1.5 SUBMITTALS

A. Submit 3 complete sets of Drawings showing the kind of control equipment for each of the various systems and their functions, along with indications on the drawing of all original setpoints and calibration values, and setup parameters, and sequence of operation of the DDC system. These Drawings shall be submitted for approval to the Architect, together with a complete brochure describing the equipment and their functions and operation. Include all application software documentation (actual programs or their job-specific flow charts) with DDC system and schedule a review meeting with the Architect at least 2 weeks before installation and start-up. 1. Manufacturer’s Product Data:

a. All equipment components.




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2. Shop Drawings: a. System wiring diagrams with sequence of operation for each system as specified. b. Submit manufacturer’s product information on all hardware items along with descriptive literature

for all software programs to show compliance with specifications. c. System configuration diagram showing all panel types and locations as well as communications

network and workstations. d. System architecture diagram and descriptions. e. Approved room numbers are required to be included on all temperature control submittals, and

all control as-built drawings.

B. Where installation procedures, or any part thereof, are required to be in accordance with the recommendations of the manufacturer of the material being installed, printed copies of these recommendations shall be furnished to the Architect prior to installation. Installation of the item will not be allowed to proceed until the recommendations are received.

1.6 COMMISSIONING

A. Provide necessary personnel as required to assist the Engineer and the University in providing complete system operational testing.

PART 2 - PRODUCTS

2.1 DDC CONTROL PROCESSORS PANEL

A. DDC Control Processors Panel shall be 16 bit microprocessor based with EPROM operating system. DDC programs and data files shall be non-volatile EEPROM or flash memory to allow simple and reliable additions and changes. Each DDC control processor shall have an on-board 30 day battery backed realtime clock. DDC control processor shall be provided where shown or specified with capacity to accommodate input/output (I/O) points required for the application plus spare points specified. Each panel shall be provided with a socket for a Portable Operators Terminal (POT), and a port for network communications at no less than 78,000 baud. DDC outputs shall be binary for On-Off control, and true variable voltage (0-10v) for driving analog or pneumatic transducer devices. Analog outputs shall have a minimum incremental resolution of one percent of the operating range of the controlled device. DDC control processor shall have LEDs for continuous indication of all bus communications, power, and operational status. All panel electronics and associated equipment shall be installed in suitable enclosures. 1. Each DDC control processor shall have sufficient memory, a minimum of 1 megabyte, to support its

own operating system and databases, including: a. Control processes. b. Energy management applications. c. Alarm management applications including custom alarm messages for each level alarm for each

point in the system. d. Historical/trend data for points specified. e. Maintenance support applications. f. Custom processes. g. Operator I/O. h. Dial-up communications. i. Manual override monitoring.

2. Each DDC control processor shall support: a. Monitoring of the following types of inputs.

1) Analog Inputs: a) 4-20 mA. b) 0-10 Vdc. c) Thermistors. d) 1000 ohm RTDs.

b. Digital Inputs: 1) Dry contact closure. 2) Pulse Accumulator. 3) Voltage Sensing.




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c. Direct control of electronic actuators and control devices. Each DDC control processor shall be capable of providing the following control outputs. 1) Digital Outputs (contact closure):

a) Contact closure (motor starters, sizes 1-4). 2) Analog Outputs:

a) 0-20 psi. b) 4-20 mA. c) 0-10 Vdc.

3. Each DDC control processor shall have a minimum of 10 per cent spare capacity for future point connection. The type of spares shall be in the same proportion as the implemented I/O functions of the panel, but in no case shall there be less than 2 spares of each implemented I/O type. Provide all processors, power supplies and communication controllers complete so that the implementation of a point only requires the addition of the appropriate point input/output termination module and wiring. a. Provide sufficient internal memory for the specified control sequences and have at least 25% of

the memory available for future use. 4. DDC control processor shall provide at least 2 serial data communication ports for operation operator

I/O devices such as industry standard printers, operator terminals, modems and portable laptop operator's terminals. DDC control processor shall allow temporary use of portable devices without interrupting the normal operation of permanently connected modems, printers or terminals.

5. Each DDC control processor shall continuously perform self-diagnostics, communication diagnosis and diagnosis of all panel components. The DDC control processor shall provide both local and remote annunciation of any detected component failures, low battery conditions or repeated failure to establish communication.

6. Isolation shall be provided at all peer-to-peer network termination’s, as well as all field point termination’s to suppress induced voltage transients consistent with IEEE Standards 587-1980.

7. The operator shall have the ability to manually override automatic or centrally executed commands at the DDC Controller via local, point discrete, on-board hand/off/auto operator override switches for digital control type points and gradual switches for analog control type points. These override switches shall be operable whether the panel processor is operational or not. a. Switches shall be mounted either within the DDC Controllers key-accessed enclosure, or

externally mounted with each switch keyed to prevent unauthorized overrides. b. DDC Controllers shall monitor the status of all overrides and inform the operator that automatic

control has been inhibited. DDC Controllers shall also collect override activity information for reports.

8. In the event of the loss of normal power, there shall be an orderly shutdown of all DDC Controllers to prevent the loss of database or operating system software. Programs residing in memory shall be protected either by using EEPROM or by an uninterruptible power source (battery backup). The backup power source shall have sufficient capacity to maintain volatile memory in event of an AC power failure. Where uninterruptible power source is rechargeable (a rechargeable battery), provide sufficient capacity for a minimum of seventy-two hours backup. Charging circuitry, while the controller is operating under normal line power, shall constantly charge the rechargeable power source. A non-rechargeable power source shall not be permitted. Batteries shall be implemented to allow replacement without soldering. a. Upon restoration of normal power, the DDC Controller shall automatically resume full operation

without manual intervention. 9. Provide a separate DDC control processor for each AHU or group of AHU's and other HVAC systems

as required. It is intended that each unique system be provided with its own point resident DDC control processor.

10. Control strategies that separate the function of the above DDC control processor controller into multiple controller (i.e. control process controller and communications) shall be acceptable provided that all requirements specified are fully met. This includes but is not limited to: a. Spare Point Capacity. b. Spare Internal Memory. c. Serial Communication Ports. d. A separate PCP per Unique System.




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2.2 PCP SOFTWARE

A. Control Software: 1. Time Programs. Each DDC control processor shall contain up to 20 unique user modifiable time

programs (TP). Each TP shall consist of daily, weekly, and annual programs plus a "TODAY" temporary function. DAILY programs shall be definable for day types such as working day, half day, holiday, weekend, etc. Each daily program shall allow a list of time based (or optimum time based) analog and digital commands to be issued to user selected plant elements and points. WEEKLY programs shall allow a user selected set of daily programs to be defined for each day of the week (Monday through Sunday). The ANNUAL program shall initially be an automatic compilation of 52 weekly programs. Selecting a date of the ANNUAL program shall allow modification of the daily selection entered into the weekly program (such as changing Dec. 25 from a working day to a holiday).

B. Management Software: 1. Trending. In addition to supporting OWS trending specified elsewhere, each DDC control processor

shall be provided with a trend archive of at least the last 200 events (digital transitions or analog value changes) of any user selected group of up to 20 points. A stored event shall include date and time, and value or status. Events occurring in excess of 200 shall overwrite the oldest events.

2. Alarms. Each DDC control processor shall monitor and report all analog input points and specified digital points for off-normal conditions. Each alarm shall have an "alarm delay" attribute which shall determine how long (in seconds) a point must be off-normal prior to being considered in an alarm state.

3. TEC Support. DDC control processor and devices managing sub-networks of TECs shall report TEC alarms and shall be programmed to perform data reduction, sorting, and DDC control processor optimizing routines. In no case shall mass TEC optimizing data be allowed on the primary bus.

2.3 WEB-BASED WORKSTATION OPERATOR INTERFACE

A. Basic Interface Description: 1. Operator workstation interface software shall minimize operator training through the use of English

language prompting, English language point identification and industry standard PC application software. The software shall provide, as a minimum, the following functionality: a. Graphical viewing and control of environment. b. Scheduling and override of building operations. c. Collection and analysis of historical data. d. Definition and construction of dynamic color graphic displays. e. Editing, programming, storage and downloading of controller databases.

2. Provide a graphical user interface which shall minimize the use of a typewriter style keyboard through the use of a mouse or similar pointing device and “point and click” approach to menu selection. Users shall be able to start and stop equipment or change setpoints from graphical displays through the use of a mouse or similar pointing device. a. Provide functionality such that all operations can also be performed using the keyboard as a

backup interface device. b. Provide additional capability that allows at least 10 special function keys to perform often-used

operations. 3. The software shall provide a multi-tasking type environment that allows the user to run several

applications simultaneously. The mouse shall be used to quickly select and switch between multiple applications. This shall be accomplished through the use of Microsoft Windows or similar industry standard software that supports concurrent viewing and controlling of systems operations. a. Provide functionality such that any of the following may be performed simultaneously, and in any

combination, via user-sized windows: 1) Dynamic color graphics and graphic control. 2) Alarm management. 3) Time-of-day scheduling. 4) Trend data definition and presentation. 5) Graphic definition. 6) Graphic construction.

b. If the software is unable to display several different types of displays at the same time, the DDC Contractor shall provide at least 2 operator workstations.




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4. Multiple-level password access protection shall be provided to allow the user/manager to limit workstation control, display and data base manipulation capabilities as he deems appropriate for each user, based upon an assigned password. a. A minimum of five levels of access shall be supported:

1) Level 1 - View all applications, but perform no database modifications. 2) Level 2 = Custodial privileges plus the ability to acknowledge alarms. 3) Level 3 = All privileges except system configuration. 4) Level 4 = All configuration privileges except passwords. 5) Level 5 = All privileges.

b. A minimum of 50 unique passwords, including user initials, shall be supported. c. Operators will be able to perform only those commands available for their respective passwords.

Menu selections displayed shall be limited to only those items defined for the access level of the password used to log-on.

d. The system shall automatically generate a report of log-on/log-off time and system activity for each user.

e. User-definable, automatic log-off timers of from 5 to 60 minutes shall be provided to prevent operators from inadvertently leaving devices on-line.

5. Software shall allow the operator to perform commands including, but not limited to, the following: a. Start-up or shutdown selected equipment. b. Adjust setpoints. c. Add/modify/delete time programming. d. Enable/disable process execution. e. Lock/unlock alarm reporting for points. f. Enable/disable totalization for points. g. Enable/disable trending for points. h. Override PID loop setpoints. i. Enter temporary override schedules. j. Define holiday schedules. k. Change time/date. l. Automatic daylight savings time adjustments. m. Enter/modify analog alarm limits. n. Enter/modify analog warning limits. o. View limits. p. Enable/disable demand limiting for each meter. q. Enable/disable duty cycle for each load.

6. Reports shall be generated and directed to either CRT displays, printers or disk. As a minimum, the system shall allow the user to easily obtain the following types of reports: a. A general listing of all points in the network. b. List of all points currently in alarm. c. List of all points currently in override status. d. List of all disabled points. e. List of all points currently locked out. f. DDC Controller trend overflow warning. g. List all weekly schedules. h. List of holiday programming. i. List of limits and deadbands: Summaries shall be provided for specific points, for a logical point

group, for a user-selected group or groups or for the entire facility without restriction due to the hardware configuration of the building automation system. Under no conditions shall the operator need to specify the address of the hardware controller to obtain system information.

B. Scheduling: 1. Provide a graphical spreadsheet-type format for simplification of time-of-day scheduling and overrides

of building operations. Provide the following spreadsheet graphic types as a minimum: a. Weekly schedules. b. Zone schedules. c. Monthly calendars.




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2. Weekly schedules shall be provided for each building zone or piece of equipment with a specific occupancy schedule. Each schedule shall include columns for each day of the week as well as holiday and special day columns for alternate scheduling on user-defined days. Equipment scheduling shall be accomplished by simply inserting occupancy and vacancy times into appropriate information blocks on the graphic. In addition, temporary overrides and associated times may be inserted into blocks for modified operating schedules. After overrides have been executed, the original schedule will automatically be restored.

3. Zone schedules shall be provided for each building zone as previously described. Each schedule shall include all commandable points residing within the zone. Each point may have a unique schedule of operation relative to the zone’s occupancy schedule, allowing for sequential starting and control of equipment within the zone. Scheduling and rescheduling of points may be accomplished easily via the zone schedule graphic.

4. Monthly calendars for a 24-month period shall be provided which allow for simplified scheduling of holidays and special days in advance. Holidays and special days shall be user-selected with the point device and shall automatically reschedule equipment operation as previously defined on the weekly schedules.

C. Collection and Analysis of Historical Data: 1. Provide trending capabilities that allow the user to easily monitor and preserve records of system

activity over an extended period of time. Any system point may be trended automatically at time-based intervals or changes of value, both of which shall be user-definable. Trend data may be stored on hard disk for future diagnostics and reporting.

2. Trend data report graphics shall be provided to allow the user to view all trended point data. Reports may be customized to include individual points or pre-defined groups of at least 6 points. Provide additional functionality to allow any trended data to be transferred easily to an off-the-shelf spreadsheet package such as Microsoft Excel. This shall allow the user to perform custom calculations such as energy usage, equipment efficiency and energy costs and shall allow for generation of these reports on high-quality plots, graphs and charts.

3. Provide additional functionality that allows the user to view trended data on trend graph displays. Displays shall be actual plots of both static and/or real-time dynamic point data. A minimum of 4 points may be viewed simultaneously on a single graph, with color selection and line type for each point being user-definable. Displays shall include an ‘X’ axis indicating elapsed time and a ‘Y’ axis indicating a range scale in engineering units for each point. The ‘Y’ axis shall have the ability to be manually or automatically scaled at the user’s option. Different ranges for each point may be used with minimum and maximum values listed at the bottom and top of the ‘Y’ axis. All ‘Y’ axis data shall be color-coded to match the line color for the corresponding point. a. Static graphs shall represent actual point data that has been trended and stored on disk. Exact

point values may be viewed on a data window by pointing or scrolling to the place of interest along the graph. Provide capability to print any graph on the system printer for use as a building management and diagnostics tool.

b. Dynamic graphs shall represent real-time point data. Any point or group of points may be graphed, regardless of whether they have been predefined for trending. The graphs shall continuously update point values. At any time the user may redefine sampling times or range scales for any point. In addition, the user may pause the graph and take “snapshots” of screens to be stored on the workstation disk for future recall and analysis. As with static graphs, exact point values may be viewed and the graphs may be printed.

D. Dynamic Color Graphic Displays: 1. Color graphic floor plan displays and system schematics for each piece of mechanical equipment,

including hot water boiler system, shall be provided by the DDC Contractor to optimize system performance analysis and speed alarm recognition.

2. The operator interface shall allow users to access the various system schematics and floor plans via a graphical penetration scheme, menu selection or text-based commands.

3. Dynamic temperature values, flow values and status indication shall be shown in their actual respective locations and shall automatically update to represent current conditions without operator intervention.

4. The windowing environment of the PC operator workstation shall allow the user to simultaneously view several graphics at a time to analyze total building operation or to allow the display of a graphic associated with an alarm to be viewed without interrupting work in progress.

5. Graphic generation software shall be provided to allow the user to add, modify or delete system graphic displays.




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a. The DDC Contractor shall provide libraries of pre-engineered screens and symbols depicting standard air handling unit components (e.g., fans, cooling coils, filters, dampers, etc.), complete mechanical systems (e.g., constant volume-terminal reheat, VAV, etc.) and electrical symbols.

b. The graphic development package shall use a mouse or similar pointing device in conjunction with a drawing program to allow the user to perform the following: 1) Define symbols. 2) Position and size symbols. 3) Define background screens. 4) Define connecting lines and curves. 5) Locate, orient and size descriptive text. 6) Define and display colors for all elements. 7) Establish correlation between symbols or text and associated system points or other

displays. c. Graphical displays can be created to represent any logical grouping of system points or

calculated data based upon building function, mechanical system, building layout or any other logical grouping of points which aids the operator in the analysis of the facility. 1) To accomplish this, the user shall be able to build graphic displays that include point data

from multiple DDC controllers including TECS used for DDC equipment or VAV terminal unit control.

2.4 PORTABLE OPERATOR SOFTWARE, PROGRAMMING AND COMMISSIONING

A. Provide hard copies of all programs when the University’s Representative has signed off as complete.

2.5 FIELD DEVICES

A. All devices and equipment shall be approved for installation.

B. All analog inputs and outputs to/from all items, relating to the monitoring and control of variable speed drives shall be 4-20 MA DC devices, loop-powered, isolated, allowing any single sensor to report identically to multiple systems.

C. Temperature Sensors: Each temperature sensor shall match the requirements of the associated temperature controller. Each sensor shall be designed for the appropriate application (i.e. duct, immersion, etc.) and be provided with all necessary installation accessories. Ranges shall be selected to the middle of the control range. All space temperature sensors not provided with an associated application specific controller shall match the sensors furnished with application specific controllers. 1. Electronic: A modulating solid state controller with built-in detector, P, PI, or PID controller, as

required, with continuous voltage or current output. Each controller shall have individual setpoint, proportional band, start point, and span adjustments. Input voltage shall be 24 VAC or less. Each controller to be provided with night setback, summer/winter switchover or remote reset capabilities as required. Controllers shall be of matching type to the input detectors and output drives or sequencers. Thermostats to be key operated.

2. All hot water temperature sensors in piping systems shall be provided with a separable stainless steel thermowell to be installed by the HVAC Contractor, but furnished by the Temperature Control Contractor. Chilled water supply and return temperature sensors shall have an accuracy of +1/4 degrees F.

3. Outside air sensors shall be accurate within 0.5 degrees F over a range of -50 degrees F to 120 degrees F. Special care must be taken to place sensor away from building exhausts. Outside sensors shall be watertight and must have sun shielding.

4. Provide temperature sensors as required to meet the sequence of operation.

D. Fan and Pump Proofs: Proof points for exhaust fans and pumps will be accomplished through the use of current sensing relays at the motor control center or motor starters. Current sensing relays shall be split-core design, for installation over any single power lead. Current sensing relays shall include field adjustable set screw for amperage setpoint adjustment, and shall include integral LED status light to locally indicate the ‘on’ and ‘off’ condition.




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2.6 LABELING

A. Provide labels for all field devices including sensors, transducers, thermostats, and relays. Exception: Room temperature and/or humidity sensors shall not be labeled.

B. Labels shall be black laminated plastic with white letters and adhesive backing or screw fasteners. Labels shall be located adjacent to device and permanently affixed to device mounting surface. Do not install the label on the device. Labels for sensors in pipes may be secured using chain around the sensor well.

C. Labels shall include system virtual/pseudo point name as well as English language name of device being controlled or specific condition being sensed.

D. Identify all control wiring and pneumatic tubing at each end with a number.

PART 3 - EXECUTION

3.1 WIRING AND CONDUIT

A. Refer to Division 23 Section “General HVAC Provisions” for a description of the wiring responsibilities for the temperature control system by the Temperature Control Contractor and the Electrical Contractor. Also refer to the control diagrams on the Contract Drawings which further clarify wiring responsibilities.

B. All low voltage temperature control wiring shall be run in EMT conduit. Conduit and junction boxes shall be labeled as being for the temperature control system.

C. All status and control wiring at line voltage power, (Class I circuits) must run in EMT conduit or flexible metal conduit. All Class I wiring shall be copper, THHN, 14 gauge AWG with 600 volt minimum isolation class insulation. Power and Class I 120 volt control circuits may not run together with Class II or III data transmission or signal circuits. Where different wiring classes terminate per NEC requirements, all control system wiring shall be labeled with control system logical point name. These point names shall be exactly as shown on control drawings, digital controller, sensor, actuator device terminal connectors and on "As-Built" drawings exactly as installed.

D. The Temperature Control Contractor shall be responsible for making correct connections to all equipment, (i.e. motor starters) necessary to provide digital and analog input signals to the direct digital control system. The Temperature Control Contractor shall install all necessary interface devices, relays, isolators, to insure both proper operation of interfaced equipment and the digital control system. The Contractor shall be responsible for procuring engineering, technical information and field assistance from all other HVAC/electrical contractors and shall include this cost within their bid proposal.

E. All electrical work shall be done in strict accordance with the latest edition of the National Electric Code and all local codes. The Temperature Control Contractor shall be fully responsible for proposals and modifications necessary to meet any and all code required modifications.

F. All wires connected to control items shall be tagged with their logical point name.

G. All temperature control panels shall be completely prewired by the Temperature Control Contractor to terminal strips within the control cabinet. All internal interlock wiring within the control panel shall be complete to the terminal strips.




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3.2 SPACE THERMOSTATS/SENSORS

A. Thermostats and room sensors shall be mounted at 5'-0" above floor unless otherwise noted on Architectural elevations. Coordinate installation with the Architect/Engineer and work of other trades before any rough-ins are made.

3.3 TEMPERATURE CONTROL DIAGRAMS

A. Complete temperature control diagrams including motor control schematics, wiring diagrams and a written description of the system operation shall be provided by the Temperature Control Contractor. Diagrams shall include face elevations of the temperature control panels.

B. A set of floor plans shall be provided showing the location of all temperature control panels to be installed. Locations shall be approved by the Engineer. The floor plans to be submitted as an AutoCAD drawing file with blocks defined for all control equipment; panels, Terminal Equipment Controllers (TEC’s) and sensors, etc. The blocks should contain pertinent technical information such as panel numbers, node numbers and any other specific information about control system entities.

C. The Temperature Control Contractor shall provide submittals of all shop drawings for all work prior to start of project. Provide a complete written description of the system proposed. Start with a general overview of the product leading to specific and detailed sequences necessary to provide the highest level of operational efficiency. Show how proposed hardware and software meets specifications, especially in its ability to deliver accurate, reliable, trouble-free performance along with ease of operation.

D. Submittals shall include detailed schematics of all systems and equipment controlled for the project, as well as diagrams detailing interconnection of all digital controllers and interfacing to existing temperature control networks and campus Ethernet data highway. Schematics to include all devices proposed for the project and shall incorporate industry standard HVAC and control symbols and naming conventions. Detailed wiring diagrams for all devices shall be provided as part of the submittal package. All schematics shall be prepared using the latest revision of AutoCAD or similar computer aided drafting software. Manual sketches or drafting techniques are not acceptable.

E. Furnish complete sets of Operating and Maintenance Instructions for temperature controls, including control diagrams, to the HVAC Contractor for inclusion in the "Operating and Maintenance Manuals". As-built control drawings must show setpoints and spring ranges.

F. Provide the University with a copy of the control diagrams on computer disk.

3.4 CALIBRATION

A. Inasmuch as controllers are factory calibrated and controlled devices have nominal operating ranges, different from actual field conditions, all controllers shall be calibrated and set for the actual field conditions. (A listing of actual spring ranges on controlled devices, such as for valves, damper motors, etc., shall be submitted to the University’s Operating Engineer for future recalibration/maintenance.)

B. The University shall have the option to review the operation of up to 5% of the controllers furnished on the project. If the operation of the controllers is not acceptable to the University, they may require that the operation of the remainder of the controllers be reviewed.

3.5 SUPERVISION

A. All temperature controls shall be installed and calibrated under the supervision of a qualified representative of the Temperature Control Manufacturer.

3.6 CONTROL ACCESS

A. All control elements shall be placed in locations affording easy access for service. All devices remote from control panels shall be identified as specified for control items in control panels.




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3.7 SYSTEM START-UP

A. After installation is complete, and during the warranty, the Temperature Control Contractor shall be responsible for commissioning, continued software de-bugging, software revisions and control loop tuning necessary to insure that control sequences are functioning as specified and that setpoints are being maintained without excessive cycling of actuators. To this end, the Temperature Control Contractor shall generate hard copy historical trend log data reports showing hourly readings of all important system points. Reports shall be delivered (or mailed) to the Engineer. The trend reports will document that each control loop is properly tuned and that all software functions are performing as specified.

B. All initial application software shall be programmed by the Temperature Control Contractor. (The University shall be provided with copies of the source program and all documentation necessary for them to interpret it and make any changes they desire.)

3.8 WARRANTY

A. All components, system software and devices supplied by the Temperature Control Contractor shall be guaranteed against defects in material and workmanship for one year from final acceptance date. (The acceptance date is defined when the total system is demonstrated to the University to be complete and when all hardware, sensors, controllers, and software are functioning according to the sequence of operation specified for the project.) Punch list items shall not prevent final acceptance where the nature of the problem and resolution of the problem is underway by the Contractor.

B. Labor to trouble shoot, repair, re-program, or replace any component shall be furnished by the Temperature Control Contractor at no charge to the University during the warranty period.

C. All corrective modifications made during warranty service shall be updated and saved on master archive software disks to be kept in for safe keeping. The Temperature Control Contractor shall keep an identical copy in their local office during the warranty period.


A. All system components shall be designed and built for fault tolerance, shall operate satisfactory at 110% above and 85% below rated voltage. Static and transient, and short circuit protection shall be on all inputs and outputs. The system shall be protected against incorrect wiring, static and lighting induced transients and magnetic interference. Data transmission trunk connected devices, (i.e., digital controllers, etc.) shall be AC coupled or be optically isolated so that a single device failure will not damage or disrupt or halt trunk communications between other digital controllers, unitary or terminal controllers.

B. All electrical equipment shall conform to the F.C.C. regulation Part 15, Section 15 governing radio frequency electromagnetic interference and be so labeled.

C. The system shall be installed by factory trained technicians and mechanics regularly employed by the temperature control manufacturer whose principal business is the manufacturing and installation of direct digital control systems.

3.10 DOCUMENTATION

A. Upon completion of the system, the Temperature Control Contractor shall deliver complete documentation pertaining to the system installed. Include control system wiring diagrams, schematics, layouts, input/output point lists, complete program listings for each controller and a complete building operators manual and system engineering and programmers manual. The manual shall cover all functions, descriptions, routines necessary to both modify system software, add points and to completely maintain the system hardware and software.




Section 23 09 00

23 09 00 – 13

3.11 SYSTEM ACCESS

A. System Access (Passwords) shall be provided at the start of beneficial occupancy or near project completion to allow the University the time necessary to inspect the system and to provide an accurate and timely Punch List to speed project completion.

3.12 CONTROL CONTRACTOR REMOTE MONITORING

A. The Temperature Control Contractor shall provide an on-line remote monitoring of the project for software and hardware problems during initial system start up and for at least two months following system completion. This assistance shall be performed during 8:00 a.m. to 5:00 p.m. Monday through Friday. A modem for communication to the Temperature Control Contractor's office shall be provided for this purpose. Provide the necessary software or firmware for its operation.

3.13 TECHNICAL SUPPORT

A. The Temperature Control Contractor shall provide as part of this contract technical support personnel available for immediate response during normal business hours, to provide emergency service on the system during the warranty period.

B. The Temperature Control Contractor shall submit to the University the cost per hour for emergency service after normal 8:00 a.m. to 5:00 p.m., Monday through Friday for work necessary during the warranty period.

3.14 TRAINING

A. The Contractor shall provide competent instructions to give full instruction to designated personnel in the adjustment, operation and maintenance of the system installed rather than a general training course. Instructors shall be thoroughly familiar with all aspects of the subject matter they are to teach. All training shall be held during normal work hours of 7:00 a.m. to 3:30 p.m. weekdays as follows:

B. Provide 25 hours of training for University’s operating personnel. Training shall include: 1. Explanation of drawings, operations and maintenance manuals. 2. Walk-through of the job to locate control components. 3. Operator workstation and peripherals. 4. DDC controller and TEC operation/function. 5. Operator control functions including graphic generation and field panel programming. 6. Operation of portable operator’s terminal. 7. Explanation of adjustment, calibration and replacement procedures.

C. Since the University may require personnel to have more comprehensive understanding of the hardware and software, additional training must be available from the Contractor. If the University requires such training, it will be contracted at a later date. Provide description of available local and factory customer training.

3.15 SERVICE AND GUARANTEE

A. General Requirements: Provide all services, materials and equipment necessary for the successful operation of the entire DDC system for a period of one year after completion of successful performance test. Provide necessary material required for the work. Minimize impacts on facility operations when performing scheduled adjustments and non-scheduled work.

B. Description of Work: The adjustment and repair of the system includes all computer equipment, software updates, transmission equipment and all sensors and control devices. Provide the manufacturer's required adjustments and all other work necessary.

C. Personnel: Provide qualified personnel to accomplish all work promptly and satisfactorily. The University shall be advised in writing of the name of the designated service representative, and of any changes in personnel.




Section 23 09 00

23 09 00 – 14

D. Systems Modifications: Provide any recommendations for system modification in writing to the University. Do not make any system modifications, including operating parameters and control settings, without prior approval of the University. Any modifications made to the system shall be incorporated into the operations and maintenance manuals, and other documentation affected.

E. Software: Provide all software updates and verify operation in the system. These updates shall be accomplished in a timely manner, fully coordinated with the system operators, and shall be incorporated into the operations and maintenance manuals, and software documentation.




Sequence of Operations for HVAC Controls

Section 23 09 93

23 09 93 – 1

SECTION 23 09 93 – SEQUENCE OF OPERATIONS FOR HVAC CONTROLS PART 1 - GENERAL



B. Refer to Electrical Drawings for specific requirements as they relate to Control Diagrams.

1.2 SUMMARY

A. This Section includes control sequences for HVAC systems, subsystems, and equipment.

B. Related sections include the following: 1. Division 23 Section “Instrumentation and Control for HVAC” for control equipment and devices,

submittals, quality assurance, coordination and training requirements.

1.3 SCOPE

A. The control sequences as described below shall be incorporated in the DDC (Direct Digital Control) system operation.

B. The controls contractor shall confirm the system is fully functioning. Refer to Division 23 Section “Instrumentation and Control for HVAC” for more detailed requirements.

PART 2 - PRODUCTS

Not Applicable.

PART 3 - EXECUTION

3.1 DDC TEMPERATURE CONTROL SEQUENCES

A. Condensing Hot Water Boilers B-1 and B-2 and Associated Primary Heating Water Pumps P-1 and P-2: 1. A boiler and its associated primary pump will operate as a system i.e. Boiler B-1 and Pump P-1 and

Boiler B-2 and Pump P-2. 2. A DDC temperature sensor located in the secondary heating water supply header shall cycle the

primary heating water pumps and the associated boilers in sequence to maintain the temperature in the secondary loop per the following reset schedule:

Outdoor Temperature 0 degrees F 180 degrees F

Water Temperature

65 degrees F 120 degrees F

3. On a call for heat, the DDC system shall start the lead primary heating water pump. Upon verification of flow through the primary pump current sensing relay, the DDC system shall activate the associated boiler. The boiler, through its own self-contained controls, shall maintain the leaving water temperature according to the reset schedule(adjustable). If a single pump/boiler is unable to achieve the desired heating water supply temperature, the DDC system shall start the second pump/boiler in a similar manner.

4. When the supply water temperature exceeds the setpoint, the DDC system shall shut down the boilers in sequence until the desired water temperature is achieved. The associated pump with each boiler shall operate for 5 minutes (adjustable) after the boiler is commanded OFF.

5. The DDC system shall have the capability to rotate Boilers B-1 and B-2 and the associated pumps as the lead system and the capability of notifying the operator's terminal when it is time to rotate the lead system. Verify with the Owner their preference for rotating systems or notifying the operator during initial setup.




Section 23 09 93

23 09 93 – 2

6. Current sensing relays shall be furnished to provide input for proof of flow at each pump. The DDC system shall provide an alarm at the operator's terminal and shut off the associated boiler upon detecting no flow when the primary pump is sequenced ON.

7. Temperature Control Contractor to provide a Hand-Off-Auto switch to override the DDC contact and allow the boiler to operate if the DDC system is inoperable (an integral switch on the DDC controller is acceptable).

8. DDC system shall monitor the common alarm at the boiler control panel and provide an alarm at the operator's terminal upon detecting a boiler alarm.

9. The Electrical subcontractor shall furnish and install an Emergency Power Off (EPO) switch in the boiler room and wire to the boiler control circuit to shut off the boilers in an emergency situation. Coordinate wiring requirements with the boiler manufacturer and Temperature Control Contractor.

10. Provide temperature sensors as detailed on the Drawings.

B. Variable Flow Secondary Heating Water Pumps with DDC Controls, Pumps P-3 and P-4: 1. The “operating” heating water pump shall operate continually. The DDC system shall determine which

pump is operating and which pump is standby through DDC programming and DDC outputs to the pump control circuits.

2. DDC differential pressure sensors provided by the Temperature Control Contractor and located towards the end of the heating water piping system shall maintain adequate differential pressure by modulating the speed of the operating pump through the adjustable frequency drive. A total of 4 pressure sensors shall be provided in the existing heating water branch mains as shown on drawings. Specific location to be determined in the field.

3. A second pump shall act as standby to the operating pump. The DDC system, upon sensing no flow from the operating pump which has been indexed ON, shall automatically start the standby pump and incorporate it into the operating sequence described above.

4. The DDC system shall have the capability to rotate the operating and standby pumps and the capability of notifying the operator’s terminal when it is time to rotate the pumps.

5. Current sensing relays shall be provided for proof of flow at each pump. The DDC system shall provide an alarm at the operator’s terminal upon detecting no flow when the pump is sequenced ON.

C. Summer Reheat Circulation Isolation Control Valve:

1. A normally open two-way control valve located as shown on the drawings on the heating water supply main shall close when outside temperature exceeds 65°F (adjustable). Valve shall open when temperatures fall below 65°F (adjustable).

2. Boilers and pumps shall continue to operate according to sequences noted above regardless of valve position.

D. Mechanical Room Exhaust Ventilation Control: 1. A wall mounted temperature sensor shall be wired to “Start” the exhaust fan through a DDC contact in

the fan starter provided by the Electrical Contractor when the space temperature exceeds 75 degrees F (Adjustable). All wiring between the starter and the motor operated dampers shall be by the Temperature Control Contractor. Furnish a heavy duty guard for the sensor.

E. DDC Points Lists: 1. The following points shall be provided for each system as listed. Many of these points will be required

to provide the specified operating sequence of the respective system. Others will be required for monitoring purposes only. Alarms shall be provided at the operator’s terminal, coordinate alarm settings with the University’s Facility Manager. a. Ambient Conditions:

1) Graphics. 2) Outside air temperature.

b. Heating Water Plant: 1) Graphics. 2) Heating water supply temperature (typical of 2). 3) Heating water return temperature (typical of 2). 4) Heating water pressure. 5) Pump P-1 start-stop. 6) Pump P-2 start-stop. 7) Pump P-1 status. 8) Pump P-2 status. 9) Pump P-3 start-stop.




Section 23 09 93

23 09 93 – 3

10) Pump P-4 start-stop. 11) Pump P-3 status. 12) Pump P-4 status. 13) Pump P-3 frequency output. 14) Pump P-4 frequency output. 15) Pumps P-3, P-3 differential pressure sensors. 16) Boiler B-1 start-stop. 17) Boiler B-2 start-stop. 18) Boiler heating water supply temperature. 19) Boiler heating water return temperature. 20) Boiler B-1 alarm. 21) Boiler B-2 alarm.

c. Exhaust Fan: 1) Graphics. 2) Start-stop. 3) Status. 4) Space temperature sensor.



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Natural Gas Piping System

Section 23 10 23


SECTION 23 10 23 – NATURAL GAS PIPING SYSTEM PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of natural gas piping and related items: 1. Natural gas distribution system.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ANSI Z223.1 - Fuel Gas Code. 2. ASME B31.1 - Power Piping. 3. ASME B31.8 - Gas Transmission and Distribution Piping Systems.


A. Fabrication and Installation Personnel Qualifications: Trained and experienced in the fabrication and installation of the materials and equipment.

B. Installation shall comply with: 1. State and local codes and ordinances. 2. Requirements of:

a. Owner's insurer. b. Gas distribution utility.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Interior gas piping shall be Schedule 40 steel pipe, ASTM A53, black steel pipe. Joints in 1-1/2 inch and smaller pipe shall be screwed fittings, Class 150 lb. banded, malleable iron, black. Use of bushings is prohibited. Weld joints in pipe 2 inch and larger, in accordance with Division 23 Section “Steel Pipe and Fittings for HVAC” and this Section.

B. Refer to Gas Piping Schedule in Part 3 of this specification for complete materials specification.

2.2 PIPING SPECIALTIES

A. Appliance Flexible Connectors: 1. Indoor, Fixed-Appliance Flexible Connectors: Comply with ANSI Z21.24. 2. Operating Pressure Rating: 0.5 psig (3.45 kPa). 3. End Fittings: Zinc coated steel. 4. Threaded Ends: Comply with ASME B1.20.1. 5. Maximum Length: 72 inches (1830 mm).


/2


Section 23 10 23


PART 3 - EXECUTION

3.1 NATURAL GAS DISTRIBUTION SYSTEM

A. Description of Work: 1. Connect to the existing natural gas service inside the boiler room and provide complete natural gas

distribution system as indicated on Drawings and as required to comply with applicable codes and regulations.

2. This includes, but is not limited to, the following: a. Vent lines to atmosphere where applicable. b. Connect gas to equipment outlets. c. Auxiliaries and accessories.

B. Indoor Piping and Installation: 1. Install gas piping and valves in accordance with the requirements of the plumbing code, the gas

company, and the American Gas Association. 2. Run gas piping and make final connections to equipment requiring gas. 3. Install gas cock and drip in branch laterals serving each piece of equipment. 4. Install piping indicated to be exposed and piping in equipment rooms and service areas at right angles

or parallel to building walls. Diagonal runs are prohibited unless specifically indicated otherwise. 5. Locate valves for easy access. 6. Install natural gas piping at uniform grade of 2% down toward drip and sediment traps. 7. Install piping free of sags and bends. 8. Verify final equipment locations for roughing-in. 9. Drips and Sediment Traps: Install drips at points where condensate may collect, including service

meter outlets. Locate where accessible to permit cleaning and emptying. Do not install where condensate is subject to freezing. a. Construct drips and sediment traps using tee fitting with bottom outlet plugged or capped. Use

nipple a minimum length of 3 pipe diameters, but not less than 3 inches (76 mm) long and same size as connected pipe. Install with space below bottom of drip to remove plug or cap.

10. Extend relief vent connections for service regulators, line regulators and overpressure protection devices to outdoors and terminate with weatherproof vent cap.

11. Connect branch piping from top or side of horizontal piping. 12. Install unions in pipes NPS 2 (DN 50) and smaller, adjacent to each valve, at final connection to each

piece of equipment. Unions are not required at flanged connections.

C. Connections: 1. Connect piping to appliances using manual gas shutoff valves and unions. Install valve within

72 inches (1800 mm) of each gas fired appliance and equipment. Install union between valve and appliances or equipment.

2. Sediment Traps: Install tee fitting with capped nipple in bottom to form drip, as close as practical to inlet of each appliance.

3.2 SCHEDULES


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Section 23 10 23


Gas Piping

125 PSI Maximum Pressure – 250 Degree F Maximum Temperature Pipe Size Schedule Material ASTM Grade Remarks 1/2 to 1-1/2 40 Seamless Steel A53 B Threaded and Coupled 2 to 6 40 Seamless Steel A53 B Plain End

Fittings Size Description ANSI ASTM Ells 1/2 to 1-1/2

2 to 6 150# Malleable Iron Screwed Standard Weight Steel L.R. Butt Weld

B16.3 B16.9

A197 A234

Tees 1/2 to 1-1/2 2 to 6

150# Malleable Iron Screwed Miter Branch and Weld into Run or Butt Weld Tees

B16.3 B16.9

A197 A234

Reducers 1/2 to 1-1/2 2 to 6

150# Malleable Iron Screwed Standard Weight Steel Butt Weld

B16.3 B16.9

A197 A234

Bushings 1/2 to 1-1/2 Outside Hex. Head Iron B16.4 Couplings 1/2 to 1-1/2 150# Malleable Iron Screwed B16.3 A197 Unions 1/2 to 1-1/2 150# Malleable Irion Screwed with

Iron-to-Iron Seat B16.3 A197

Plugs 1/2 to 1-1/2 Malleable Iron Square Head Solid Caps 1/2 to 1-1/2

2 to 6 150# Malleable Iron Screwed Standard Weight Steel Butt Weld

B16.3 B16.9

A197 A234

Flanges 1/2 to 6 150# F.S. Slip-On or Weld Neck B16.9 A181 Class 60

Gaskets Nitrile Butadiene Rubber – 1/16 Inch B16.21

Valves Size Description Ends Shut-Off 1/2 to 1-1/2 200# WOG-Semi-Steel Homestead Figure 601. Screwed 2 to 6 200# WOG-Semi Steel Homestead Figure 602. Flanges



/1

Piping Specialties for HVAC

Section 23 20 19


SECTION 23 20 19 – PIPING SPECIALTIES FOR HVAC PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of piping specialties.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ANSI Standards:

a. B16.5 - Pipe Flanges and Flanged Fittings. b. B16.24 - Bronze Pipe Flanges and Flanged Fittings, Class 150 and 300.

2. ASME American Society of Mechanical Engineers: a. Boiler and Pressure Vessel Code - Section II. b. B31.1 - Power Piping. c. B31.5 - Building Services Piping.

1.4 SUBMITTALS

A. Manufacturer's Literature: For all items listed in PART 2 – PRODUCTS. Include dimensions, details of construction and installation, name of Manufacturer, and model.



PART 2 - PRODUCTS

2.1 STRAINERS

A. Manufacturer: Armstrong, Mueller.

B. Type: "Y".

C. Screen: 20 mesh brass, removable.

D. Area: 5 times pipe diameter.

E. Pressure Rating: Match piping.

F. Install in front of each modulating valve, steam trap, pressure regulating valve, pump suction and where indicated. Each strainer shall be equipped with a blow down valve and trap assembly, if on steam line.


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Piping Specialties for HVAC

Section 23 20 19


2.2 MANUAL AIR VENTS

A. Manufacturer: Bell & Gossett or Dole.

B. Size: 1/8-inch.

C. Type: Slotted head (Bell & Gossett 4V or Dole No. 9).

D. Location: 1. At all high points in the piping. 2. Wherever called for on Drawings.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install all piping specialties in conformance with the Manufacturer's recommendation. END OF SECTION 23 20 19


/2

Hydronic Piping

Section 23 21 13


SECTION 23 21 13 – HYDRONIC PIPING PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of a hydronic piping and circulation system for heating hot water.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. American Society of Mechanical Engineering (ASME):

a. B31.1 - Code for Pressure Piping. b. B31.5 - Code for Building Services Piping. c. Power Boiler Code. d. Heating Boiler Code.

1.4 SUBMITTALS

A. Manufacturer's Literature: For all products listed in Part 2. 1. General:

a. Dimensions. b. Details of construction and installation. c. Name of Manufacturer. d. Model number.

2. Air Separator: a. Performance curve. b. Itemized list by Tag Number giving head and flow characteristics.



1.6 MAINTENANCE

A. Valve and Vent Schedule: 1. Provide the following schedules:

a. Air Vents: Indicate air vent number and location of all manual air vents that are not attached to a univent, heating unit, ventilating unit or other equipment.

b. Valves: Indicate valve number, location and function of all valves. 2. Mount schedules under plexiglass in the Boiler Room.


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Hydronic Piping

Section 23 21 13


PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Except as otherwise indicated on the Drawings or specified herein, the manufactured units and flow measurement devices shall be supplied by one of the following: 1. Bell & Gossett. 2. Armstrong Pumps, Inc. 3. Taco, Inc. 4. Flow Design, Inc. (Circuit Setter).

2.2 MATERIALS

A. Piping: 1. Pipe - Schedule 40, black steel, ASTM Specification A-53 Grade A or B, ERW. Pipe 12-inches and

larger shall be standard weight, ASTM Specification A-53 Grade A or B, ERW. 2. Fittings for piping 2-1/2-inches and smaller - 125 lb. black cast iron except the Contractor may, at their

option, use weld joints in piping 1-1/2-inches and larger. Use standard weight welding fittings. 3. Fittings for piping 3-inches and larger - standard weight welding fittings. 4. Comply with schedule in Part 3 of this section.

2.3 MANUFACTURED UNITS

A. Air Separator: 1. ASME construction, 125 psi working pressure at 400 degrees F. 2. Air vent and drain connections. 3. Field installed insulated jacket and thermometer.

B. Strainer: 1. ASME, 125 psi, 375 degrees F. 2. Strainer Material: Galvanized. 3. Diameter Holes: 3/16-inch. 4. Free Area: 5 times pipe area. 5. Blow Down Connection: Yes. 6. Size: As indicated on the Drawings.

C. Pressure Relief Valve: 1. ASME rated, diaphragm-operated, type with cast iron body and brass internals. 2. Provide as indicated on the Drawings. 3. Valve pressure setting compatible with system operation. 4. 125 psig maximum working pressure; 250 degrees F maximum operating temperature.

D. Triple-Duty Valve: Not acceptable for any application.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install piping and circulation system in accordance with:

a. The Drawing. b. These Specifications. c. The Shop Drawings reviewed by Engineer. d. The Manufacturer's recommendations.

2. System shall not interfere with passage, head room or openings of doors and windows. 3. Pipe: Straight, without rust or other defects.


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Hydronic Piping

Section 23 21 13


4. Joints: a. Welded: Required for pipes 2-1/2 inches and larger. Screwed:

1) Reamed after cutting and before threading. 2) Sharp, clean threads. 3) Use pipe compound on male threads only.

B. Mains and Branches: 1. Install above the ceiling and in bar joists, above bottom chord, as indicated on the Drawings. 2. Sizes as indicated on the Drawings. 3. Install Tops of Mains Level:

a. Use eccentric fittings at changes in pipe size. b. Provide adequate supports to prevent air pockets.

4. Branches: a. Take off bottom of main. b. Provide swing connection before vertical riser to a heating unit or convector.

C. Risers and Vertical Pipes: Plumb, straight and without unnecessary fittings or offsets.

D. Fittings: 1. Provide Air Vents:

a. As indicated on the Drawings. b. At all high points on the system.

2. Provide Drain Valves: a. At the bottom of all risers. b. At boiler.

3. At all low points. 4. Provide insulating couplings or unions where copper and steel pipes are joined. 5. Provide unions at all valves and at all equipment for making repairs.

E. Valves: 1. Provide Shutoff Valves:

a. On both sides of all pumps where necessary to ensure proper operation of the system. b. On all branches at the main. c. So that equipment can be serviced without shutting down the system.

2. Provide unions at all valves and at all equipment for making repairs.


/2

Hydronic Piping

Section 23 21 13


3.2 SCHEDULES

SCHEDULE FOR HYDRONIC PIPING

125 PSI MAXIMUM PRESSURE - 200 DEGREES F MAXIMUM TEMPERATURE

PIPE SIZE SCHEDULE MATERIAL ASTM GRADE REMARKS 3/4 – 2 40 CW Steel A53 B Threaded and Coupled

2-1/2 – 12 40 ERW Steel A53 B Beveled End

FITTINGS SIZE (IN) DESCRIPTION ANSI ASTM Ells 1/2 – 2

2-1/2 – 18

150# Malleable Iron Screwed Standard Weight Steel L.R. Butt Weld

B16.3 B16.9

A197 A234 WPA

Tees 1/2 – 2 2-1/2 - 18

150# Malleable Iron Screwed Miter Branch & Weld into Run or Butt Weld Tees

B16.3 B16.9

A197 A 234 WPA

Reducers 1/2 – 2 2-1/2 - 18

150# Malleable Iron Screwed Standard Weight Steel Butt Weld

B16.3 B16.9

A197 A234 WPA

Bushings 1/2 – 2 Outside Hex. Head Malleable Iron B16.3 A197 Couplings 1/2 – 2

2-1/2 - 18 150# Malleable Iron Screwed Butt Weld

B16.3 A197

Unions 1/2 – 2 150# Malleable Iron Screwed B16.3 A197 Plugs 1/2 – 2 Malleable Iron Square Head Solid Caps 1/2 – 2

2-1/2 - 18 Malleable Iron Screwed Standard Weight Steel Butt Weld

B16.3 B16.9

A197 A234 WPA

Flanges 2-1/2 - 18 150# F.S. Slip-on Welding B16.9 A181-I Gaskets Non-Asbestos Compressed Material B16.21 Bolts Regular "Unfinished" Square Head Machine A307 Gr.B Nuts American Standard "Heavy Series"

Semi-finished Hex

A194 Gr.2H END OF SECTION 23 21 13


/1

Hydronic Pumps

Section 23 21 23


SECTION 23 21 23 – HYDRONIC PUMPS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of the HVAC pumps.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. American Society of Mechanical Engineers (ASME):

a. B31.5 - Code for building services piping. 2. Underwriter's Laboratories, Inc. (UL).

1.4 SUBMITTALS

A. Manufacturer's Literature: For each pump. 1. Pump make and model designation. 2. Pump efficiency at design: 3. Dimensions. 4. Total head at design. 5. Shut off head. 6. Required NPSH at design. 7. Motor Manufacturer, type and characteristics. 8. BHP required at design conditions. 9. List of construction materials. 10. Performance curves: With NPSH curves.

B. Operation and Maintenance Manuals: For each pump. 1. Equipment function, normal operating characteristics and limiting conditions. 2. Assembly, installation, alignment, adjustment and checking instructions. 3. Operating instructions for start-up, routine and normal operating, regulation and control, and shutdown

and emergency conditions. 4. Lubrication and maintenance instructions. 5. Guide to "troubleshooting". 6. Parts lists and predicted life of parts subject to wear. 7. Outline, cross-sections, assembly drawings, engineering data and wiring diagrams. 8. Test data and performance curves.




A. All materials shall be delivered in original, unbroken, brand marked containers.

B. Handle and store materials in a manner which will prevent deterioration and contamination with foreign matter.


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Hydronic Pumps

Section 23 21 23


C. Reject damaged, deteriorated or contaminated material and immediately remove from the Site. Replace removed materials at no additional cost to Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Bell & Gossett.

B. Peerless.

C. Aurora.

2.2 MANUFACTURED UNITS

A. Base-Mounted Pumps: 1. Base-mounted, single-stage, end suction design with true back pull-out. 2. Pump Volute: Class 30 cast iron with integrally-cast pedestal support. 3. Impeller:

a. Case bronze. b. Enclosed type. c. Dynamically balanced. d. Keyed to the shaft and secured by a locking capscrew.

4. The liquid cavity shall be sealed off at the pump shaft by an internally-flushed mechanical seal with ceramic seal seat of at least 98% alumina oxide content, and carbon seal ring, suitable for continuous operation at 250 degrees F.

5. A replaceable stainless steel shaft sleeve shall completely cover the wetted area under the seal. 6. Rated for minimum of 175 psi working pressure. 7. Casings:

a. Gage ports at nozzles. b. Vent and drain ports at top and bottom of casing.

8. Pump Bearing Housing Assembly: a. Heavy-duty regreaseable ball bearings, replaceable without disturbing piping connections. b. Foot support at coupling end.

9. Base Plate: Structural steel or fabricated steel channel configuration fully enclosed at sides and ends, with securely welded cross members and fully open grouting area.

10. A Flexible-Type Coupler: a. Capable of absorbing torsional vibration. b. Between the pump and motor. c. Equipped with a suitable coupling guard as required.

B. In-Line Pumps: 1. In-line type for installation in vertical or horizontal piping, capable of removal without disturbing piping. 2. Pump Body:

a. Class 30 cast iron. b. Rated 175 psi working pressure. c. Gage ports at nozzles. d. Vent and drain ports.

3. Impeller: a. Nonferrous material. b. Enclosed type. c. Dynamically balanced. d. Keyed to the shaft and secured by a locking capscrew or nut.

4. The liquid cavity shall be sealed from the pump bearing by an internally-flushed mechanical seal with ceramic seal seat of at least 98% alumina oxide content and carbon seal ring, suitable for continuous operation at 250 degrees F.

5. A nonferrous shaft sleeve shall completely cover the wetted area under the seal.


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Hydronic Pumps

Section 23 21 23


6. Pump Bearing Bracket: a. Oil lubricated bronze journal and thrust bearings. b. Bracket shaft: Alloy steel having ground and hardened thrust bearing faces. c. A flexible coupling to dampen starting torque and torsional vibrations shall be employed.

C. Motors: 1. 1,750 RPM unless otherwise noted, of horsepower and voltage as indicated on the Drawings. All

motors shall be open drip-proof with ball bearings, be premium efficiency type meeting Energy Code and have 1.15 service factor.

2. All motors served by adjustable frequency A/C drives shall be inverter duty rated. Furnish and install motor shaft grounding rings similar to AEGIS SGR for all motors with AFD’s.

D. Pump Operation: 1. Pump capacities shall be as indicated on the Drawings at total head noted. The operating point of

each pump at the conditions indicated shall be within 5 percentage points of the maximum efficiency on its impeller curve. The impeller furnished shall not exceed 90% of the maximum diameter catalogued impeller available for the pump casing furnished. To assure stable pump operation, the impeller curve shall be continuously rising throughout the range contained within its efficiency curves. The peak of the impeller curve at maximum total head shall be a minimum of 10% above the total head indicated on the Drawings. The pump shall not overload the motor at any point on the impeller curve.

2.3 SOURCE QUALITY CONTROL

A. Factory align and run test pumps.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install pumps in conformance with: 1. The Drawings. 2. These Specifications. 3. The Shop Drawings reviewed by Engineer. 4. The Manufacturer's recommendation. 5. Pump locations indicated on the Drawings are approximately. Determine exact locations before

roughing in piping and electrical connections.

3.2 CONCRETE BASES

A. Install pumps on 4-inch high concrete pads by Contractor. Grout under pump base to level. Refer to Division 23 Section “Hangers and Supports for HVAC Piping and Equipment.” 1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel

rods on 18-inch centers around full perimeter of base. 2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete base and

anchor into structural concrete floor. 3. Place and secure anchorage devices. Use setting drawings, templates, diagrams, instructions, and

directions furnished with items to be embedded. 4. Install anchor bolts to elevations required for proper attachment to supported equipment.

3.3 PUMP INSTALLATION

A. Inline Pumps: 1. Install pipe hangers on piping within 6 inches of pump inlet and discharge on inline pumps. Do not

support in-line pumps independently of piping. 2. Install pumps as indicated on drawings. 3. Verify with manufacturer requirements for vertical or horizontal installation.


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Hydronic Pumps

Section 23 21 23


B. Base Mounted Pumps: 1. Install on 4-inch high concrete pads by Contractor. 2. Install long radius increaser (or decreaser) type ells at suction of pumps. 3. Support vertical piping drops from floor or isolation base (when furnished) to avoid stress on pump

connections. 4. Install flexible connectors on suction and discharge sides of pumps. 5. Install a vent ball valve on the volute casing.

3.4 ALIGNMENT

A. Align pump and motor shafts and piping connections after setting on foundation, grout has been set and foundation bolts have been tightened, and piping connections have been made.

B. Comply with pump and coupling manufacturer’s written instructions.

C. Pump Alignment: - The Contractor and manufacturer’s representative before starting any pumping unit with pump and driver mounted on a common base plate with a flexible coupling, shall check the following points: 1. Make sure base plate is level in both directions. 2. Make sure pump shaft and driver shaft are parallel in both horizontal and vertical planes. 3. Make sure shafts are concentric. 4. Make sure the flexible coupling is correctly installed and aligned.

3.5 STARTUP SERVICE

A. Engage a factory-authorized service representative to perform startup service. 1. Complete installation and startup checks according to manufacturer’s written instructions. 2. Check piping connections for tightness. 3. Clean strainers on suction piping. 4. Perform the following startup checks for each pump before starting:

a. Verify bearing lubrication. b. Verify that pump is free to rotate by hand and that pump for handling hot liquid is free to rotate

with pump hot and cold. If pump is bound or drags, do not operate until cause of trouble is determined and corrected.

c. Verify that pump is rotating in the correct direction. 5. Prime pump by opening suction valves and closing drains, and prepare pump for operation. 6. Start motor. 7. Open discharge valve slowly.

3.6 DEMONSTRATION

A. Engage a factory-authorized service representative to train University’s maintenance personnel to adjust, operate, and maintain hydronic pumps. Refer to Division 01 requirements for Demonstration and Training.



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HVAC Water Treatment

Section 23 25 00


SECTION 23 25 00 – HVAC WATER TREATMENT PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of a complete water treatment system for closed circuit hydronic and boiler systems including, but not limited to, the major items listed below: 1. All pre-operational system cleanout chemicals. 2. Chemical feed equipment as described herein. 3. All necessary test equipment for control of chemicals. 4. Instruct the Contractor on pre-cleaning procedures. 5. Instruct the Contractor on the installation of the feed equipment. 6. Provide training for the operating personnel. 7. Provide 1 year field service and consultation which will include monthly service visits with written test

results, recommended adjustments, and a written report to the University. 8. Provide 1 year supply of chemical treatment. 9. Provide laboratory testing of samples as needed. 10. System start-up assistance.

1.3 SYSTEM DESCRIPTION

A. Provide a chemical treatment system for closed loop hot water systemas indicated on the Drawings.

.

B. Contractor shall include the cost of chemicals and a Service Contract as described below.

1.4 PERFORMANCE REQUIREMENTS

A. Maintain water quality for HVAC systems that controls corrosion and buildup of scale and biological growth for maximum efficiency of installed equipment without posing a hazard to operating personnel or the environment.

B. Base chemical treatment performance requirements on quality of water available at project Site, HVAC system equipment material characteristics and functional performance characteristics, operating personnel capabilities, and requirements and guidelines of authorities having jurisdiction.

1.5 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. ANSI Standard for Power Piping - B31.1. 2. American Society of Mechanical Engineers (ASME) publications:

a. Boiler and Pressure Vessel Code. b. Power Boiler Code.

3. ASHRAE Guideline 12-2000, Minimizing the Risk of Legionellosis.


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Section 23 25 00


1.6 SUBMITTALS

A. Manufacturer's Literature: 1. Name of all Manufacturers and suppliers of equipment and chemicals. 2. Dimensions. 3. Performance characteristics. 4. Details of construction and installation. 5. Electrical requirements. 6. Data sheets on all components and chemicals, including Material Safety Data Sheets (MSDS). 7. System piping, including operational schematic, and wiring schematic.



B. Manufacturer’s personnel shall be full-time employees of the chemical Manufacturer or authorized representative.

C. Testing of water samples in accordance with Division 01 requirements for Testing Services.

D. Regulatory Agencies Requirements: 1. All state and local codes and ordinances. 2. Owner's insurer.

1.8 START-UP AND MAINTENANCE

A. Provide all consulting services for a period of 1 year including start-up of the water systems: 1. Initial water analysis and recommendations. 2. Preoperation system cleanout procedure supervision. 3. Installation and system start-up and shutdown procedure recommendations. 4. Training of operating personnel on proper feeding, control and maintenance techniques. 5. Periodic field service and consultation meetings. 6. All necessary log sheets and record forms. 7. All required laboratory and technical assistance.

B. All services provided by a qualified, full-time representative of the chemical company.

C. It is the responsibility of the chemical supplier to obtain water Sample(s) for testing to determine the correct process and equipment to install.


A. All materials shall be delivered in original, unbroken, brand marked containers or wrapping as applicable.

B. Handle and store materials in a manner which will prevent deterioration or damage, contamination with foreign matter and damage by weather or elements in accordance with Manufacturer's directions.

C. Reject damaged, deteriorated or contaminated material and immediately remove from the Site. Replace rejected materials with new materials at no additional cost to Owner.

PART 2 - PRODUCTS

2.1 MANUFACTURER

A. HVAC water treatment system based on WEAS Engineering (Steve Eisle phone - 317-867-4477, cell - 513-508-5494, e-mail - [email protected]).


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Section 23 25 00


2.2 PRE-OPERATIONAL CLEANING

A. Upon installation completion of the piping systems and operational pumps, the systems are to be chemically cleaned. The chemical shall be capable of removing oil, grease, welding slag, dirt and corrosion byproducts. All closed-loops and other pertinent piping and equipment is to be cleaned prior to operation.

B. Preparation for Clean-Out: All systems must be prepared prior to the introduction of the chemical cleaner. 1. Contractor shall flush all systems, including mud from drop legs. Remove, clean and replace all

strainer screens. 2. Complete circulation must be achieved during the cleaning procedure. A minimum flow rate of 2 feet

per second shall be maintained to ensure the cleaning chemicals will work properly. All electric, air, and thermostatic operated valves shall be open. All dead end runs shall be looped together with piping not less than 1/3 the size of the run. This piping is to remain in place until the cleaning is complete.

3. The cleaner shall not require external heat to ensure its effectiveness.

C. Cleaning Chemicals: The cleaning solution shall be formulated to remove light grease, cutting oils, loose mill scale, organics and extraneous construction debris. The cleaner shall contain an organic phosphate, an organic corrosion inhibitor, a dispersant and an oil emulsifier. Sufficient cleaner shall be used to treat all piping to remove oil and grease and to permit a uniform passivating film to form.

D. Pre-Operational Cleaning Procedure: 1. Temporary piping connections at the ends of all dead end branches must be provided between the

supply and return piping to circulate the cleaning solution. 2. Add recommended quantity of cleaning chemical directly into the closed loop before the recirculating

pumps to ensure rapid mixing and distribution throughout the system. A small amount of antifoam may be added to prevent excessive foaming.

3. Recirculate the system for 16 to 24 hours. 4. Open and drain mud legs and low points periodically during the cleaning process. Drain system

completely paying particular attention to mud from drop legs and all low points. 5. Refill the system with clean potable water. Clean all strainers. Recirculate for 8 to 12 hours and

completely drain the system. 6. Refill the system. The length of time between the completion of the cleaning procedure and the

addition of the corrosion inhibitor shall not exceed 24 hours. 7. Add the recommended level of inhibitor. The system is now ready for operation. 8. A service report shall be generated on Site by the water treatment representative certifying that the

system has been cleaned in accordance with the above procedure and shall be forwarded to the HVAC Subcontractor with a copy to the Engineer.

2.3 CLOSED LOOP SYSTEMS

A. Chemical Feed and Control Equipment: 1. For each closed loop system the Contractor shall provide and install the following apparatus (including

isolation and drain valves): a. One Pot Feeder - 5 gallon capacity. The feeder shall have a 3-1/2-inch opening with a 2-1/2

turn cap. The feeder shall be rated for 300 psi service and provide for on-line filtering when being used for chemical injection. Two replacement filter bags (20 micron) shall be provided. 1) Neptune Model FTF-5DB.

B. Water Treatment Chemicals: 1. Furnish a 1 year supply of liquid closed loop inhibitor for control of scale and corrosion in a closed

recirculating system. Formulations shall not contain any ingredient which may be harmful to system materials of construction. The corrosion inhibitor shall contain a multi-functional blend of nitrite, molybdate, tolytriazole, anionic polymer and buffering agents. MSD sheets shall be provided for all chemical products. No system shall be operated without the benefits of chemical protection.

C. Test Equipment: 1. Furnish a 1 year supply of water test equipment, including storage case and spare reagents for

maintaining control of the program standards in the closed loop system. Test kits shall include reagents and apparatus for the determination of nitrite and pH levels in the closed loop system.


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Section 23 25 00


PART 3 - EXECUTION

3.1 GENERAL

A. Furnish and install all mounts, piping, tubing and valves necessary to install the complete operable water treatment system as indicated on the Drawings and under the supervision of the chemical company.

B. Upon acceptance, the Contractor shall inform the University in writing as to the treatment applied during start-up and testing. The Contractor shall state specifically the chemicals used and the quality of the fluids in the systems, which shall include: 1. Total hardness. 2. Alkalinity. 3. pH. 4. Dissolved solids. 5. Suspended solids. 6. Sodium sulfite. 7. Phosphonate.

3.2 ADJUSTING – BOILER TREATMENT SYSTEMS

A. Sample boiler water at 1 week intervals after boiler start-up for a period of 5 weeks, and prepare certified test report for each required water performance characteristic. Where applicable, comply with ASTM D3370 and the following standards: 1. Silica: ASTM D859. 2. Steam System: ASTM D1066. 3. Acidity and Alkalinity: ASTM D1067. 4. Iron: ASTM D1068. 5. Water Hardness: ASTM D1126.

B. Occupancy Adjustments: Within 12 months of Substantial Completion, perform 2 separate water analyses to prove that automatic chemical feed systems are maintaining water quality within performance requirements specified in this Section. Perform analyses at least 60 days apart. Submit written reports of water analysis.

3.3 WATER TREATMENT SERVICE PROGRAM

A. Provide all consulting services for a period of 1 year including start-up of the water systems: 1. Initial water analysis and recommendations. 2. Preoperation system cleanout procedure supervision. 3. Installation and system start-up procedure recommendations. 4. Training of operating personnel on proper feeding and control techniques. 5. Periodic field service and consultation meetings. 6. Any necessary log sheets and record forms. 7. Any required laboratory and technical assistance.

B. All services provided by a qualified, full-time representative of the chemical company.

C. It is the responsibility of the chemical supplier to obtain water Sample(s) for testing to determine the correct process and equipment to install.


A. In all locations where chemicals are dispensed, provide safety data sheets in “see-thru-folder” and posted in visible work area. Chemical supplier shall provide all special safety equipment required for handling chemicals.

B. Furnish a sufficient 1 year supply of chemicals to maintain all systems free of corrosion, scale, and biological growth. Chromates will not be accepted.


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Section 23 25 00


C. Furnish a 1 year service program by a qualified service person performing service on a full time basis. Service calls will be no less than 1 per month, but as often as required to keep all systems in balance. Service shall include supervision of installation of the feed equipment and start up of the systems when notified. A minimum of a 4 hour training program will be provided for the maintenance personnel within 30 days of start up of the systems and as needed thereafter even if dictated by turnover of personnel. Response to emergency calls shall be within 24 hours. Records of service calls shall be available for review.



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Breechings, Chimneys, and Stacks

Section 23 51 00


SECTION 23 51 00 – BREECHINGS, CHIMNEYS, AND STACKS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of a complete gas vent system.

B. Unless noted otherwise, all fuel fired appliances, whether furnished as part of Division 23 or other Divisions, including equipment that may be furnished by the Owner, is included in the venting requirements of this Work.


A. For use with natural gas, propane, or oil-fired appliances operating at neutral, positive, and negative stack pressures as indicated by equipment schedules or specified herein.

B. Single or double wall vent system complete with rain cap, thimbles, flashing collar and necessary fittings.

C. Adequate support for wind stress.

D. Vent System: Gas tight and prevent leakage of combustion products into a building.

E. Compensate for all flue gas inducted thermal expansions.

F. Comply with fuel fired appliance Manufacturer’s recommendations for vent materials and installation.

1.4 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. NFPA: 54 – National Fuel Gas Code. 2. UL:

a. UL 441 – Gas Vents. b. UL 1738 – Standard for Safety Venting Systems for Gas Burning Appliances.

1.5 SUBMITTALS

A. Manufacturer's Literature: 1. Dimensions. 2. Details of construction and installation. 3. Name of Manufacturer. 4. Model.




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Section 23 51 00


B. Regulatory Agencies Requirements: 1. Entire assembly shall be listed and labeled by Underwriters' Laboratories, Inc. and comply with

UL Test Standard 441 - Gas Vents. 2. System shall comply with applicable provisions of:

a. NFPA 54 - National Fuel Gas Code. 3. All state and local codes and ordinances. 4. Owner's insurer.

1.7 WARRANTY

A. Manufactured breaching and the stack shall be warranted against functional failure due to defects in material and Manufacturer's workmanship for a period of 10 years.

PART 2 - PRODUCT

2.1 MANUFACTURERS

A. Pre-fabricated Vent Pipe Systems: 1. Selkirk Metalbestos. 2. Van Packer Company. 3. Metal-Fab.

2.2 PRESSURIZED VENT STACK – DOUBLE WALL

A. Stack and Breeching Vent Pipe and Fittings: 1. Inner wall: superferritic stainless steel, AL29-4C Aluminized coated steel outer wall minimum

0.025-inch. 2. 1-inch nominal air space. 3. Inner pipe joints shall be sealed by use of factory supplied V-bands and sealant as specified in the

Manufacturer's installation instructions.

B. Classification: 1. 500 degrees F continuous, 2000 degrees F intermittent operation. 2. Positive pressure, condensing flue gas service. 3. UL listed for use with Category III and IV appliances and elsewhere as specified.

C. Vent shall be listed for an internal static pressure of 10-inch w.g. and tested to 25-inch w.g.

2.3 NON-METALLIC MATERIAL FOR COMBUSTION INTAKE FOR CONDENSING GAS FIRED EQUIPMENT

A. Pipe and Fittings: 1. Schedule 40 PVC or CPVC pipe. 2. Joints made with primer conforming to ASTM F656, cement conforming to ASTM D2564.

2.4 ACCESSORIES

A. General: Provide all necessary rain caps, thimbles, flashing, supports, expansion joints, and fittings required for a complete installation.

B. Drains: Provide threaded pipe connection to allow drainage at all low points in vent systems. Slope piping system to the drain. Pipe size shall be 1-inch (25 mm) minimum.


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Section 23 51 00


PART 3 - EXECUTION

3.1 INSTALLATION

A. Route Vents as indicated on Drawings: 1. Pitch upward in direction of flow. 2. Maintain minimum clearances from combustibles in accordance with Manufacturer's

recommendations.

B. Provide supports where necessary to eliminate any sagging or strain on vent pipe joints.

C. Aluminized or galvanized steel surfaces exposed to the elements shall be protected by a minimum of one base coat of primer and one finished coat of corrosion resistant point suitable for outer jacket skin temperatures of the particular installation (such as Series 4100 or 9400 as manufactured by Rust-Oleum).

D. Sidewall termination in accordance with manufacturer’s recommendation.

3.2 CLEANING

A. Clean materials installed under this Section according to Division 01 requirements for Cleaning.

B. Clean all surfaces of rust, mill scale, and apply prime coat of heat and corrosion resistant paint. Apply finish coats of heat and corrosion resistant paint to all exposed uninsulated surfaces. Select paint system compatible with maximum surface temperature.



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Condensing Boilers

Section 23 52 16

SECTION 23 52 16 - CONDENSING BOILERS PART 1 - GENERAL


A. Drawings and general provisions of the Contract, including General and Conditions and Division 01 Specifications, apply to this Section.

B. References: 1. Ohio Energy Code. 2. ASME Boiler and Pressure Vessel Code.

1.2 SUMMARY

A. This section includes packaged factory fabricated and assembled high efficiency full condensing natural gas fired heating hot water boilers.

1.3 SCOPE

A. Install two 2,000 MBH Input forced draft type gas fired high efficiency condensing hot water heating boilers with appurtenances as hereinafter specified and as shown on drawings. Boilers will be pre-purchased by University. Refer to Appendix “A” for an approved copy of the purchased boiler submittal.

B. Contactor will be responsible for coordinating delivery, receiving boilers and storage as required. Upon completion of installation, contractor shall be responsible for obtaining and including necessary submittals for inclusion in Operation and Maintenance Manuals, Facilitating Manufacturer conducted testing and Warranty Documentation.

1.4 SUBMITTALS

A. Shop Drawings: For boilers, boiler trim and accessories, include: 1. Plans, elevations, sections, details and attachments to other work. 2. Wiring Diagrams for power, signal and control wiring.

B. Source Quality Control Test Reports: Reports shall be included in submittals.

C. Field Quality Control Test Reports: Reports shall be included in submittals.

D. Operation and Maintenance Data: Data to be included in boiler emergency, operation and maintenance manuals.

E. Warranty: Standard warranty specified in this Section.

F. Other Informational Submittals: 1. ASME Stamp Certification and Report: Submit "A," "S," or "PP" stamp certificate of authorization, as

required by authorities having jurisdiction, and document hydrostatic testing of piping external to boiler.

1.5 QUALITY ASSURANCE (PROVIDED BY BOILER MANUFACTURER)

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



Condensing Boilers

Section 23 52 16

B. I=B=R Performance Compliance: Condensing boilers must be rated in accordance with applicable federal testing methods and verified by AHRI as capable of achieving the energy efficiency and performance ratings as tested within prescribed tolerances.

C. ASME Compliance: Condensing boilers must be constructed in accordance with ASME Boiler and Pressure Vessel Code, Section IV “Heating Boilers”.

D. ASHRAE/IESNA 90.1 Compliance: Boilers shall have minimum efficiency according to "Gas and Oil Fired Boilers - Minimum Efficiency Requirements."

E. UL Compliance: Boilers must be tested for compliance with UL 795, "Commercial-Industrial Gas Heating Equipment." Boilers shall be listed and labeled by a testing agency acceptable to authorities having jurisdiction.

1.6 OPERATION AND MAINTENANCE DATA

A. Receive and include operation and maintenance data.

B. Include manufacturer's descriptive literature, operating instructions, cleaning procedures, replacement parts list, and maintenance and repair data.

C. Provide operation and maintenance manuals at least 2 weeks prior to training.


A. Deliver products to site under provisions of Division 01.

B. Store and protect products under provisions of Division 01.

C. Protect units before, during and after installation from damage to casing by leaving factory shipping protective packaging in place until immediately prior to final acceptance and start-up.

1.8 WARRANTY (Provided by Boiler Manufacturer)

A. Provide 10-year manufacturer's warranty for coverage for pressure vessel/heat exchanger against failure due to condensate corrosion, thermal stress, mechanical defects or workmanship. Manufacturer’s warranty on burner and associated components shall be five years.

B. All other components shall be guaranteed against any failure for 18 months from shipment or 1 year from start-up, whichever is greater.

C. In addition to above described manufacturer’s warranty, the manufacturer shall provide alternate pricing for an extended three year service contract including all parts and labor costs. This cost shall be submitted as an alternate separate from boiler price.

1.9 START-UP AND DEMONSTRATION

A. The Boiler manufacturer shall provide minimum 4 hours operation, adjustment and maintenance training for the University’s maintenance personnel. The contractor shall be responsible for scheduling start-up and training and shall be present for both.

B. Start-up and training shall not coincide.



Condensing Boilers

Section 23 52 16

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Boiler shall be sealed combustion with the following capacity: 1. 2,000,000 btuh input, 1,708,000 output, min 85.4% efficiency when heating 115 GPM from

150 degrees F to 180 degrees F. 2. 14-inch w.c. inlet gas pressure, 120V-60HZ-1Ø power, 125 psig relief valve, 125 psig max pressure.

Builder shall be capable of producing 190 degrees F supply water based on 160 degrees F return temperature.

B. Condensing Boilers meeting all requirements of the specifications by the following manufacturers are approved for submittal: 1. Aerco (Model: Bendhmark BMK-2.0LN). 2. Cleaver Brooks (Model: Clearfire-C2500). 3. Fulton (Model: Vantage 2000). 4. Lochinvar (Model: Crest FBN 2000).

2.2 CONSTRUCTION

A. Boiler shall be sealed combustion natural gas fired, fully condensing, fire tube design. Power burner shall have full and discharge into a positive pressure vent. Boiler efficiency shall increase with decreasing load (output), while maintaining setpoint. Boiler shall be factory-fabricated, factory-assembled and factory-tested, fire-tube condensing boiler with heat exchanger sealed pressure-tight, built on a steel base, including insulated jacket, flue-gas vent, combustion-air intake connections, water supply, return and condensate drain connections, and controls.

B. Heat Exchanger: The heat exchanger shall be constructed of 439 stainless steel fire tubes and tubesheets, with a one-pass combustion gas flow design. The fire tubes shall be 5/8-inch OD, with no less than 0.049-inch wall thickness. The upper and lower stainless steel tubesheet shall be no less than 0.25-inch thick. The pressure vessel/heat exchanger shall be welded construction. The heat exchanger shall be ASME stamped for a working pressure not less than 160 psig. Access to the tubesheets and heat exchanger shall be available by burner and exhaust manifold removal. Minimum access opening shall be no less than 10-inch diameter.

C. Pressure Vessel. The pressure vessel shall have a maximum water volume of 24 gallons. The boiler water pressure drop shall not exceed 1.7 psig at 170 gpm. The boiler water connections shall be 4-inch flanged 150-pound, ANSI rated. The pressure vessel shall be constructed of SA53 carbon steel, with a 0.25-inch thick wall and 0.50-inch thick upper head. Inspection openings in the pressure vessel shall be in accordance with ASME Section IV pressure vessel code. The boiler shall be designed so that the thermal efficiency increases as the boiler firing rate decreases.

D. Modulating Air/Fuel Valve and Burner. The boiler burner shall be capable of a 5-to-1 turndown ratio of the firing rate without loss of combustion efficiency or staging of gas valves. The burner shall produce less than 20 ppm of NOx corrected to 3% excess oxygen. The burner shall be metal-fiber mesh covering a stainless steel body with spark ignition and flame rectification. All burner material exposed to the combustion zone shall be of stainless steel construction. There shall be no moving parts within the burner itself. A modulating air/fuel valve shall meter the air and fuel input. The modulating motor must be linked to both the gas valve body and air valve body with a single linkage. The linkage shall not require any field adjustment. A variable frequency drive (VFD), controlled cast aluminum pre-mix blower shall be used to ensure the optimum mixing of air and fuel between the air/fuel valve and the burner.



Condensing Boilers

Section 23 52 16

E. Minimum boiler efficiencies shall be as follows at a 30 degree delta-T: EWT 100% Fire 60% Fire 40% Fire 20% Fire

150 °F 85.4% 85.6% 85.7% 85.8% 130 °F 86.0% 86.7% 87.0% 87.8% 110 °F 88.5% 89.2% 89.5% 90.6%

F. Exhaust Manifold: The exhaust manifold shall be of corrosion resistant cast aluminum with an 8-inch diameter flue connection. The exhaust manifold shall have a collecting reservoir and a gravity drain for the elimination of condensation.

G. Blower: The boiler shall include a variable-speed, DC centrifugal fan to operate during the burner firing sequence and pre-purge the combustion chamber. 1. Motors: Blower motors shall comply with requirements of The State of Ohio Code for Energy

Conservation. a. Motor Sizes: Minimum size as indicated. If not indicated, large enough so driven load will not

require a motor to operate in the service factor range above 1.0.

H. Ignition: Ignition shall be via spark ignition with 100 percent main-valve shutoff and electronic flame supervision.

2.3 CONTROLS

A. The boiler control system shall be segregated into three components: Control Panel, Power Box and Input/Output Connection Box. The entire system shall be Underwriters Laboratories recognized.

B. The control panel shall consist of 6 individual circuit boards using state-of-the-art surface-mount technology in a single enclosure. These circuit boards shall include: 1. A display board incorporating LED display to indicate temperature and a vacuum fluorescent display

module for all message enunciation. 2. A CPU board housing all control functions. 3. An electric low-water cutoff board with test and manual reset functions. 4. A power supply board. 5. An ignition/stepper board incorporating flame safeguard control. 6. A connector board.

Each board shall be individually field replaceable.

C. The combustion safeguard/flame monitoring system shall use spark ignition and a rectification-type flame sensor.

D. The control panel hardware shall support both RS-232 and RS-485 remote communications.

E. The controls shall annunciate boiler and sensor status and include extensive self-diagnostic capabilities that incorporate a minimum of 8 separate status messages and 34 separate fault messages.

F. The control panel shall incorporate three self-governing features designed to enhance operation in modes where it receives an external control signal by eliminating nuisance faults due to over-temperature, improper external signal or loss of external signal. These features include: 1. Setpoint high limit: Allows for a selectable maximum boiler outlet temperature and acts as temperature

limiting governor. Setpoint limit is based on a PID function that automatically limits firing rate to maintain outlet temperature within a 0 to 10 degree selectable band from the desired maximum boiler outlet temperature.

2. Setpoint Low Limit: Allows for a selectable minimum operating temperature. 3. Failsafe Mode: Failsafe mode allows the boiler to switch its mode to operate from an internal setpoint

if its external control signal is lost, rather than shut off. This is a selectable mode, enabling the control can to shut off the unit upon loss of external signal, if so desired.



Condensing Boilers

Section 23 52 16

G. The boiler control system shall incorporate the following additional features for enhanced external system interface: 1. System start temperature feature. 2. Pump delay timer. 3. Auxiliary start delay timer. 4. Auxiliary temperature sensor. 5. Analog output feature to enable simple monitoring of temperature setpoint, outlet temperature or fire

rate. 6. Remote interlock circuit. 7. Delayed interlock circuit. 8. Fault relay for remote fault alarm.

H. Each boiler shall include an electric, single-seated combination safety shutoff valve/regulator with proof of closure switch in its gas train. Each boiler shall incorporate dual over-temperature protection with manual reset, in accordance with ASME Section IV and CSD-1.

I. The Boiler Manufacturer shall supply as part of the boiler package a completely integrated Control System (CS) to control all operation and energy input of the multiple boiler heating plant. The CS shall be comprised of a microprocessor based control capable of adjusting set-point in response to outdoor temperature, externally applied signal and external BACnet network communications. 1. The controller shall have the ability to vary the firing rate and energy input of each individual boiler

throughout its full modulating range to maximize the condensing capability and thermal efficiency output of the entire heating plant. The CS shall control the boiler outlet header temperature within +2 degrees F. The controller shall be a PID type controller and uses Ramp Up/Ramp Down control algorithm for accurate temperature control with excellent variable load response. The CS controller shall provide contact closure for auxiliary equipment such as system pumps and combustion air inlet dampers based upon outdoor air temperature.

2. The CS shall have the following anti-cycling features: a. Manual designation of lead boiler and last boiler. b. Lead boiler rotation at user-specified time interval. c. Delay the firing/shutting down of boilers when header temperature within a predefined

deadband. 3. When set on Internal Setpoint Mode, temperature control setpoint on the CS shall be fully field

adjustable from 50 degrees F to 190 degrees F in operation. When set on Indoor/Outdoor Reset Mode, the CS will operate on an adjustable inverse ratio in response to outdoor temperature to control the main header temperature. Reset ratio shall be fully field adjustable from 0.3 to 3.0 in operation. When set on 4ma to 20ma Temperature Control Mode, the CS will operate the plant to vary header temperature setpoint linearly as an externally applied 4-20 mA signal is supplied.

4. When set on external Temperature Control Mode, the CS will operate the plant to vary header temperature setpoint as an external communication utilizing the BACnet protocol is supplied. The CS controller shall have a vacuum fluorescent display for monitoring of all sensors and interlocks. Non-volatile memory backup of all control parameters shall be internally provided as standard. The controller will automatically balance the sequence of operating time on each boiler by a first-on first-off mode and provide for setback and remote alarm contacts. Connection between central CS system and individual boilers shall be twisted pair low voltage wiring, with the boilers ‘daisy-chained’ for ease of installation.

J. Boiler shall include integral factory wired operating controls capable of adjusting set-point in response to outdoor temperature, externally applied signal, and external BACnet network communication.

2.4 ELECTRICAL POWER

A. Single-Point Field Power Connection: Factory-installed and factory-wired switches, motor controllers, transformers and other electrical devices shall provide a single-point field power connection to the boiler.

B. Electrical Characteristics: 1. Voltage: 120 V. 2. Phase: Single.



Condensing Boilers

Section 23 52 16

3. Frequency: 60 Hz. 4. Full-Load Current 9.0 Amps.

2.5 VENTING

A. The exhaust vent must be UL Listed for use with Category III and IV appliances and compatible with operating temperatures up to 480 degrees F, positive pressure, condensing flue gas service. UL-listed vents of Al 29-4C stainless steel must be used with boilers.

B. Combustion-Air Intake: Boilers shall be capable of drawing combustion air from the outdoors via a metal or PVC duct connected between the boiler and the outdoors.

C. Contractor shall be responsible for furnishing and installing exhaust vent and combustion air intake material suitable for sidewall venting application. Wall penetration and termination by Contractor in accordance to manufacturer’s recommendations.

D. Boiler manufacturer shall be responsible for review of exhaust vent and combustion air intake sizes and routing to ensure proper boiler operation.

E. Minimum Vent and Intake sizes shall be 8”. Contractor shall confirm size with boiler manufacturer based on proposed layout and modify as required.

2.6 SOURCE QUALITY CONTROL

A. Burner and Hydrostatic Test: Factory adjust burner to eliminate excess oxygen, carbon dioxide, oxides of nitrogen emissions and carbon monoxide in flue gas, and to achieve combustion efficiency. Perform hydrostatic testing.

B. Test and inspect factory-assembled boilers, before shipping, according to ASME Boiler and Pressure Vessel Code. 1. If boilers are not factory assembled and fire-tested, the local vendor is responsible for all field

assembly and testing.

C. Allow University access to source quality-control testing of boilers. Notify Engineer 14 days in advance of testing.

PART 3 - EXECUTION

3.1 BOILER INSTALLATION

A. The boilers will be pre-purchased by the University for installation by the Contractor.

B. All aspects of installation of Boiler Plant shall be in strict accordance with manufacturer's instructions. The vent system must conform to all manufacturers' recommendations and shall utilize UL listed stainless steel AL-29-4C Positive Pressure. The vent must be sized in accordance with manufacturer's recommendations. Boiler plant piping shall be field constructed of materials as specified. Each boiler shall have individually isolating shutoff valves for service and maintenance.

C. Manufacturer's representative to supervise installation of burner and controls and to make all necessary adjustments to insure proper performance of the equipment.

D. Provide for connection to electrical service.

E. Provide connection of gas service in accordance with ANSI/AGA Z223.1. Regulators shall be vented to outdoors.



Condensing Boilers

Section 23 52 16

F. Pipe relief valves to 6-inches above floor and all drains to nearest floor drain associated with each individual boiler.

G. Pipe flue condensate drain and main condensate drain in accordance with manufacturer's recommendations.

3.2 MANUFACTURER'S FIELD SERVICES

A. Contractor shall schedule and coordinate system start and testing under provisions of Division 01.

B. Boiler manufacturer shall provide field representative for starting unit, training operator, and additional inspections and adjustments required by commissioning to achieve maximum improvements on energy consumption. Contractor shall provide the services of a local factory authorized representative to supervise all phases of equipment startup. A letter of compliance with all factory recommendations and installation instructions shall be submitted to the engineer with operation and maintenance instructions.

C. Boiler manufacturer shall provide field combustion test upon completion of installation and submit report. Test shall include boiler firing rate, overfire draft, gas flow rate, heat input, burner manifold gas pressure, percent carbon monoxide, percent oxygen, percent excess air, flue gas temperature at outlet, ambient temperature, net stack temperature, percent stack loss, percent combustion efficiency, and heat output.

3.3 INSTALLATION

A. Install boiler on 4-inch high concrete pad by HVAC Contractor.

B. Clamp the drain line to the floor. END OF SECTION 23 52 16


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Variable Frequency Motor Controllers

Section 23 85 00

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SECTION 23 85 00 – VARIABLE FREQUENCY MOTOR CONTROLLERS PART 1 - GENERAL



1.2 SUMMARY

A. Provide variable frequency drives (VFD) to control new pumps as indicated on the Drawings.).

B. Provide 3 auxiliary “Form-C” Type contacts for drive for additional control interlocking

C. Provide terminals for remote start/stop contact.

D. The VFD manufacturer shall perform harmonic analysis as described in Quality Assurance below. Additional power filtering required to meet these requirements shall be provided by this manufacturer

E. All components shall be mounted in a common enclosure.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. UL 508C. 2. IEEE 519.

1.4 SUBMITTALS

A. Shop Drawings: For VFDs. 1. Name of Manufacturer. 2. Model number. 3. Details of construction and installation. 4. Assembly drawings, including elevations, plans, sections, dimensions, weight, and conduit entry

locations. 5. Project Specific Wiring Diagrams:

a. Diagrams shall clearly identify all field wiring requirements. b. Typical diagrams are acceptable for multiple motors controlled in the same manner.

6. Electrical Ratings: a. Voltage. b. Horsepower. c. Interrupt rating. d. Enclosure type.

7. Color and finish. 8. Options and accessories.

B. Installation Instructions: For VFDs.

C. Manufacturer’s Certification of VFDs: 1. Sworn statement that the equipment furnished complies with this Specification. 2. Written approval of installation.


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Section 23 85 00


D. Operation and Maintenance Manuals: For VFDs. 1. Equipment function, normal operating characteristics, and limiting conditions. 2. Assembly, installation, alignment, adjustment, and checking instructions. 3. Operating instructions for start-up, routine and normal operating, regulation and control, shutdown,

and emergency conditions. 4. Maintenance instructions. 5. Guide to "troubleshooting". 6. Parts lists and predicted life of parts subject to wear. 7. Project specific outline and cross sections, assembly drawings, engineering data, and wiring diagrams.

Wiring diagrams shall reflect final, as-installed conditions, and include wire numbers. 8. Test data and performance curves.

E. Harmonic Analysis: Submit 3 copies.


A. The VFD manufacturer shall maintain, as part of a national network, engineering service facilities within 250 miles of project to provide start-up service, emergency service calls, repair work, service contracts, maintenance and training of customer personnel.

B. The VFD manufacturer shall perform harmonic analysis meeting IEEE-519 with the point of common coupling (PCC) designated as the closest feeder bus serving the VFD. Calculations shall include all VFD’s connected to that bus whether provided by this manufacturer or not. Voltage distortion shall be no more than 5% (General Systems). Calculations shall be performed as described in ASHRAE Handbook HVAC Systems and Equipment (latest edition).

C. Manufacturer's Services: 1. Submit Manufacturer's sworn statement that the equipment furnished complies with this Specification. 2. Provide Manufacturer's field start-up service.

D. All VFD assemblies shall be listed and labeled by UL or ETL for compliance with UL 508.


A. Delivered materials in original, unbroken, brand marked containers or wrapping as applicable.

B. Handle and store materials in a manner which will prevent deterioration or damage, contamination with foreign matter, damage by weather or elements, and in accordance with Manufacturer's directions.

C. Store materials indoors and protect from weather. When necessary to store outdoors, elevate materials above grade and enclose with durable, watertight wrapping.

D. Reject damaged, deteriorated, or contaminated materials and immediately remove from the Site. Replace rejected materials with new materials at no additional cost to Owner.

1.7 DATA COLLECTION FOR HARMONIC ANALYSIS

A. Contractor Responsibilities: Provide all required data for the preparation of the harmonic analysis. Data shall include, but not be limited to, system one-line diagram and X/R, %Z, and KVA information for the utility transformer(s) and generator(s)

PART 2 - PRODUCTS

A. Adjustable Frequency A/C Drives based on Yaskawa E7.


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Section 23 85 00


B. Adjustable Frequency A/C Drives by the following manufacturers of the same size, type, capacity and meeting other requirements may be furnished at the contractor’s option. 1. ABB. 2. Allen Bradley.

2.2 VFD RATINGS

A. Comply with the applicable requirements of the latest standards of ANSI, IEEE, NEMA and the National Electric Code.

B. Controllers and factory-mounted options shall be UL listed. 2.3 CONTROL

A. The controller shall be capable of varying its output in response to a 3-15 psig, 0-10 volt DC and 4-20 MA signal. Coordinate type of interface required with the Temperature Control Contractor or Pump Package Manufacturer.

B. The following controls shall be mounted in the face of the enclosure:

1. Pilot lights for “Power On”, “Drive Fault”, “Motor Safety Fault”, “Running on Drive”. Pilot lights must be LED style.

2. Door mounted diagnostic indicator with touch pad interface shall incorporate: a. Controller Run. b. Voltage to Motor. c. Current to Motor. d. Speed Indication in Hertz, Percent, RPM. e. Elapsed Time Meter. f. Over Temperature. g. Over Current. h. Over Voltage. i. Motor Overload. j. Ground Fault. k. Short Circuit. l. Phase Loss. m. Control Circuit Fault.

3. Hand-Off-Auto speed control selector switch and manual speed adjustment with switches and indication on face of cover. Switch shall only select motor speed control signal. Speed control signal shall be from either the building DDC system or manual speed adjustment by means of the drive mounted keypad.

C. “Test – Run” Switch: To allow startup diagnostics of drive without a load.

2.4 INPUT/OUTPUT FUNCTIONS

A. The controller shall include the following input and output functions at a labeled terminal strip. All inputs and outputs must be completely isolated from the analog reference source. 1. Inputs:

a. Run Control. b. Stop Control. c. Fault Reset. d. Manual/Remote Speed Reference. e. Speed Control Signal. f. External Trip Control NO/NC. g. Pre-Set Speed Contacts: The digital operator keypad shall be programmed so that safeties

cannot be bypassed. 2. Outputs:

a. Trip (Form C Contact). b. One programmable Contact (Form A Contact). c. Output Frequency (0-10 VDC). d. Choice of Output Current, Voltage and Frequency.


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Section 23 85 00


2.5 CONTROL RATINGS

A. The controller shall be rated for the voltage as indicated on the Drawings. As a minimum, the continuous full load output current of the drive shall be equal to 1.05 times the full load current of the motors serving.

B. The controller shall be rated for the following service conditions: 0 to 40 degrees C, 0 to 95% relative humidity, 3,300 foot altitude without deration, ±10% input voltage fluctuation, ±5% input frequency fluctuation.

2.6 SPEED CONTROL

A. Speed control shall be linear from 10 to 100 percent of full speed. Both the minimum and maximum speed limits shall be adjustable. The controller output frequency shall not change as a result of up to a 10 percent input voltage fluctuation. The acceleration and deceleration shall be fully adjustable. Provide current limit function to avoid excessive automatic acceleration and deceleration when an over-current condition exists. The volts-to-hertz ratio shall be adjustable. Critical frequency rejection points shall be provided and shall be programmable, minimum of 3 deadbands available.

B. The speed control output transistors are to be Insulated Gate Bipolar Transistors (IGBT) type for PWM

design to facilitate a switching frequency of up to 15 kHz to eliminate the audible noise associated with PWM designs. The audible noise emitted from the motor must be within 5 dB of the noise during across-the-line operation at all frequencies within the human audible spectrum (up to 15kHz operating frequency). The controller must be selected for operation at or above 8 kHz up to 75 HP and 4 kHz for 100 hp and larger without de-rating to satisfy the conditions for current, voltage and horsepower as indicated on the equipment schedule.

2.7 POWER REQUIREMENTS

A. The controller shall permit disconnection of power from the input or output line voltage with the controller running under load without damage to the controller components. The controller shall be able to withstand an output line short (phase-to-phase or phase-to-ground) without damage to the controller components. Controller shall shut down on short circuit and detection of any of the following conditions: current 150 percent above rated current, phase loss, input over voltage and under voltage, high internal temperature, ground fault and under frequency.

B. The controller shall have an automatic restart function to attempt restart (programmable up to 10 attempts) after the unit trips off when power is lost to the unit. A time delay shall be provided between restarts. The unit shall not attempt to restart more than five times in the automatic mode. In addition, the controller shall have a “power dip” ride-thru feature of at least 2 seconds (120 cycles) to prevent unnecessary trip-out due to momentary input power interruptions.

C. The drive system (motor and controller) shall provide a minimum power factor of 97 percent at power input

throughout the speed range, and a minimum efficiency (output-to-input line) of 94 percent at 100 percent speed and 70 percent at 50 percent speed.

2.8 COMMUNICATION

A. The controller shall meet the requirements for Radio Frequency Interference (RFI) above 7 MHz as specified by FCC regulations, part 15, subpart J, for Class A devices.

B. All units must be provided with a 3% input line reactor.

C. Provide with RS232 and RS485 interface with communication with Echelon LonWorks, Siemens System 600/Apogee and Metasys N2 Modbus Connector. Provide the necessary communication cards and coordinate with the Temperature Control Contractor as required.


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Section 23 85 00


2.9 ADDITIONAL FEATURES

A. The following additional features shall be provided for the controller:

1. The input breaker shall provide a disconnect means. Breaker operating handle shall protrude through the AFD door and breaker shall not be mounted on the door. Extended breaker operating handles not permitted. Handle position shall indicate ON, OFF or TRIPPED condition of the circuit breaker. The handle shall have provisions for padlocking in the off position. Interlocks shall prevent unauthorized opening or closing of the AFD door with disconnect handle in the ON position. This shall be defeatable by maintenance personnel.

2. Output Overload Relay: Provide an overload relay for motor protection with manual reset pushbutton, all inside the enclosure. Provide the proper size overload elements to match motor nameplate ratings before allowing the motors to be put into service. Provide overload for each motor where multiple motors are served by one controller. a. Provide relay contacts for motor thermal overloads for remote monitoring.

3. NEMA 1 enclosure – the controller shall be provided in a ventilated enclosure intended for indoor use. The AFD and Circuit Breaker shall be in a common NEMA 1 enclosure. Separate enclosures are prohibited.

4. Motor shaft grounding rings similar to AEGIS SGR shall be furnished for all motors with AFD’s.

PART 3 - EXECUTION 3.1 INSTALLATION

A. Install and connect adjustable frequency controller in accordance with manufacturer’s instructions.

B. All wiring to be done by Electrical Contractor unless otherwise specified.

C. Motor and controller furnished and installed by HVAC Contractor and wired by the Electrical Contractor.

D. Temperature Control Contractor shall provide a signal to variable speed drive unit for air handlers, exhaust fans and pumps. Coordinate type of interface required with the Temperature Control Contractor.

E. Provide complete wiring diagrams to the Temperature Control Contractor for use in interfacing the

equipment. Also submit these diagrams with the shop drawings.

F. Unless indicated otherwise on Drawings, smaller size controllers shall be mounted on unistrut frames secured to the floor, independent of equipment. Larger units designed for floor mounting shall be mounted on 4-inch concrete housekeeping pads.


A. Each controller shall be started up under the supervision of the manufacturer’s representative. Start-up services shall consist of an initial start-up programming and check out of the controller for proper operation. After initial start-up, the representative shall meet with and work with the Temperature Control Contractor as part of commissioning the temperature control system. In addition to start-up services, the manufacturer’s representative shall provide a minimum of two four-hour training classes at the Site for University operation, maintenance and servicing. The University shall be permitted to video tape these classes for future reference.



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Electrical General Provisions

Section 26 00 10


SECTION 26 00 10 – ELECTRICAL GENERAL PROVISIONS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of a complete electrical system.

1.3 SYSTEM DESCRIPTION

A. Work Included: 1. This Division includes all labor, materials, and equipment, tools, supervision, start-up services,

Owner's instructions, including all incidental and related items necessary to complete installation and successfully test and start-up and operate in a practical and efficient manner all electrical work and systems indicated on Drawings and described in each Section of Division 26 and conforming with all Contract Documents.

2. This Section defines certain terms used in the Specifications and explains the language, abbreviations thereof, format and certain conventions used in the Specifications and associated Contract Documents.

3. The following are not intended to supersede but to clarify the definitions in the General Conditions, the Supplementary Conditions, and Division 01.

B. Site and Contract Documents Examination: Submission of a Bid is considered evidence Contractor has visited Site, examined Drawings and Specifications of all trades, and fully informed himself with all Project and Site conditions, and is proficient and experienced and knowledgeable of all standards, codes, ordinances, permits, and regulations which affect every trades' completion, cost and time required, and that all costs are included in his Bid.

C. Responsibility: 1. Contractor shall be responsible for all subcontractors and Suppliers, and include in his Bid and

apportion all materials, labor, and equipment to several trades involved in accordance with all local customs, rules, regulations, jurisdictional awards, decisions and secure compliance of all parts of Specifications and Drawings regardless of Sectional inclusion in these Specifications.

2. Each electrical subcontractor and sub-subcontractor shall be responsible for all parts applicable to his trade in accordance with Specifications and Drawings and for coordinating locations and arrangements of his work with all other relevant Specifications, Drawings, Shop Drawings, and details.

D. Demolition: 1. Contractor shall be responsible to remove and/or relocate any electrical equipment in conflict of new

construction. 2. Determination by Owner shall be made concerning all items to be removed from Project as to if Owner

shall keep or if Contractor is to remove from Site.

E. Drawings and Specifications: 1. Drawings and Specifications are intended to supplement each other and all work specified or indicated

in either shall be provided. 2. Drawings are diagrammatic and indicate general arrangement of systems and work included in

Contract and shall serve only as design drawings and not as working drawings for general layout of various equipment and systems. Drawings do not necessarily indicate every required junction box, pull box, off-set, mounting support, access panel, etc., which shall be provided as required.

3. Each Contractor shall examine all Drawings and Specifications of his trade and work of Drawings, Shop Drawings, and field layouts of all other trades on the Project, including Architectural, structural, mechanical and electrical. If any discrepancies occur between these various Drawings or between


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Section 26 00 10


these Drawings and these Specifications, he shall report same to Engineer in writing and obtain written instructions for changes in construction. Should interferences develop during construction which cannot be avoided, Engineer shall decide which work is to be relocated regardless of which was first installed. This work shall be done at no extra cost to Owner.

4. Should Drawings disagree in themselves or with Specifications, the better quality or greater quantity of work shall be provided.

5. All schedules on Drawings and Specifications are only for convenience of Contractor. Contractor shall make his own count and where fixtures or equipment are indicated on Drawings but not on schedule, provide like equipment or fixtures for like rooms or use.

6. Manufacturer's Model Number: a. Wherever on Drawings or in Specifications that a Manufacturer's catalog number or model or

type designation is made, it is intended as a general qualification and it is Contractor's responsibility before ordering, to determine the proper type or model with arrangement, mounting, and accessories applicable for each location on the Project.

b. Approval of Shop Drawings by Engineer will not obviate Contractor's responsibility. 7. Drawings shall not be scaled for measurement and shall not serve as Shop Drawings.

F. Definitions: 1. Furnish: Supply and deliver to Project Site, ready for unloading, unpacking, assembly, installation,

and similar subsequent requirements. 2. Install: Operations at Project Site including unloading, unpacking, assembly, erection, placing,

anchoring, applying, working to dimension, finishing, protection, cleaning, and similar requirements. 3. Provide: Furnish and install, complete and ready for intended use. 4. Minimum Requirements:

a. Indicated requirements are for a specific minimum acceptable level of quality and quantity as recognized in the industry. Actual work must comply, within specified tolerances, or may exceed minimums within reasonable limits.

b. Refer uncertainties to Engineer before proceeding. 5. Abbreviations, Plural Words:

a. Abbreviations, where not defined in Contract Documents, will be interpreted to mean the normal construction industry terminology determined by recognized grammatical rules by Engineer.

b. Plural words will be interpreted as singular and singular words will be interpreted as plural where applicable for context of Contract Documents.

c. "In conformity herewith" "shall be" "as noted or indicated on Drawings" "according to Drawings" "a" "the" "and" "all", etc., are omitted in places but shall be supplied by inference.

6. Raceway: Conduit, wireway, channels, boxes, fittings, hangers, supports, and items necessary or required in connection with or relating to raceway to provide a complete installation.

7. Concealed: Embedded in masonry or other construction below floor slabs, installed behind wall furring, within double partitions of hung ceiling, in trenches, tunnels or crawl spaces.

G. Substitution and Changes: 1. Substitutions and changes shall be in accordance with Division 01 for Product Substitution

Procedures. 2. When a material, method or product is listed by trade names or catalog number for one use, it is basis

of design. Other Manufacturers are listed as acceptable providing specific item is comparable with basis and intent of design.

3. Contractor and/or equipment supplier may propose other materials, methods or products of equal quality, function, durability, and appearance. Proof of equality must be submitted to Engineer at least 10 days prior to due date for Bids and, if approved, an Addendum naming the material or product so approved will be issued to all Bidders prior to Building. Acceptance and approval is responsibility of Engineer.

4. Contractor is liable for all added costs to himself or others and is responsible for verifying adequate available space for variations in dimensions, clearance, weight, and roughing-in requirements when product not named as basis of design is used and is responsible for advising all other trades of variations and, when requested shall submit revised drawing layout for approval of Engineer.


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Section 26 00 10



A. Qualifications: Compliance with standard codes and permits shall be in accordance with the General and Supplementary Conditions.

B. Regulatory Agencies Requirements: All work under Division 26 shall comply with latest edition of applicable standards and codes of following: 1. NEC (NFPA 70), National Electric Code. 2. AWS Standards for welding. 3. ANSI C2, National Electrical Safety Code. 4. ANSI C73, Dimensions of Attachment Plugs and Receptacles. 5. NECA Standards for installation. 6. NEMA Standards for materials and products. 7. ASTM American Society for Testing Materials. 8. ASA American Standards Association. 9. NFPA National Fire Protection Association. 10. UL Underwriters' Laboratories, Inc. 11. OSHA Occupational Safety and Health Act. 12. State and local Building Codes. 13. Americans With Disabilities Act (ADA).

C. All labor, materials, and equipment shall comply with all applicable: 1. City, county, and state laws, ordinances, codes, and regulations. 2. Applicable fire marshal's office. 3. Federal specifications.

D. Excess Quantities and Sizes: Where quantities, sizes or other requirements on Drawings or Specifications are in excess of code requirements, Drawings or Specifications govern.

E. Conflicts: When conflicts exist between referenced Specifications or standards, more stringent requirements govern. No extra compensation for such compliance allowed.

F. Notices and Payments: Contractor shall give all notices, file all Drawings, obtain necessary approvals, obtain all permits, pay all fees, deposit and expenses required for installation of all work under this Contract. Within 10 days after the contract award, Contractor shall show proof that permits have been obtained and fees paid.

G. Inspections and Certificate of Inspection: 1. No work shall be covered or enclosed until work is tested in accordance with applicable codes and

regulations and successful tests witnessed and approved by authorized inspection authority. 2. Provide to Engineer's office evidence that the installation has been inspected and approved by

authorized governmental inspector having jurisdiction over that phase of work involved.

H. UL Labels: In general, all material where applicable shall be labeled or listed by Underwriter's Laboratories, Inc.

1.5 COORDINATION OF ELECTRICAL WORK

A. Coordination: Advise other trades of openings required in their work for the subsequent move in of large units of electrical work (equipment).

B. Locations: Locate operating and control equipment properly to provide easy access and arrange entire electrical work with adequate access for operation and maintenance. Allow for clearance around equipment in accordance with NEC.


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Section 26 00 10


1.6 SUBMITTALS

A. General: Shop and installation drawings shall serve the purpose of checking Contractor's interpretations of the design Drawings and Specifications, aid in correlation and coordination of the various trades and be used by Contractor's field personnel as installation instructions. Rough-in and connections to equipment furnished by this Contractor or by other trades shall be according to Shop Drawings, furnished for this equipment. Contractor shall coordinate all his work with various other trades and check these Shop Drawings before installing services.

B. Schedule of Equipment and Subcontractors: 1. Submit to Engineer for a schedule of all equipment and materials on which Bid is based, including all

items being provided by all Subcontractors. 2. After schedule of Equipment and Subcontractors is approved, no deviation will be permitted without

written consent of Engineer.

C. Shop Drawings Include the following: 1. After schedule of Equipment and Subcontractor is approved, an electronic copy of Shop Drawings on

all equipment and materials. Shop Drawings shall be submitted bound and separated, forming booklets containing one drawing of each item. Mark clearly on the cover which project these drawings pertain to. Mark each drawing with the corresponding marking by which the item is listed on the Drawings.

2. Shop Drawing submittals shall include signatures of Contractor and electrical Subcontractor certifying they have inspected submittal as to substantial compliance with Contract Documents, space allowance for installation and service, and work of other trades. Submittals not complying with the above will be returned unchecked.

3. Submit complete Manufacturer's Shop Drawings of all equipment, accessories, and controls, including dimensions, weights, capacities, construction details, installation, operating, and maintenance instructions, controls and wiring diagrams; all applicable Manufacturers' warranties; and all details involving other trades.

4. Itemize required accessory items not specifically included in submittal being provided on separate submittal.

5. Submittals containing items not applicable to Project must be distinctly and completely identified. 6. General catalog cuts without detailed Engineering and installation details will not be accepted. 7. Engineer's approval of Shop Drawings is a service only and not considered as a guarantee of

compliance with or as relieving Contractor of basic responsibilities under Contract Documents and does not approve changes in time or cost.

8. After approval, Contractor shall provide information to all affected trades.

D. "As-Built" Drawings: Provide one set of redlined "as-built" drawings to Engineer at the completion of the project.

1.7 DELIVERY, STORAGE, HANDLING, AND PROTECTION

A. Deliver, storage, handling, and protection shall be in accordance with the General and Supplementary Conditions, and in accordance with each Division 26 Section.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Product Listing: 1. Prepare the product listing for electrical work, separately from the listing(s) of products for other work. 2. Include listing of each significant item of equipment and material used in the work and indicate the

generic name, product name, Manufacturer, model number, related specification section number(s), and estimated date for start of installation.

3. Materials such as conductors, conduit, and boxes taken from installer's stock need not be listed. 4. For principal equipment items, list the input/output ratings. 5. Submit list within 14 days of contract date.


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Section 26 00 10


B. Compatibility: 1. Provide products which are compatible with other products of the electrical work and with other work

requiring interface with the electrical work, including electrical connections and control devices. 2. For exposed electrical work, coordinate colors, and finishes with other work.

PART 3 - EXECUTION

3.1 CUTTING AND PATCHING

A. General: 1. Perform cutting and patching in accordance with Division 01 requirements, and this Section. 2. Except as individually authorized by Engineer, cutting and patching of electrical work to accommodate

the installation of electrical work is not permitted.

3.2 ELECTRICAL WORK CLOSE-OUT

A. General: Except as otherwise indicated in this Section, close-out shall be in accordance with Division 01 requirements for Closeout Procedures.

B. Coordination with Mechanical: 1. Coordinate close-out operations with close-out of mechanical systems and other power consuming

equipment. 2. Accurately record locations of conductors which are underground or otherwise concealed. 3. Test run electrical equipment in coordination with test runs of mechanical systems. 4. Clean and lubricate operational equipment. 5. Check all fuses and thermal overload units for proper sizing as per load, as determined in the field. 6. Instruct Owner's operating personnel thoroughly in the operation, sequencing, maintenance, and

safety/emergency provisions of the electrical systems. 7. Turn over the operations to Owner's personnel at the time(s) of Substantial Completion. 8. Until the time of final acceptance of the total Work of the Contract, respond promptly with consultation

and services to assist Owner's personnel with operation of electrical systems. END OF SECTION 26 00 10


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Common Work Results for Electrical

Section 26 05 00


SECTION 26 05 00 – COMMON WORK RESULTS FOR ELECTRICAL PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the following: 1. Electrical equipment coordination and installation. 2. Sleeves for raceways and cables. 3. Sleeve seals. 4. Grout. 5. Duct seal. 6. Common electrical installation requirements.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with 1. NECA 1 - Standards Practices for Good Workmanship in Electrical Construction. 2. NEC – National Electrical Code (NFPA 70)

1.4 DEFINITIONS

A. EPDM: Ethylene-propylene-diene terpolymer rubber.

B. NBR: Acrylonitrile-butadiene rubber.

1.5 SUBMITTALS

A. Product Data: For sleeve seals.


A. Deliver materials in original, unbroken, brand marked containers or wrapping as applicable.

B. Handle and store materials in a manner which will prevent deterioration, damage, contamination with foreign matter, and damage by weather or elements, and according to Manufacturer's directions.

C. Store materials indoors and protect from weather. When necessary to store outdoors, elevate materials above grade and enclose with durable, weathertight wrapping.

D. Reject damaged, deteriorated or contaminated material and immediately remove from the Site. Replace rejected materials with new materials at no additional cost to Owner.

1.7 COORDINATION

A. Coordinate arrangement, mounting, and support of electrical equipment: 1. To allow maximum possible headroom unless specific mounting heights that reduce headroom are

indicated. 2. To provide for ease of disconnecting the equipment with minimum interference to other installations. 3. To allow right-of-way for piping and conduit installed at required slope. 4. So connecting raceways, cables, wireways, cable trays, and busways will be clear of obstructions and

of the working and access space of other equipment.


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Section 26 05 00


B. Coordinate installation of required supporting devices and set sleeves in cast-in-place concrete, masonry walls, and other structural components as they are constructed.

PART 2 - PRODUCTS 2.1 SLEEVES FOR RACEWAYS AND CABLES

A. Steel Pipe Sleeves: ASTM A53/A53M, Type E, Grade B, Schedule 40, galvanized steel, plain ends.

2.2 GROUT

A. Nonmetallic, Shrinkage-Resistant Grout: ASTM C1107, factory-packaged, nonmetallic aggregate grout, noncorrosive, nonstaining, mixed with water to consistency suitable for application and a 30-minute working time.

PART 3 - EXECUTION

3.1 COMMON REQUIREMENTS FOR ELECTRICAL INSTALLATION

A. Comply with NECA 1 and NEC.

B. Headroom Maintenance: If mounting heights or other location criteria are not indicated, arrange and install components and equipment to provide maximum possible headroom consistent with these requirements.

C. Equipment: Install to facilitate service, maintenance, and repair or replacement of components of both electrical equipment and other nearby installations. Connect in a manner as to facilitate future disconnecting with minimum interference with other items in the vicinity.

D. Right of Way: Give to piping systems installed at a required slope.

3.2 SLEEVE INSTALLATION FOR ELECTRICAL PENETRATIONS

A. Electrical penetrations occur when raceways, cables, wireways, cable trays, or busways penetrate concrete slabs, concrete or masonry walls, or fire-rated floor and wall assemblies.

B. Use pipe sleeves unless penetration arrangement requires rectangular sleeved opening.

C. Fire-Rated Assemblies: Install sleeves for penetrations of fire-rated floor and wall assemblies unless openings compatible with firestop system used are fabricated during construction of floor or wall.

D. Cut sleeves to length for mounting flush with both surfaces of walls.

E. Size pipe sleeves to provide 1/4-inch annular clear space between sleeve and raceway or cable, unless otherwise indicated on the Drawings.

F. Seal space outside of sleeves with grout for penetrations of concrete and masonry. Promptly pack grout solidly between sleeve and wall so no voids remain. Tool exposed surfaces smooth; protect grout while curing.

G. Interior Penetrations of Non-Fire-Rated Walls and Floors: Seal annular space between sleeve and raceway or cable, using joint sealant appropriate for size, depth, and location of joint.

H. Fire-Rated-Assembly Penetrations: Maintain indicated fire rating of walls, partitions, ceilings, and floors at raceway and cable penetrations. Install sleeves and seal raceway and cable penetration sleeves with firestop materials.

I. Roof-Penetration Sleeves: Roof penetrations shall be made using EMT, IMC, and RMC. Seal all penetrations of individual raceways with flexible boot-type flashing units applied in coordination with roofing work.


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Section 26 05 00


3.3 SLEEVE-SEAL INSTALLATION

A. Install to seal exterior wall penetrations.

B. Use type and number of sealing elements recommended by manufacturer for raceway or cable material and size. Position raceway or cable in center of sleeve. Assemble mechanical sleeve seals and install in annular space between raceway or cable and sleeve. Tighten bolts against pressure plates that cause sealing elements to expand and make watertight seal.



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Conductors and Cables – 600V and Below

Section 26 05 20

Z:\2012\120270CD\WORK\SPECS\BID SET\26_05_20.DOCX

26 05 20 – 1

SECTION 26 05 20 – CONDUCTORS AND CABLES – 600V AND BELOW PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all electrical conductors, cables, splices, and connectors.

B. Major Systems Include: 1. 600V and below service entrance, feeders and electrical distribution. 2. Branch circuit wiring. 3. System wiring.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the standards of the following organizations as applicable to materials, construction and testing of wire cables: 1. NEMA - National Electrical Manufacturer Association Standards. 2. IEEE Standards. 3. Insulated Cable Engineers Association - Standards. 4. ASTM Standards. 5. NEC - National Electric Code


A. Fabrication and Installation Personnel Qualifications: 1. Trained and experienced in the fabrication and installation of the materials and equipment. 2. Knowledgeable of the design and the reviewed submittals.

B. Manufacturers: Firms regularly engaged in the manufacture of electrical conductor and cable products of the types and ratings required, whose products have been in satisfactory use in similar service for not less than 5 years.


A. Deliver all materials in original, unbroken, brand marked containers or wrapping as applicable.





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Section 26 05 20


26 05 20 – 2

PART 2 - PRODUCTS

2.1 MATERIALS

A. General: Except as otherwise indicated, provide conductors, cables, and connectors of Manufacturer's standard materials, as indicated by published product information; designed and constructed as recommended by the Manufacturer and as required for the installation.

B. Power Wire: 1. All conductors and cables shall be new with a minimum wire size of No. 12 AWG. Manufacturer's

name, type, and size shall be permanently marked on the outer covering at regular intervals and delivered in complete coils or reels.

2. Provide factory fabricated conductors of size, rating, material, and type as indicated for each service. Where not indicated, provide proper selection as determined by installer to comply with installation requirements and with NEC standards, from only following types and conductors: a. Type THHN/THWN, 600 Volt, 75/90 Degrees C Rated with Nylon Jacket: Stranded copper for all

sizes. b. Bare Conductors: Stranded copper for all sizes.

C. Control Cable: No. 14 AWG minimum, type THHN/THWN.

D. Power Wiring Cable Accessories: For Connectors: 1. Wing nuts by Ideal. 2. Stan-Kon by Thomas & Betts. 3. Scotchlox Spring by Minnesota Mining & Manufacturing Company. 4. Compression Type 53200 by Thomas & Betts. 5. Hydent by Burndy. 6. Insulated multi-cable mechanical connector blocks by Polaris, or Ilsco.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install electrical conductors, cables, and connectors as indicated on the Drawings, in accordance with

the Manufacturer's written instructions, the applicable requirements of NEC and the National Electrical Contractors Association's "Standard of Installation," and in accordance with recognized industry practices to ensure that products serve the intended functions.

2. Conductors and cables shall be sized in accordance with the Drawings or, in the absence thereof, in accordance with NEC requirements. Except and indicated herein, conductor sizes greater than No. 12 AWG are indicated on the Drawings.

B. Voltage Drop Compensation: 1. Provide No. 10 AWG conductors in lieu of No. 12 AWG conductors to compensate for voltage drop as

follows: a. For each 277V, 20 ampere branch circuit that exceeds 200 feet in length between the branch

circuit panelboard and the last outlet. b. For each 120V, 20 ampere branch circuit that exceeds 100 feet in length between the branch

circuit panelboard and the last outlet. 2. When conductor size is increased to compensate for voltage drop, provide equipment grounding

conductor increased in size in accordance with NEC.

C. Installation Procedures: 1. Install interior conductors after building is enclosed and water tight. 2. Each conduit shall be free of moisture and debris before conductors are installed. 3. Remove moisture from conduits by swabbing. 4. Install conductors so insulation is not damaged. Replace all conductors that are damaged. 5. Install conductors and cables only in code conforming raceway.


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Section 26 05 20


26 05 20 – 3

6. Pull conductors together where more than 1 conductor is being installed in a raceway. 7. Use manufacturer-approved pulling compound or lubricant, where necessary. Compound shall not

deteriorate conductor and insulation. Compounds shall be UL listed. 8. Use a pulling means, including fish tape, cable or rope, and basket-weave wire/cable grips, that will

not damage the raceway or the wire. 9. Keep conductor splices to a minimum. 10. Install splices and taps which have equivalent or better mechanical strength and insulation as the

conductor. 11. Use splice and tap connectors which are compatible with the conductor material. 12. Make all joints, splices, and connections only at accessible junction or outlet boxes, never inside

conduit or fitting. Make splices in No. 10 AWG and smaller wire with insulated spiral mechanical connectors.

13. Make splices in No. 8 AWG and larger copper wire with compression type mechanical connectors. 14. Insulate all joints at splices with "Scotch" brand electrical pressure sensitive tape to 150% of conductor

insulation value. 15. Make conductor length for parallel feeds identical. 16. Where exposed cables are installed, cables shall be installed parallel and perpendicular to exposed

structural members and building lines. 17. Do not lace, strap or tie feeder or branch circuit conductors together in panels, switchboards, variable

speed drives, motor control centers, automatic transfer switches, boxes, and wireways. 18. Feeders and service entrance conductors entering electrical equipment shall be adequately secured

with cable cleats. 19. Use color coded conductors as follows:

a. Phases: Black-red-blue (under 150V to ground). b. Phases: Brown-orange-yellow (over 150V to ground). c. Neutral: White identified (feeders); White (branch circuits). d. Ground: Green identified (feeders); Green (branch circuits).

20. Support conductors in vertical raceways in accordance Division 26 Section “Hangers and Supports for Electrical Systems.”


A. General: 1. Prior to energization, check conductors and cables for continuity of circuitry and for short circuits.

Correct malfunctions when detected. 2. Subsequent to conductor and cable hook-ups, energize circuitry and demonstrate functioning in

accordance with requirements. END OF SECTION 26 05 20


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Grounding and Bonding

Section 26 05 27


SECTION 26 05 27 – GROUNDING AND BONDING PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of a complete and continuous grounding system.


A. All equipment, raceway systems, interior wiring systems with neutrals, receptacles, and power outlets, motors and motorized equipment shall be grounded.


A. Fabrication and Installation Personnel Qualifications: 1. Trained and experienced in the fabrication and installation of the materials and equipment. 2. Knowledgeable of the design.

B. Grounding system shall be in accordance with the current National Electrical Code.

C. Grounding system rods, connectors and clamps shall be UL labeled.

PART 2 - PRODUCTS

2.1 MATERIALS

A. General: A portion of the required materials for grounding systems are specified in the Division 26 – Electrical Sections.

PART 3 - EXECUTION

3.1 POWER SYSTEM GROUNDING

A. Connect grounding conductors to all component grounding points and to the service entrances.

3.2 DISTRIBUTION SYSTEM GROUNDING

A. Circuit Grounding: Install grounding bushings, grounding studs, and grounding jumpers at distribution centers, pull boxes, motor control centers, and panelboards.

B. Bonding Jumpers: 1. Provide green insulation, size correlated with overcurrent device protecting the wire, attached to

grounding bushings on conduits, to lugs on boxes, and other enclosures. 2. Bond to neutral only at service neutral bar.

C. FMC and LTFMC: Install separate grounding conductor in FMC and LTFMC. Connect each end to a grounding bushing.

D. Receptacles and Power Outlets: Ground receptacles and power outlets to the conduit system with a Type THHN green grounding conductor sized in accordance with NEC Article 250 and connected between the device grounding screw and outlet box.


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Grounding and Bonding

Section 26 05 27


E. Metallic Conduit: When grounding conductors are enclosed in metallic conduit, the conduit shall be bonded to the grounding conductors at both ends.

F. Nonmetallic Conduit: Install separate ground conductor in conduit runs.

G. Ground motor bases and frames by pulling a separate conductor in with the motor feeder.

H. Expansion Joints: Install a bonding jumper around expansion fittings in metallic conduit to maintain ground continuity.


A. Tests: 1. Measured resistance of grounding electrode system to ground shall be 5 Ohms or less. Perform Earth

Ground Resistance (Fall of Potential) tests and provide additional grounding electrodes to grounding electrode system until measured resistance to ground is 5 ohms or less.

2. Transmit test results to Engineer. END OF SECTION 26 05 27


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Hangers and Supports for Electrical Systems

Section 26 05 29


26 05 29 – 1

SECTION 26 05 29 – HANGERS AND SUPPORTS FOR ELECTRICAL SYSTEMS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of the hangers and supports for electrical equipment and systems.

1.3 DEFINITIONS

A. Electrical Supports: Angles, channels, brackets, and mounting accessories for supporting all conduit, luminaires, switches, and other electrical equipment which are hung or mounted above floor.


A. This Section defines general criteria for the selection and installation of supporting devices, but does not cover all types specifically required for the Project.

B. Choose or design supporting devices in accordance with these general criteria.



B. Regulatory Agencies Requirements: 1. Provide supporting devices listed by Underwriters' Laboratory for their application as installed. 2. Comply with National Electrical Code (NFPA 70) as applicable to construction, installation, and

requirements for supporting devices. 3. Comply with seismic-restraint requirements in the applicable building code.

1.6 DELIVERY, STORAGE, AND HANDLING


B. Handle and store materials in a manner which will prevent deterioration or damage, contamination with foreign matter, damage by weather or elements, and in accordance with Manufacturer’s directions.


D. Reject damaged, deteriorated, or contaminated material and immediately remove from the Site. Replace rejected materials with new materials at no additional cost to Owner.


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Hangers and Supports for Electrical Systems

Section 26 05 29


26 05 29 – 2

PART 2 - PRODUCTS

2.1 MATERIALS

A. Conduit Supports: 1. Single Runs: Galvanized conduit straps or ring bolt type hangers with spring clips. Do not use

plumber’s perforated straps. 2. Vertical Runs: Channel support with conduit fittings. 3. Manufacturers:

a. Cooper B-Line; a division of Cooper Industries b. ERICO International Corporation. c. Allied Support Systems; Power-Strut Unit. d. GS Metals Corp. e. Michigan Hanger Co., Inc.; O-Strut Div. f. National Pipe Hanger Corp. g. Thomas & Betts Corporation. h. Unistrut; Tyco International, Ltd. i. Wesanco, Inc. j. Or equal.

B. Mounting, Anchoring, and Attachment Components 1. Mechanical-Expansion Anchors: Insert-wedge-type, zinc-coated steel, for use in hardened Portland

cement concrete with tension, shear, and pullout capacities appropriate for supported loads and building materials where used.

2. Powder-Actuated Fasteners: Threaded-steel stud, for use in hardened Portland cement concrete, steel, or wood, with tension, shear, and pullout capacities appropriate for supported loads and building materials where used.

3. Manufacturers: a. Hilti, Inc. b. ITW Construction Products. c. MKT Fastening, LLC. d. Or equal.

C. Supports for Conductors in Vertical Conduit: 1. Install in compliance with NEC article 300.19. 2. Factory-fabricated assembly consisting of threaded body and insulating wedging plug or plugs for non-

armored electrical conductors or cables in riser conduits. Plugs shall have number, size and shape of conductor gripping pieces as required to suit individual conductors or cables supported. Body shall be malleable iron.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Layout to maintain headroom, neat mechanical appearance, and to support equipment loads. 2. Secure Engineer's approval before welding or bolting to steel framing or anchoring to concrete

structure. 3. Where equipment is to be suspended from cast-in-place concrete construction, set approved concrete

inserts in formwork to receive hanger rods. Where equipment is to be suspended from metal deck and beam or joist construction, support equipment from beams or joists only.

4. Install seismic restraint components and assemblies as required by applicable building code. END OF SECTION 26 05 29


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Raceways for Electrical Systems

Section 26 05 34


SECTION 26 05 34 – RACEWAYS FOR ELECTRICAL SYSTEMS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of conduits and fittings for electrical wiring.


A. Fabrication and Installation Personnel Qualifications: 1. Trained and experienced in the fabrication and installation of the materials and equipment. 2. Knowledgeable of the design.

B. Regulatory Agencies Requirements: 1. ACI – American Concrete Institute – Standards pertaining to conduits embedded in concrete (Section

6.3 in ACI 318 – Building Code Requirements for Structural Concrete and Section 6.3 in ACI 350R – Environmental Engineering Concrete Structures.)

2. NEMA – National Electrical Manufacturer's Association – Standards pertaining to raceways. 3. NEC – National Electric Code – As applicable to construction and installation of conduit system. 4. Provide conduit which is listed and labeled by Underwriters' Laboratories.



B. Handle and store materials in a manner which will prevent deterioration or damage (e.g., bending, end damage, finish scoring), contamination with foreign matter, damage by weather or elements, and in accordance with Manufacturer's directions.

C. Store materials indoors and protect from weather. When necessary to store outdoors, elevate materials above grade and enclose with durable, watertight wrapping. Provide color coded end cap thread protectors on exposed threads of threaded metal conduit.

D. Reject damaged, deteriorated, or contaminated material and immediately remove from the Site. Replace rejected materials with new materials at no additional cost to Owner.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Rigid Steel Conduit (RSC): Galvanized steel, heavy wall conduit with threaded fittings, 1/2-inch trade size minimum, insulated bushings.

B. Intermediate Metal Conduit (IMC): Galvanized steel, reduced wall conduit with threaded fittings, 1/2-inch trade size minimum, insulated bushings.

C. Electrical Metallic Tubing (EMT): 1. Thin wall, hot galvanized, steel tubing, 1/2-inch trade size minimum with insulated throat steel

connector. 2. Fittings: Steel setscrew type (die cast fittings are expressly prohibited).


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Section 26 05 34


D. Flexible Metal Conduit (FMC): 1/2-inch trade size minimum with galvanized steel flexible conduit insulated throat steel connectors.

E. Liquid Tight Flexible Metal Conduit (LTFMC): 1/2-inch trade size minimum. galvanized steel flexible conduit with flexible, moisture-proof PVC jacket and liquid tight connectors. 1. In Corrosive Locations, LTFMC fittings shall be PVC coated.

F. Joint Compound for RSC and IMC: Listed for use in cable connector assemblies, and compounded for use to lubricate and protect threaded raceway joints from corrosion and enhance their conductivity.

G. Conduit Hubs for RSC and IMC: 1. Suitable for environment served. 2. Grounding screw. 3. O-ring gasket. 4. Material: Malleable Iron with zinc electroplate. 5. Manufacturer:

a. Cooper Myers Hubs. b. Thomas & Betts. c. Killark.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Unless otherwise specified or indicated on the Drawings, conceal conduit to the extent possible.

B. Exposed conduit permitted in: 1. Boiler Room. 2. Service equipment rooms. 3. Rooms without finished ceilings (overhead only). 4. Unfinished rooms.

C. Install conduit products in accordance with: 1. The Drawings. 2. The Manufacturer's written instructions. 3. Applicable requirements of NEC and National Electrical Contractors Association's "Standard of

Installation." 4. Recognized industry practices to ensure that products serve intended function.

D. Conduit Joints: Cut square, reamed smooth and drawn up tight.

E. Threaded Conduit Joints, Exposed to Wet, Damp, Corrosive or Outdoor Conditions: Apply listed compound to threads of raceway and fittings before making up joint. Follow compound manufacturer’s written instructions.

F. Bends: 1. Number per run for conduit that support feeder and branch circuits: Do not exceed the equivalent of 4

quarter bends (360 degrees) between pull points. 2. Number per run for conduit that supports data/communications cabling: Do not exceed the equivalent

of 2 quarter bends (180 degrees) between pull points. 3. Make bends and offsets so as not to reduce the inner diameter of the conduit. 4. To the extent possible, avoid using large junction boxes as 90 degree junctions.

G. Routing: 1. Concealed Conduits: Run in a direct line with long sweep bends and offsets. 2. Exposed Conduits: Run parallel to, and at right angles to, building lines. 3. Run continuous from outlet to outlet and from outlets to cabinets, pull or junction boxes. 4. Secure to all boxes and cabinets with locknuts and bushings in such a manner that each system is

electrically continuous throughout.


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Section 26 05 34


H. Cap conduit ends to prevent entrance of foreign materials during construction.

I. Provide insulated bushings on all threaded conduit run terminations and where entering the bottom of open-bottom switchboards, motor control centers, transformers, primary switches, and similar equipment.

J. Where entering the bottom of open-bottom equipment (i.e., switchboards, panelboards, motor control centers, transformers, and similar equipment) conduit shall not be installed flush with the floor/equipment pad and shall not rise more than 3 inches above the bottom of the enclosure.

K. Conduit entering control panels shall not obstruct internal components and shall allow for neat and workmanlike wire management.

L. Completely install all conduit systems before installing conductors.

M. Provide listed sealant in underground and above grade conduit that is exposed to temperature differences to prevent the passage of air and condensation.

N. Support:

1. Adequately support conduit from structural elements of the building. 2. Do not drill or tap structural building steel without approval from Engineer. 3. Do not rest conduit on, nor support it from, ceiling suspension systems, ceiling tiles or mechanical

equipment including, but not necessarily limited to ductwork and fans. 4. Conduit shall be supported in accordance with the NEC and Division 26 Section “Hangers and

Supports for Electrical Systems.”

O. Provide conduit expansion couplings where conduits cross building or structure expansion joints.

P. Install pull wires in empty raceways. Use polypropylene or monofilament plastic line with not less than 200 pound (90 kg) tensile strength. Label and leave at least 12 inches of slack at each end of pull wire.

Q. FMC and LTFMC Installation: 1. Provide separate grounding conductor in accordance with Division 26 Section “Grounding and

Bonding.” 2. Connection to light fixtures shall not exceed 6 feet in length within an accessible ceiling and 3 feet in

length where exposed. Connection to solenoids, pressure switches, motors, fans, HVAC equipment, and similar equipment shall not exceed 3 feet in length.

R. Firestopping: Firestop penetrations of fire rated barriers in accordance with University standards.

3.2 CONDUIT SCHEDULE

A. Feeders, Branch Circuits and System Conduits: 1. Above Slab or Grade:

a. Exposed Conduit Below 10'-0" AFF: RSC or IMC where subject to physical damage. EMT where not subject to physical damage.

b. Exposed Conduit Above 10'-0" AFF: EMT. c. Concealed In Walls: EMT. d. Concealed Above Ceiling: EMT. e. Exposed Conduit Serving Roof Mounted Equipment: RSC, IMC, EMT. f. Wet Locations: RSC or IMC.

B. Connection To Equipment: 1. Lighting Fixtures and Control Devices (including, but not necessarily limited to solenoids, pressure

switches, and field instruments): a. Dry Locations: FMC. b. Wet or Damp Locations: LTFMC.


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Section 26 05 34


2. Vibrating Equipment (including, but not necessarily limited to motors and transformers): a. Motors:

1) Dry Locations: FMC. 2) Wet or Damp Locations: LTFMC.

b. Equipment Mounted On Vibration Isolators:: 1) Dry Locations: FMC. 2) Wet or Damp Locations: LTFMC.

C. Provide separate raceway systems for: 1. Normal power wiring. 2. Low voltage signal and control wiring.



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Boxes for Electrical Systems

Section 26 05 35


SECTION 26 05 35 – BOXES FOR ELECTRICAL SYSTEMS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all electrical boxes and the major items listed below: 1. Outlet boxes. 2. Junction boxes. 3. Pull boxes.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. NEMA - National Electrical Manufacturer's Association: Standards as applicable to nonmetallic fittings

for underground installation. 2. NECA - National Electrical Contractor's Association's: Applicable portions of "Standard of Installation".



B. Regulatory Agencies Requirements: 1. Provide boxes which are listed and labeled by Underwriters' Laboratories. 2. NEC - National Electrical Code (NFPA 70) - As applicable to construction and installation of electrical

boxes.






PART 2 - PRODUCTS

2.1 MATERIALS

A. Interior Outlet Boxes: Galvanized steel outlet boxes of the type, shape, and size, including depth of box, to suit each respective location and installation; constructed with stamped knockouts in back and sides, and with threaded holes with screws for securing box covers or wiring devices.


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Boxes for Electrical Systems

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B. Interior Outlet Box Accessories: 1. As required for each installation, including mounting brackets, wallboard hangers, extension rings,

fixture studs, cable clamps, and metal straps for supporting outlet boxes. Accessories shall be compatible with outlet boxes being used and meet the requirements of individual wiring situations.

2. Choice of accessories is installer's option.

C. Surface Mounted: 4-inch square.

D. Junction and Pull Boxes: Sheet steel junction and pull boxes, with screw-on covers; of the type and shape and size to suit each respective location and installation; with welded seams and equipped with stainless steel nuts, bolts, screws, and washers. Dry interior location boxes shall have baked enamel finish. Damp location and exterior boxes shall have galvanized finish.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install electrical boxes as indicated, in compliance with NEC requirements and in accordance with the

Manufacturer's written instructions and recognized industry practices to ensure that the boxes and fittings serve the intended purposes.

2. Provide weatherproof outlet boxes for interior and exterior locations exposed to weather or moisture. 3. Provide knockout closures to cap unused knockout holes where blanks have been removed. 4. Locate boxes and conduit bodies so as to ensure accessibility of electrical wiring. 5. Secure boxes rigidly to the substrate upon which they are being mounted, or solidly embed boxes in

concrete or masonry. 6. Mount outlet boxes flush in areas other than mechanical rooms, electrical rooms, and above

removable ceilings. 7. Adjust position of outlets in finished masonry walls to suit masonry course lines. 8. Do not install boxes back-to-back in same wall. Coordinate cutting of masonry walls to achieve neat

openings for boxes. 9. Do not use sectional or handy boxes unless specifically requested. 10. For boxes mounted in exterior walls install insulation behind outlet boxes to prevent condensation in

boxes. 11. For outlets mounted above counters, benches, and splashbacks, coordinate location and mounting

heights with built-in units. Adjust outlet mounting height to agree with required location for equipment served.

12. Outlet boxes in finished areas shall be located as indicated on the Drawings and so set that the face plates will be flush with the finish on which it is mounted. Where 2 or more devices of any kind are set side by side, set them in gang boxes unless otherwise noted on the Drawings.

13. Locate pull boxes and junction boxes above removable ceilings or in electrical rooms, utility rooms, or storage areas such that boxes will be accessible after completion of building.

14. All boxes shall have covers installed at completion of construction. END OF SECTION 26 05 35


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Identification for Electrical Systems

Section 26 05 53


SECTION 26 05 53 – IDENTIFICATION FOR ELECTRICAL SYSTEMS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of proper identification for electrical system components.

B. Items requiring identification or labeling include: 1. Cables and conductors. 2. Conduit systems. 3. Controls:

a. Motor starters. b. Variable frequency drives. c. Boiler emergency shutdown push button.

4. Distribution Equipment: a. Disconnect switches. b. Panelboards.

1.3 SUBMITTALS

A. Nameplate schedule identifying each device to be labeled and project specific label text.

PART 2 - PRODUCTS

2.1 ELECTRICAL LABELS

A. Provide engraved laminated plastic nameplate to identify each piece of electrical equipment: 1. Nameplate shall have 3/8-inch minimum black letters on a white background. 2. Punched or drilled for mechanical fasteners.

B. Provide printed labels by Brady or T&B to identify conductors.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Attach nameplates directly to each piece of electrical equipment. In finished areas of building, install

nameplates behind enclosure door where possible. 2. Where several conductors pass through a pull box, junction box, or enclosure, provide wire labels.

Group wires before labeling.

B. Cables and Conductors: In accordance with Division 26 Section “Conductors and Cables – 600V and Below.”

C. Conduit Systems: 1. Junction boxes used for fire alarm system wiring shall be red. 2. Provide label inside each junction and pull box identifying circuit numbers for all conductors contained

inside the box. Labeling shall be printed neatly with permanent, waterproof, black ink marker.


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Identification for Electrical Systems

Section 26 05 53


D. Controls: For each of the following control devices, provide label attached to enclosure cover. Label shall identify: 1. Motor Starters: Name of equipment served and load (example, “EF-5, 5 HP). 2. Variable Frequency Drives: Name of equipment served and load (example, “P-1, 25 HP”.

E. Distribution Equipment: For each of the following pieces of distribution equipment, provide label attached to enclosure cover. Label shall identify: 1. Disconnect Switches: Name of equipment served, number of poles, ampere rating/fuse size (where

applicable), and load (example, “RTU-1, 3P30/25, 8 TON”). 2. Panelboards:

a. Name of device as indicated on one line diagram, voltage-phase, and area served (example, “LPA, 208Y/120V-3Ø, First Floor Lighting”).

b. Equip interior of enclosure door with a circuit directory frame, typewritten card, and clear plastic cover. Directory shall identify load description for each circuit, including spares. Hand lettering is not acceptable.



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Panelboards

Section 26 24 16


SECTION 26 24 16 – PANELBOARDS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all panelboards.

B. Division of Work: 1. In accordance with the General Conditions, Contractor is responsible for dividing the Work among the

Subcontractors and Suppliers and for delineating the work to be performed by specific trades.

1.3 SUBMITTALS

A. Shop Drawings: For panelboards. 1. Name of Manufacturer. 2. Model number. 3. Details of construction and installation. 4. Assembly drawings, including elevations, plans, sections, dimensions, weight, and conduit entry

locations. 5. Electrical Ratings:

a. Voltage. b. Amperage. c. Interrupt rating. d. Enclosure type.

6. Color and finish. 7. Project specific one line diagram. 8. Options and accessories.

B. Installation Instructions: For panelboards.

C. Operation and Maintenance Manuals: For panelboards. 1. Equipment function, normal operating characteristics, and limiting conditions. 2. Assembly, installation, alignment, adjustment, and checking instructions. 3. Operating instructions for start-up, routine and normal operating, regulation and control, shutdown,

and emergency conditions. 4. Maintenance instructions. 5. Guide to “troubleshooting.” 6. Parts list and predicted life of parts subject to wear. 7. Project specific outline and cross sections, assembly drawings, engineering data, and wiring diagrams. 8. Test data and performance curves.



B. All panelboards and accessories shall bear the UL label.




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Panelboards

Section 26 24 16





PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. 240/120 V AC Maximum: 1. Square D Company: NQ. 2. Cutler Hammer: Pow-R-Line 1. 3. General Electric: AQ. 4. Siemens Energy and Automation: Sentron S1.

B. All panelboards shall be products of the same Manufacturer.

2.2 MATERIALS

A. General: 1. All panelboards shall have plated copper bus bars and full-sized neutral bar. 2. Bussing shall meet UL Standard 67 for maximum heat rise. 3. Bussing Type: Distributed phase.

B. Circuit Breaker Panels: 1. Automatic circuit breaker type with individual breaker unit for each circuit, interchangeable, and

removable without disturbing adjacent units. 2. Complete front trim with door and flush lock, with 2 keys. 3. Cabinets and fronts shall meet UL Standards for gutter space and material gage. 4. All panelboards shall have common keying. 5. All panels shall have a circuit directory frame with plastic cover and card mounted inside cover. 6. Flush mounted double tub panels in finished areas shall have a common front cover. 7. Panel shall have electrical rating as indicated on the Drawings. 8. Flush mounted panelboards shall have cover flange to overlap cabinet. 9. Finish panels in gray enamel over rust inhibitor primer. 10. Load centers not allowed unless noted otherwise.

C. Short-Circuit Rating: Provide a single integrated rating of each panelboard certifying capability of withstanding fault stresses equal to the lowest interrupting rating of any overcurrent protective device contained in the panelboard.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine the areas and conditions under which panelboards and enclosures are to be installed and notify Engineer in writing of conditions detrimental to the operation or the proper and timely completion of the work.

3.2 INSTALLATION

A. Anchoring: 1. Anchor enclosures firmly to walls and structural surfaces, ensuring that they are permanently and

mechanically secured. 2. Locate top of enclosures approximately 6'-0" above floor, at a masonry joint if applicable.


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Panelboards

Section 26 24 16


3. Mount free-standing distribution panels on 6-inch high concrete pads with 1-inch chamfered edges. 4. Install all flush mounted panelboards with 1-1/2-inch conduit stubbed from panel to ceiling space.

B. Directories: 1. Fill out the enclosures circuit directory card upon completion of work and install in lighting panels and

branch circuit panels. 2. Lettering:

a. Typewritten. b. Hand lettering will not be acceptable.

C. Panel Identification: In accordance with Division 26 Section “Identification for Electrical Systems.” END OF SECTION 26 24 16


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Wiring Devices

Section 26 27 26


SECTION 26 27 26 – WIRING DEVICES PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all wiring devices and the major items listed below: 1. Receptacles. 2. Switches. 3. Wall plates. 4. Plugs. 5. Connectors. 6. Box covers.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. NEMA - National Electrical Manufacturer's Association - Standards for general and specific purpose

wiring devices WD-1, WD-5. 2. Federal Specifications WC-596 and WS-896. 3. Underwriter Laboratories (UL) Standard 498.

1.4 SUBMITTALS

A. Shop Drawings: For wiring devices. 1. Name of Manufacturer. 2. Model number. 3. Details of construction and installation. 4. Electrical specifications and ratings. 5. Dimensional data. 6. Color and finish.


A. Regulatory Agencies Requirements: 1. NEC - National Electrical Code (NFPA 70) as applicable to construction and installation of electrical

wiring devices. 2. UL Labels. Provide wiring devices which have been tested and are listed and labeled by Underwriters'

Laboratories.







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Wiring Devices

Section 26 27 26


PART 2 - PRODUCTS

2.1 WIRING DEVICES

A. General: 1. Provide factory-fabricated wiring devices in type, color, and electrical rating as indicated below. 2. Where type and grade are not indicated, proper selection shall be determined by installer to fulfill the

wiring requirements and to comply with NEC and NEMA standards for wiring devices.

B. Manufacturers: Provide equal products by one of the following Manufacturers for switches and receptacles specified: 1. Cooper Wiring Devices 2. Leviton. 3. Hubbell, Inc. 4. Pass and Seymour, Inc. 5. Bryant Electric, Inc.

C. Switches: 1. Switch Rating: 20 amp, 120/277V, specification grade, quiet operating. 2. Switch Provisions: Back and side wiring. 3. Device Color: Ivory. 4. Manufacturer: Hubbell HBL1220.

D. Convenience Receptacles: 1. Ratings: 15 amp, 125V, industrial, heavy duty specification grade. 2. Provisions: Back and side wiring, grounding screw. 3. Wraparound Mounting Strap: 260 brass, 0.05-inch thick. 4. Device Color: Ivory. 5. Manufacturer: Hubbell 5262.

E. Wall Plates: 1. Number: Provide a single switch or duplex outlet wall plate for wiring devices grouped at each

location. 2. Attachment: Provide metal screws for securing plates to devices, screw heads colored to match finish

of plate. 3. Construction:

a. Steel: Hot dip galvanized, 1.25 ounce per square foot minimum. 4. Plate Application:

a. Surface Mounted Devices In Unfinished Process Spaces: Galvanized steel, plastic, stainless steel.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install wiring devices in accordance with:

a. The Drawings. b. Manufacturer's written instructions. c. Applicable requirements of NEC and National Electrical Contractors Association's "Standard of

Installation". d. Recognized industry practices to ensure that products serve intended function.

2. Delay installation of devices until wiring is completed. 3. Install receptacles and switches only in electrical boxes which are clean and free from excess building

materials and debris.

B. Switches: 1. Install as indicated on the Drawings to control lights as indicated. 2. Where more than 1 wall switch is installed in same location, set under 1 cover plate.


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Wiring Devices

Section 26 27 26


C. Receptacles: 1. Locate approximately as indicated on the Drawings, long dimension vertical, with grounding pole at

top. 2. Centerline generally at 18 inches above floor on a tile or block joint unless otherwise indicated on the

Drawings. When mounting height exceeds 27 inches above floor, mount horizontally with grounding pole at left.

3. Refer to mechanical Drawings for coordination with mechanical equipment, radiation, fin tube, grilles, and diffusers.

4. Provide bonding jumper from outlet to box.

D. Wall Plates: 1. Install coverplates on all wiring devices. 2. Plate shall cover entire wall opening.


A. Testing: Test wiring devices to ensure electrical continuity of grounding connections, and test after energizing circuitry, to demonstrate compliance with requirements.

3.3 PROTECTION OF WALL PLATES AND RECEPTACLES

A. Upon installation of wall plates and receptacles, advise Subcontractors regarding proper and cautious use of convenience outlets. At time of Substantial Completion, replace those items which have been damaged, including those burned and scored by faulty plugs.



/1

Low Voltage Circuit Protective Devices

Section 26 28 00


SECTION 26 28 00 – LOW VOLTAGE CIRCUIT PROTECTIVE DEVICES PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all low voltage circuit protective devices: 1. The types of low voltage circuit protective devices required for the Project and specified in this Section

include the following: a. Fuses. b. Circuit breakers.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. UL 489 – Molded Case Circuit Breakers. 2. NEMA AB1 – Molded Case Circuit Breakers. 3. NEMA 250 – Enclosures for Electrical Equipment. 4. NFPA 70 – National Electrical Code.

1.4 SUBMITTALS

A. Manufacturer’s literature for each type of low voltage circuit protective device furnished to include: 1. Name of Manufacturer. 2. Model. 3. Time-current curves. 4. Interrupt ratings. 5. NEC class. 6. Details of construction and installation. 7. Options and accessories.

B. Installation Instructions: For low voltage circuit protective devices.

C. Operation and Maintenance Manuals: For low voltage circuit protective devices. 1. Equipment function, normal operating characteristics, and limiting conditions. 2. Assembly, installation, alignment, adjustment, and checking instructions. 3. Operating instructions for start-up, routine and normal operating, regulation and control, shutdown,




B. Provide fuses and circuit breakers which have been tested, listed, and labeled by Underwriters’ Laboratory.


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Low Voltage Circuit Protective Devices

Section 26 28 00







PART 2 - PRODUCTS

2.1 FUSES

A. General: Provide fuses manufactured by Bussmann, Inc. as required for all motor starters, fused disconnect switches, and other equipment requiring fuse protection as indicated on the Drawings, or in absence thereof, as selected by the installer to meet the specific electrical requirements of the equipment being served. Select only from the following: 1. Dual element plug fuses, 0-30 ampere, 150 volt, 10,000 ampere interrupting rating: Buss "Fusetron". 2. Dual element fuse, 0-600 ampere, 250 or 600 volt, 200,000 ampere interrupting rating, Type R-K5:

Buss "Fusetron". 3. 601 amperes and above, 250 or 600 volt, 200,000 ampere interrupting rating: Buss "Hi-Cap".

B. All fuses shall be by one Manufacturer.

2.2 CIRCUIT BREAKERS

A. General: 1. Provide required circuit breakers for installation in panelboards, switchboards, individual enclosures, or

motor control centers. Circuit breaker Manufacturer shall be that of the equipment in which it is installed or shall be supplied by that equipment Manufacturer.

2. Provide electronic trip circuit breakers where indicated on the Drawings. 3. All breakers shall be rated for the applied voltage and have a minimum 10,000-amp interrupt rating.

B. Mechanism: Molded case circuit breakers shall have over center toggle-type mechanisms, providing quick-make, quick-break action. Breakers shall be calibrated for operation in an ambient temperature of 40 degrees C. Each circuit breaker shall have trip indication by handle position and shall be trip-free. 2 and 3 pole breakers shall be common trip.

C. Thermal Magnetic Trip: 1. Each circuit breaker shall have a permanent trip unit containing individual thermal and magnetic trip

elements in each pole. 2. Circuit breakers with frame sizes greater than 100 amperes shall have variable magnetic trip elements

which are set by a single adjustment (to ensure uniform tripping characteristics in each pole). 3. Single pole 15 and 20 ampere breakers shall be SWD rated.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install fuses in all combination motor starters, fused disconnects, and equipment as required. Install circuit breakers in all panelboards as required.



/1

Enclosed Switches

Section 26 28 20


SECTION 26 28 20 – ENCLOSED SWITCHES PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all switching devices or means of disconnecting motors and other electrically powered equipment.

1.3 REFERENCES

A. Except as herein specified or as indicated on the Drawings, the work of this Section shall comply with the following: 1. NEMA - National Electrical Manufacturers Association: Standard KS1 for enclosed switches.

1.4 SUBMITTALS

A. Shop Drawings: For disconnect switches. 1. Name of Manufacturer. 2. Model number. 3. Details of construction and installation. 4. Assembly drawings, including elevations, plans, sections, dimensions, weight, and conduit entry

locations. 5. Electrical Ratings:

a. Voltage. b. Amperage. c. Interrupt rating. d. Enclosure type.

6. Color and finsh. 7. Options and accessories.

B. Installation Instructions: For disconnect switches.

C. Operation and Maintenance Manuals: For disconnect switches. 1. Equipment function, normal operating characteristics, and limiting conditions. 2. Assembly, installation, alignment, adjustment, and checking instructions. 3. Operating instructions for start-up, routine and normal operating, regulation and control, shutdown,





/1

Enclosed Switches

Section 26 28 20


B. Regulatory Agencies Requirements: 1. Comply with National Electrical Code (NFPA 70) as applicable to construction and installation of

electrical disconnect switches. 2. Provide disconnect switches which have been listed and labeled by Underwriters' Laboratories. 3. Comply with OSHA lockout/tagout requirements.


A. Deliver all materials in original, unbroken, brand marked containers, or wrapping as applicable.




PART 2 - PRODUCTS

2.1 FABRICATED SWITCHES

A. Manufacturers: Provide products produced by one of the following Manufacturers (for each type of switch): 1. Square D Company. 2. General Electric. 3. Siemens Energy & Automation. 4. Cutler Hammer.

B. General: 1. Provide heavy duty disconnect switches for all motors and equipment as indicated on the Drawings. 2. Provide disconnect switches for all motors not in sight of supplying distribution panel whether indicated

on the Drawings or not, as required by NEC.

C. Switch Enclosures: Provide disconnect switches with NEMA enclosures 1, 3R, 4X, 7, or 12 as indicated on the Drawings, or in absence thereof, as determined by installer to fulfill the requirements of the environment.

D. Heavy Duty Safety Switches: 1. Provide heavy duty type, sheet steel enclosed safety switches, of the type and size and electrical

characteristics indicated, surface mounted, fusible or nonfusible, rated at 250 or 600 volts, 60 hertz, 3 blades, incorporating quick-make, quick-break type switches, constructed so switch blades are visible in "off" position with door open; equipped with operating handle which is an integral part of the enclosure base and whose position is easily recognizable and is padlockable in the "off" position; with current carrying parts constructed of high-conductivity copper, and silver-tungsten type switch contact; with positive pressure type reinforced fuse clips.

2. Fuse clips shall accept only Class R type fuses. 3. All disconnect switches shall be horsepower rated.

E. Switch Interlock: 1. Provide switches with dual cover interlock to prevent opening door with switch in "on" position or

closing switch with door open. 2. Interlocks shall be defeatable with the use of a screwdriver to intentionally gain access to an energized

switch in the "on" position.


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Enclosed Switches

Section 26 28 20


PART 3 - EXECUTION

3.1 INSPECTION

A. General: 1. Examine the areas and conditions under which disconnect switches are to be installed and notify

Engineer in writing of conditions detrimental to the proper and timely completion of the work. 2. Do not proceed with the work until unsatisfactory conditions have been corrected in a manner

acceptable to Engineer.

3.2 INSTALLATION

A. General: 1. Install disconnect switches where indicated, in accordance with Manufacturer's written instructions, the

applicable requirements of NEC and the National Electrical Contractors Association's "Standard of Installation", and in accordance with recognized industry practices to ensure that products serve the intended function.

2. Provide fused disconnect switches serving rooftop units and all other heating, air conditioning, and refrigeration equipment comprising of multimotor or combination loads.

B. Coordination: Coordinate disconnect switch installation work with electrical raceway and cable work, as necessary for proper interface.

C. Location: 1. Install disconnect switches used with motorized equipment within sight of the controller position unless

otherwise indicated. 2. Mount on wall whenever possible, otherwise provide supporting device adjacent to equipment being

served.

D. Fuses: Provide fuses for disconnect switches in accordance with Division 26 Section “Low Voltage Circuit Protective Devices.”



/1

Enclosed Controllers

Section 26 29 13


SECTION 26 29 13 – ENCLOSED CONTROLLERS PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the furnishing and installation of all motor controllers and contactors.

B. The types of motor controllers and contactors required for the Project include the following: 1. Manual motor starters. 2. Magnetic motor starters. 3. Combination magnetic starter/fusible disconnect switches. 4. Combination magnetic starter/nonfused disconnect switches.

C. Provide NEMA rated enclosures and starter sizes for all motors.

1.3 SUBMITTALS

A. Shop Drawings: For motor starters. 1. Name of Manufacturer. 2. Model number. 3. Details of construction and installation. 4. Assembly drawings, including elevations, plans, sections, dimensions, weight, and conduit entry

locations. 5. Project Specific Wiring Diagrams:

a. Diagrams shall clearly identify all field wiring requirements. b. Typical diagrams are acceptable for multiple motors controlled in the same manner.

6. Electrical Ratings: a. Voltage. b. Horsepower, NEMA size. c. Interrupt rating. d. Enclosure type.

7. Color and finish. 8. Options and accessories.

B. Installation Instructions: For motor starters.

C. Operation and Maintenance Manuals: For motor starters. 1. Equipment function, normal operating characteristics, and limiting conditions. 2. Assembly, installation, alignment, adjustment, and checking instructions. 3. Operating instructions for start-up, routine and normal operating, regulation and control, shutdown,

and emergency conditions. 4. Maintenance instructions. 5. Guide to “troubleshooting.” 6. Parts list and predicted life of parts subject to wear. 7. Project specific outline and cross sections, assembly drawings, engineering data, and wiring diagrams.

Wiring diagrams shall reflect final, as-installed conditions, and include wire numbers. 8. Test data and performance curves.


/1


Section 26 29 13




B. All equipment shall bear the UL label and be listed for the application specified.






PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Provide products manufactured by one of the following: 1. Square D Company. 2. Cutler Hammer. 3. General Electric. 4. Siemens Energy & Automation. 5. Allen Bradley.

B. All motor starters to be of the same Manufacturer.

2.2 MATERIALS AND EQUIPMENT

A. Manual Motor Starters for Fractional HP Motors: 1. Operating mechanism shall be of the toggle switch type and shall be mechanically trip-free requiring a

reset operation before the starter can be reset. Contacts shall be silver alloy. Noncurrent carrying parts shall be mounted on molded porcelain, bakelite, or composition base.

2. Overload protection shall be provided with 1 thermal overload heater block for each pole. All overload relays shall be of the melting alloy type.

3. All FHP manual starters shall be equipped with thermal overload relay and handle guard/lock-off mechanism.

B. 3-Phase Manual Starters: 1. 3-phase manual starters shall consist of a manually operated push button switch equipped with

melting alloy type thermal overload relays. Thermal units shall be of one piece construction and interchangeable. Starter shall be inoperative if a thermal unit is removed.

2. Operating mechanism shall be of the push button switch type and shall be mechanically trip-free requiring a reset operation before the starter can be reset. Contacts shall be silver plated. Noncurrent carrying parts shall be mounted on molded porcelain, bakelite, or composition base. Starter operating push button shall be capable of being padlocked in the "off" position.

3. Overload Relays: (Melting alloy type, normally open, isolated auxiliary contact, manually reset by means of an external reset button, and capable of handling the horsepower range of the starter by changing the thermal elements only.)

4. Wiring: Terminals for connections shall be easily accessible from the front and shall have large heads, capable of accommodating a wire size of current carrying equal to the current rating of the starter.

5. All manual starters shall be 3-pole type with thermal overload relays and pilot light.


/1


Section 26 29 13


C. Full Voltage Magnetic Motor Starters: Provide individual, full voltage, nonreversing magnetic motor starters with the following accessories and characteristics: 1. Contactor with 3 manually resettable, melting alloy overload relays. 2. 120 volt holding coil. 3. Cover mounted "green," transformer type, "push-to-test" pilot light energized by auxiliary contact. To

indicate motor running. 4. Cover mounted overload relay "reset" button. 5. Provide 2 sets of normally open auxiliary contacts in addition to standard auxiliary holding contacts

supplied with each contactor. Provide additional N.O. or N.C. auxiliary contacts required for interlock functions.

6. Provide 120 volt secondary control power transformer (CPT) in each magnetic starter, of sufficient capacity to handle operating coil and associated controls. Provide CPT secondary fusing and grounding.

D. Combination Starter/Fused Disconnect Switch: 1. Provide combination, full voltage, nonreversing magnetic starters and fusible disconnect switches in a

common enclosure. 2. Provide fused 3-pole load break disconnect switches with time delay, dual element fuses, external

operating handle, and lock-off facility. 3. Restrict opening of switch enclosure by use of a latch unless the switch is in the "off" position. Latch

shall be defeatable with a screwdriver. 4. Accessories are the same as for magnetic motor starters indicated above.

E. Combination Starter/Nonfused Disconnect Switch: 1. Provide combination, full voltage, nonreversing magnetic starters and nonfusible disconnect switches

in a common enclosure. 2. All characteristics are the same as fusible combination starter above.

F. Enclosures: 1. Provide manual or magnetic motor starters with NEMA enclosures 1, 3R, 4X, 7 or 12 as indicated on

the Drawings or schedules, or in absence thereof, as determined by installer to fulfill the requirements of the environment.

2. Cover mounted devices shall be provided for all starters: Hand-off-auto selector switch.

G. Remote Control Devices: 1. Provide remote "start-stop" momentary contact push button stations to control magnetic starter coils

as indicated on the Drawings. 2. Provide green transformer type pilot light with "on" nameplate at all remote push button stations. Pilot

light shall be operated by starter auxiliary contact. 3. Remote control devices shall be generally flush mounted in finished areas of the Project, with stainless

steel plates or surface mounted in unfinished areas of the Project.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: 1. Install motor controllers and contactors at locations indicated on the Drawings. 2. Overload elements and settings shall be selected based on motor nameplate ratings. 3. Label each motor starter with load served.


Appendix 1


INTERNATIONAL, INC. 159 PARIS AVENUE NORTHVALE, NJ 07647 PHONE 201.768.2400

BILL OF MATERIALS

Date: August 9, 2012 Project: Miami University – Cole Service Building Engineer: FTC&H Contractor: TBD Representative: Blackmore & Glunt DESCRIPTION . Gas Fired Boiler – Aerco Model BMK 2.0 LN Boiler Control Panel Boiler Management System Wiring Diagram Dimensional Drawing Anchor Bolt Locations Installation Clearances Multiple Unit Installation Drawing The following items will be supplied with the boiler and installed at the factory Normally Open Fault Relay Integral Adjustable High Limit Control Manual Reset High Limit Control - 200 F Setpoint Insulated Steel Jacket Exhaust Gas Temperature Limit System Fault Mode Diagnostic Panel With Digital Readout Welded Steel Base Electrical Probe Low Water Cut-Off F.M. Approved Gas Train Combination Temperature and Pressure Gauge Shell Temperature Sensor Combination Safety Shutoff and Gas Supply Regulator The following items shall be shipped loose for field installation by others Pressure Relief Valve – Please advise Pressure Setting

Condensate Trap Assembly Engineering Design Guides Gas Supply Guide Venting and Combustion Air Guide Electrical Power Wiring Guide Boiler Application Guide

CMC

New Stamp

Administrator

Text Box

Pressure setting for PRV shall be 125 psig.

Administrator

Typewritten Text

x

Administrator

Typewritten Text

GAT

Administrator

Typewritten Text

08/13/12

Administrator

Typewritten Text

Administrator

Typewritten Text

Administrator

Text Box

Perform Burner and Hydrostatic testing per spec. Provide results to University at time of shipment. Manufacturer's Representative shall be responsible for confirmation of proper installation and start-up services. Also provide University training per spec. Upon completion of installation, mfr rep to provide field combustion test per spec. Provide results in report form to University.

Administrator

Text Box

Provide external BACnet network communication interface per specification.

BMK2.0LN GWBTECHNICAL DATA SHEET

Low NOx Benchmark Gas Fired Hot Water Boiler System

FEATURES:• NaturalGas• (Optional)Dual-Fuel–NaturalGaswithPropane

Back-Up• SeparateFuelConnectionsProvidedwithDualFuel

Option• 20:1TurndownRatio• NoxEmissions<20ppmatAllFiringRates(when

firedwithnaturalgas)• DirectorConventionalVentCapabilities• AL29-4CVentMaterialsRequiredperUL1738

TheAERCO Benchmark 2.0 Low NOx (BMK2.0LN) Water Boilerisdesignedforcondensingapplicationinanyclosedloophydronicsystem. It delivers 20:1 burner turndown to match energy inputdirectly to fluctuating system loads to yield the highest possibleseasonal efficiencies. As illustrated below, the unit’s operatingefficiencyactually increasesasthe loaddecreases. Itcanachieve99+%efficiencywhensuppliedwith60°Freturnwaterwhilefiringatminimuminput.

Tominimizeemissions,theBMK2.0LNisfittedwithalowNOxburnerwhoseemissionswillconsistentlymeasure<20ppmofNOxcorrectedto3%excessoxygenatallfiringrates.CertifiedbytheSCAQMDandTCEQinitsclass,thefullymodulatingburneralsomaintainsAERCOstandardsforenergyefficiency,longevity,reliabilityandconstructionquality.

The BMK2.0LN can be used singly or in modular arrangementsandoffersselectablemodesofoperation. Inaddition tocontrollingthe boiler according to a constant set point, indoor/outdoor resetscheduleor4-20mAsignal,oneormorecanbeintegratedviaModbuscommunicationsprotocol toAERCO’smultiple boilermanagementsystem(BMSII)ora facility-wideEnergyManagementorBuildingAutomationSystem.

• QuietOperationThroughoutFiringRange• InternalLowWaterCutoff(ManualReset)• CompactFootprint(79”Hx28”Wx36”D)• PreciseTemperatureControl• SealedCombustionCapable• VentlessSupplyGasRegulator• UL,CUL,forAlcoveInstallationonCombustible

Flooring

Comprehensivetestsarebeingconductedtoconfirmtheunit’sefficiencyoveritsentire100,000 to 2,000,000 BTU/hr. operatingrangeforavarietyofoperatingconditions.The initial boundary tests indicate thatefficiency up to 99.3% can be achievedwhen theunit operatesat its lowest firingrate (5% input) with 60°F inlet watertemperature.Evenatfullfire(100%input)with 160°F inlet water temperature, theBMK2.0LNdelivers85.3%efficiency.

THERMAL EFFICIENCY

DIMENSIONS:

RATINGS AND DIMENSIONS:

(1) Assume 24” between units. Zero side wall clearance is not provided. Consult local sales representative.(a) Style to be determined by individual application requirement.(b) Altitude below 2000’. Apply altitude correction factor above 2000’.(c) Output dependent upon application – see efficiency curves

BTUInput..................................................................2,000,000BTU/H*[email protected],706,000-1,860,000BTU/H**ASMEWorkingPressure.......................................................160PSIGElectricalOptions.............................120/1/6020Amo(15.0AmpFLA)GasRequirements...................................................14”W.CMaximumStandardUnit-FMGasTrain......................4.0”W.C.Min.@FullLoadStandardUnit-IRIGasTrain.......................5.0”W.C.Min.@FullLoadDualFuel–FMGasTrain–Nat.Gas...........8.5”W.C.Min.@FullLoadDualFuel–FMGasTrain–Propane...........8.5W.C.Min.@FullLoadDualFuel–IRIGasTrain–Nat.Gas............9.5”W.C.Min.@FullLoadDualFuel–IRIGasTrain–Propane............9.5”W.C.Min.@FullLoadVentSize...............................................................................8”Diameter

WaterConnections...................................4”Flanged150lb.ANSIGasConnection...................................................................2”NPTMin./Max.WaterFlow................................25GPM/350GPM***WaterPressureDrop.................................1.7PSIG@170GPMWaterVolume.................................................................24gallonsControlRange..........................................................50°Fto190°FAmbientTemperture...................................................0°Fto130°FNOxEmissionsCertification.............................SCAQMD,TCEQStandardListings&Approvals...............UL,CUL,CSD-1,ASMEGasTrainOptions.............FMCompliantorFactoryInstalledIRIWeight,Installed..........................1,450lbs.(dry),1650lbs.(wet)

SPECIFICATIONS:

WATERHEATERS•BOILERS•PARTS&ACCESSORIESAERCOINTERNATIONAL,INC.

100ORITANIDR.•BLAUVELT,NY10913(845)580-8000•FAX(845)580-8090

www.aerco.com

RepresentedBy:

Specificationssubjecttochangewithoutpriornotice.ConsultwebsiteorcontactAERCO.BMK2.0LN01/2012NY

Modules Model(a)

MbhInput(b)

MbhOutput(b)(c) Width(1)

Depth Height Weight(wet)

One(1) BMK-2.0LN 2,000mbh 1,706mbh-1,860mbh 2’4” 3’10” 6’7” 1,650lbs.Two(2) BMK-2.0LN-2 4,000mbh 3,412mbh-3,720mbh 6’8” 3’10” 6’7” 3,330lbs.Three(3) BMK-2.0LN-3 6,000mbh 5,118mbh-5,580mbh 11’0” 3’10” 6’7” 4,950lbs.Four(4) BMK-2.0LN-4 8,000mbh 6,824mbh-7,440mbh 15’4” 3’10” 6’7” 6,600lbs.

Five(5) BMK-2.0LN-5 10,000mbh 8,530mbh-9,300mbh 19’8” 3’10” 6’7” 8,250lbs.Six(6) BMK-2.0LN-6 12,000mbh 10,236mbh-11,160mbh 24’0” 3’10” 6’7” 9,900lbs.

Seven(7) BMK-2.0LN-7 14,000mbh 11,942mbh-13,020mbh 28’4” 3’10” 6’7” 11,550lbs.Eight(8) BMK-2.0LN-8 16,000mbh 13,648mbh-14,880mbh 32’8” 3’10” 6’7” 20,640lbs.

*Up to 2000’ Altitude**Output is dependent upon return water temp. and firing rate.

CMR-1PRODUCT

OVERVIEW

AERCO C-More™ Control SystemControl More, Check More, Capture More, Communicate More

Advanced Technology for Easyand Reliable Control of AERCOGas-Fired Boilers and Water HeatersThe AERCO C-More Control System offerscustomers more than just an easy-to-use, highlyreliable control system for boiler and water heatermanagement.

The system incorporates the latest electronicstechnology to see and do more than was previouslypossible. It reports on individual system componentssuch as unit status, firing rate and temperaturecontrol settings. It provides step-by-step diagnosticmenus using clear and simple language andautomatically captures performance history andoperating trends.

Beyond these immediate benefits, the ruggedly builtsystem has been designed using flash-upgradeablesoftware components and open interoperabilitystandards to support building automation and energymanagement software systems.

Key Features include:

• Supports BAS and EMS Integration viaModBus Open Protocol

• Optional Gateway for BACnet, Lonworksand N2 Communication Also Available

• Flash-Upgradeable Software

• Common Platform Fits All Benchmark andKC1000 Units

• Log Reports and Fault History

• Rugged Hardware Design

• Replaceable Circuit Boards

• Simple and Clear Display Messages

• Step-by-Step Diagnostic Menusand System Status Reports

• Remote Monitoring Capability

• Precise Temperature Control

• UL Recognized

AERCO C-More Controllerfor Benchmark Units

AERCO C-More Controllerfor AERCO KC1000 Units

It is included as a standard component on AERCOequipment manufactured after July 2002; olderinstallations of Benchmark boilers, KC1000 boilersand water heaters can be easily retrofitted with theAERCO C-More control system.

Precise Temperature ControlThe superior performance of AERCO equipment is due, in part, to tremendous condensing capabilities and unique firingtechnology. Put simply, AERCO extracts and transfers as much heat as possible from a highly efficient combustionprocess. Unparalleled, fully modulating, non-stepped burner turndown precisely matches heat input to load requirements.

A state-of-the-art PID control system was employed to fully exploit the potential of such robust boiler mechanics. Inshort, it utilizes a Proportional + Integral + Derivative control algorithm to dynamically respond to changes throughoutthe heating plant operation. System temperatures, as well as percentage of module input can be controlled withvirtually no overshoot, droop or short cycling of equipment. A header temperature of +/– 2°F is assured duringcontinual plant operation.

Integrated Approach to Overall Heating Plant InfrastructureSuch precise temperature control would not be possible without a highly integrated approach to the overall heatingplant infrastructure. AERCO C-More controls support equipment and information systems which extend beyond thelimits of conventional boiler controls. These features will help you maximize the value of a sophisticated energymanagement system, or can assist with basic heating plant management in the absence of smart building systems.

AERCO INTERNATIONAL, INC.159 PARIS AVE. • NORTHVALE, NJ 07647

(201) 768-2400 • FAX (201) [email protected] • www.aerco.com CMR-1 New Doc 8/07 5M

Interoperability with Energy Management Systems(EMS) is achieved via the controller’s RS485 port.Customers who are not equipped to take advantage ofthese network technologies can monitor trends in setpoint, outlet temperature or firing rates using conven-tional 4-20 mA signals.

A PID Temperature Control Override function preventsunnecessary shutdowns caused by external energymanagement controls. The feature gradually lowers thefiring rate to safely operate the boiler until conditionsreturn to normal. This prevents on/off cycling to saveenergy and reduce equipment wear and tear.

To help users start the heating plant as temperatures drop –or begin to promote client comfort and energy savings astemperatures warm – System Start Temp and Indoor/Outdoor Reset controls can be used to enable or disablethe boiler based on outside air temperature.

Similarly, Fail Safe Mode lets users choose to shut downthe system or switch to constant set point operation ifexternal signal input is ever lost. By choosing to revert toa constant set point, users can ensure that basic heatand hot water is available to avoid unnecessary buildingclosures and prevent pipe freezes in the event of anEMS problem.

All AERCO equipment supports Variable Flow Designsand No Flow Conditions without supplemental pumpingrequirements. While streamlining plant design is aneffective way to reduce project and overall maintenancecosts, AERCO C-More features are robust enough tosupport the most complex heating plant infrastructures.Remote and Delayed Interlocks, a Pump Delay Timerand/or Aux Start Delay can postpone the boiler’s start-upsequence until a necessary external device is activated.Prior to operation, it can open a valve, boiler pump, gasbooster, or louver as shown.

HOT WATER SYSTEMS

Future-Proof Software in a Hardware Enclosure that is Built to LastThe most important feature of any product manufactured in today’s “information age” is its ability to network with relatedequipment. And not just the equipment and systems that are available today – but those that are still on the horizon.This indisputable fact was a guiding principle in the design of the AERCO C-More Control System. It pairs softwareflexibility with hardware durability to ensure that your AERCO equipment will be as current tomorrow as it is today.

Rugged Hardware Design UsesReplaceable Circuit BoardsBehind the easy-to-read display panels, the hard-ware design uses shrouded snaps and ruggedribbon connectors to link six replaceable controlcards to a common backplane. Each card issecurely fastened to the box for added stability andis covered by a two-year warranty. Locking, keyedconnectors on the back side of the control module(pictured below) simplify wiring.

Open Platform Integrates withEnergy Management SystemsThe C-More controller is fully compatible withbuilding-wide energy management systems andbuilding automation software via ModBus openprotocol. An optional Aerco CommunicationsGateway, to support integration with BACnet,Lonworks and N2 systems, is also available.

Flash-Upgradeable SoftwareOnce an AERCO C-More control module is inplace, all new versions of the system’s operatingsoftware can be uploaded electronically (or “flashedin”) using a laptop. The ability to upgrade thecontroller – without replacing hardware, circuitcards or boiler equipment – makes it faster, easierand less expensive to take advantage of newfeatures and management controls that becomeavailable in the future.

One Controller Fits AllAERCO C-More internal components are identicalfor Benchmark and KC1000 equipment. Wholeunits or components can be swapped betweenany of AERCO’s gas-fired boilers and waterheaters as needed.

Easy RetrofitsAn affordable retrofit kit is available to equip anyexisting AERCO gas-fired boiler or water heaterinstallation with a state-of-the-art AERCO C-Morecontrol system. Two short videos (5-7 minutes),demonstrating the removal and replacementprocedure, are available upon request.

Extensive Log ReportsThe system continuously monitors and automati-cally captures data associated with operationalevents, faults and sensor readings which can beviewed in real-time via the Modbus RS485 RTUinterface or downloaded for historical analysisthrough the RS-232 interface. Events such aspower-up, ignition and turn-off are time stampedand sensor value readings can be logged at flexibleintervals established by the user. The system alsomaintains a log of the date, time and details of thelast ten system faults to help end-users recognizeboiler shutdown patterns.

Simple & Clear Display Messages are a Breeze for Maintenance PersonnelForty-two distinct messages convey system status throughout the full start-up sequence and pinpoint the exactnature of any fault or operating problem. The easy-to-read display panel uses clear, simple language — rather thanobscure programming codes – to ensure that day-to-day operations and annual maintenance goes smoothly for on-site maintenance staff and professional service contractors.

Step-by-Step Menus Check andReport Status of Each ComponentThe system has also been designed with step-by-stepdiagnostic menus to help personnel troubleshootefficiently and quickly pinpoint problems. Users cantest all system components as well as test keypadfunction, relay settings, switch positions, air/fuel valvecalibration and sensor readings.

Remote Upgrade, Monitoring andTroubleshooting CapabilitiesOpening the control module is unnecessary for initialsystem set-up, calibration, troubleshooting or duringnormal operations. The AERCO C-More controllerlinks easily to a laptop via RS-232 connections sostaff can monitor and troubleshoot issues remotely.

DISABLED

3:05PM 9/24/02

LOW WATER

LEVEL

STANDBY

3:06PM 9/24/02

AIRFLOW FAULT

DURING PURGE

DEMAND DELAY

11 sec

LOSS OF POWER

3:09PM 9/24/02

WAIT DIRECT DRIVE

SIGNAL FAULT

PURGING

4 sec

REMOTE SETPT

SIGNAL FAULT

IGNITION TRIAL

2 sec

OUTDOOR TEMP

SENSOR FAULT

WARMUP

4 sec

LINE VOLTAGE OUT

OUT OF PHASE

FLAME PROVEN

3:08PM 9/24/02

NETWORK COMM FAULT

Start Sequence Messages Fault Message Examples

Future-Proof Software in a Hardware Enclosure that is Built to LastThe most important feature of any product manufactured in today’s “information age” is its ability to network with relatedequipment. And not just the equipment and systems that are available today – but those that are still on the horizon.This indisputable fact was a guiding principle in the design of the AERCO C-More Control System. It pairs softwareflexibility with hardware durability to ensure that your AERCO equipment will be as current tomorrow as it is today.

Rugged Hardware Design UsesReplaceable Circuit BoardsBehind the easy-to-read display panels, the hard-ware design uses shrouded snaps and ruggedribbon connectors to link six replaceable controlcards to a common backplane. Each card issecurely fastened to the box for added stability andis covered by a two-year warranty. Locking, keyedconnectors on the back side of the control module(pictured below) simplify wiring.

Open Platform Integrates withEnergy Management SystemsThe C-More controller is fully compatible withbuilding-wide energy management systems andbuilding automation software via ModBus openprotocol. An optional Aerco CommunicationsGateway, to support integration with BACnet,Lonworks and N2 systems, is also available.

Flash-Upgradeable SoftwareOnce an AERCO C-More control module is inplace, all new versions of the system’s operatingsoftware can be uploaded electronically (or “flashedin”) using a laptop. The ability to upgrade thecontroller – without replacing hardware, circuitcards or boiler equipment – makes it faster, easierand less expensive to take advantage of newfeatures and management controls that becomeavailable in the future.

One Controller Fits AllAERCO C-More internal components are identicalfor Benchmark and KC1000 equipment. Wholeunits or components can be swapped betweenany of AERCO’s gas-fired boilers and waterheaters as needed.

Easy RetrofitsAn affordable retrofit kit is available to equip anyexisting AERCO gas-fired boiler or water heaterinstallation with a state-of-the-art AERCO C-Morecontrol system. Two short videos (5-7 minutes),demonstrating the removal and replacementprocedure, are available upon request.

Extensive Log ReportsThe system continuously monitors and automati-cally captures data associated with operationalevents, faults and sensor readings which can beviewed in real-time via the Modbus RS485 RTUinterface or downloaded for historical analysisthrough the RS-232 interface. Events such aspower-up, ignition and turn-off are time stampedand sensor value readings can be logged at flexibleintervals established by the user. The system alsomaintains a log of the date, time and details of thelast ten system faults to help end-users recognizeboiler shutdown patterns.

Simple & Clear Display Messages are a Breeze for Maintenance PersonnelForty-two distinct messages convey system status throughout the full start-up sequence and pinpoint the exactnature of any fault or operating problem. The easy-to-read display panel uses clear, simple language — rather thanobscure programming codes – to ensure that day-to-day operations and annual maintenance goes smoothly for on-site maintenance staff and professional service contractors.

Step-by-Step Menus Check andReport Status of Each ComponentThe system has also been designed with step-by-stepdiagnostic menus to help personnel troubleshootefficiently and quickly pinpoint problems. Users cantest all system components as well as test keypadfunction, relay settings, switch positions, air/fuel valvecalibration and sensor readings.

Remote Upgrade, Monitoring andTroubleshooting CapabilitiesOpening the control module is unnecessary for initialsystem set-up, calibration, troubleshooting or duringnormal operations. The AERCO C-More controllerlinks easily to a laptop via RS-232 connections sostaff can monitor and troubleshoot issues remotely.

DISABLED

3:05PM 9/24/02

LOW WATER

LEVEL

STANDBY

3:06PM 9/24/02

AIRFLOW FAULT

DURING PURGE

DEMAND DELAY

11 sec

LOSS OF POWER

3:09PM 9/24/02

WAIT DIRECT DRIVE

SIGNAL FAULT

PURGING

4 sec

REMOTE SETPT

SIGNAL FAULT

IGNITION TRIAL

2 sec

OUTDOOR TEMP

SENSOR FAULT

WARMUP

4 sec

LINE VOLTAGE OUT

OUT OF PHASE

FLAME PROVEN

3:08PM 9/24/02

NETWORK COMM FAULT

Start Sequence Messages Fault Message Examples

CMR-1PRODUCT

OVERVIEW

AERCO C-More™ Control SystemControl More, Check More, Capture More, Communicate More

Advanced Technology for Easyand Reliable Control of AERCOGas-Fired Boilers and Water HeatersThe AERCO C-More Control System offerscustomers more than just an easy-to-use, highlyreliable control system for boiler and water heatermanagement.

The system incorporates the latest electronicstechnology to see and do more than was previouslypossible. It reports on individual system componentssuch as unit status, firing rate and temperaturecontrol settings. It provides step-by-step diagnosticmenus using clear and simple language andautomatically captures performance history andoperating trends.

Beyond these immediate benefits, the ruggedly builtsystem has been designed using flash-upgradeablesoftware components and open interoperabilitystandards to support building automation and energymanagement software systems.

Key Features include:

• Supports BAS and EMS Integration viaModBus Open Protocol

• Optional Gateway for BACnet, Lonworksand N2 Communication Also Available

• Flash-Upgradeable Software

• Common Platform Fits All Benchmark andKC1000 Units

• Log Reports and Fault History

• Rugged Hardware Design

• Replaceable Circuit Boards

• Simple and Clear Display Messages

• Step-by-Step Diagnostic Menusand System Status Reports

• Remote Monitoring Capability

• Precise Temperature Control

• UL Recognized

AERCO C-More Controllerfor Benchmark Units

AERCO C-More Controllerfor AERCO KC1000 Units

It is included as a standard component on AERCOequipment manufactured after July 2002; olderinstallations of Benchmark boilers, KC1000 boilersand water heaters can be easily retrofitted with theAERCO C-More control system.

Precise Temperature ControlThe superior performance of AERCO equipment is due, in part, to tremendous condensing capabilities and unique firingtechnology. Put simply, AERCO extracts and transfers as much heat as possible from a highly efficient combustionprocess. Unparalleled, fully modulating, non-stepped burner turndown precisely matches heat input to load requirements.

A state-of-the-art PID control system was employed to fully exploit the potential of such robust boiler mechanics. Inshort, it utilizes a Proportional + Integral + Derivative control algorithm to dynamically respond to changes throughoutthe heating plant operation. System temperatures, as well as percentage of module input can be controlled withvirtually no overshoot, droop or short cycling of equipment. A header temperature of +/– 2°F is assured duringcontinual plant operation.

Integrated Approach to Overall Heating Plant InfrastructureSuch precise temperature control would not be possible without a highly integrated approach to the overall heatingplant infrastructure. AERCO C-More controls support equipment and information systems which extend beyond thelimits of conventional boiler controls. These features will help you maximize the value of a sophisticated energymanagement system, or can assist with basic heating plant management in the absence of smart building systems.

AERCO INTERNATIONAL, INC.159 PARIS AVE. • NORTHVALE, NJ 07647

(201) 768-2400 • FAX (201) [email protected] • www.aerco.com CMR-1 New Doc 8/07 5M

Interoperability with Energy Management Systems(EMS) is achieved via the controller’s RS485 port.Customers who are not equipped to take advantage ofthese network technologies can monitor trends in setpoint, outlet temperature or firing rates using conven-tional 4-20 mA signals.

A PID Temperature Control Override function preventsunnecessary shutdowns caused by external energymanagement controls. The feature gradually lowers thefiring rate to safely operate the boiler until conditionsreturn to normal. This prevents on/off cycling to saveenergy and reduce equipment wear and tear.

To help users start the heating plant as temperatures drop –or begin to promote client comfort and energy savings astemperatures warm – System Start Temp and Indoor/Outdoor Reset controls can be used to enable or disablethe boiler based on outside air temperature.

Similarly, Fail Safe Mode lets users choose to shut downthe system or switch to constant set point operation ifexternal signal input is ever lost. By choosing to revert toa constant set point, users can ensure that basic heatand hot water is available to avoid unnecessary buildingclosures and prevent pipe freezes in the event of anEMS problem.

All AERCO equipment supports Variable Flow Designsand No Flow Conditions without supplemental pumpingrequirements. While streamlining plant design is aneffective way to reduce project and overall maintenancecosts, AERCO C-More features are robust enough tosupport the most complex heating plant infrastructures.Remote and Delayed Interlocks, a Pump Delay Timerand/or Aux Start Delay can postpone the boiler’s start-upsequence until a necessary external device is activated.Prior to operation, it can open a valve, boiler pump, gasbooster, or louver as shown.

HOT WATER SYSTEMS

ACSTECHNICAL DATA SHEET

FEATURES:• IncreaseSystemTurndowntoMaximizeOperating

Efficiency• ControlUpto32BoilersviaModbusInterface;8of

whichcanbedesignatedfordomesticheating• AutomaticLoadMatchingPreciselyMeetsDemand

Changes• “Bumpless”EnergyTransfer• MultipleConfigurationOptions• User-FriendlySoftwareMakesProgrammingEasy• FullInformationVFDDisplay

It requires less energy for a group ofmodulating boilers, each firing at “part load,” to heat a building, thanforasingleboileroperatingat “fullfire” tocarry theentireworkload.Tomeetbuildingdemand, theACSwillemployasmanyboilersasavailable,eachoperatingat its lowest (butmostefficient)firingrate. Importantly,becausetheACSreactsinreal-timetochangesinthenumberofboilersavailable,userscantakeaunitofflineformaintenanceatanytimeorbringonback-upboilersforextremelycoldconditionswithoutchangestotheACS.Andasindividualboilersareaddedordeleted,theenergydeliveredisautomaticallyadjustedtopreventfluctuationsintheheadertemperatureoftheplant.

• CompleteControlofAuxiliaryBoilerEquipment• EasyIntegrationtoBASorEMSviaModbusOpen

Protocol• SinglePointBASorEMSDataGatheringforupto

35OperatingParametersofEachBoiler• ForUsewithAERCOBenchmark,Modulexand

KC1000Units• Threedomestichotwaterheatingoptionsfor

controllingcombinationboilersandvalves(Benchmark,ModulexandKC1000applications)

• PlantDeltaTemperatureLimit-preventstheboilersfromfiringatlowflowconditions.

LOADSHARINGSTRATEGYMAXIMIZESENERGYEFFICIENCY

Thefirstboilerunitcomesonlineandwillgraduallyincreaseitsair-fuelvalvepositiontomeetdemand.Whenitreaches50%–asecondunitiscalledintoservice.

AERCOCONTROLSYSTEM(ACS)

TypicalStagingExampleDemonstrates“PartLoad”EfficiencyThetwoboilerswillsplittheload–eachfiringat25%air-fuelvalvepositiontomeetdemand.Ifadditionalheatisrequired,athirdunitiscalledintoservice.

Threeboilers,eachfiringat33%air-fuelvalveposition,satisfiesthedemandmoreefficientlythaneithertwounitsat50%oroneunitat100%.Thissameprincipleappliestomuchlargerplants.

Administrator

Text Box

Boiler mfr's rep to assist DDC subcontractor and coordinate proper configuration to achieve desired control sequences and maximize system efficiency.

STATE-OF-THE-ARTCONTROLSYSTEMSUPPORTSEFFICIENTBOILERPLANTOPERATION!

TheAERCOControlSystem (ACS) isa flexible controllerdesigned tomaximizeenergysavings inmodularboilerplants.TheACScanstageandcoordinatetheoperationsofupto32boilersandisuniquelydesignedtomaximizetheoperatingefficiencyofcondensingequipmentcapableofunmatchedmodulation.Eightofthese32boilerscanbedesignatedfordomesticheating.Withindividualunitturndownashighas20:1,afive-boilerplantdelivers100:1systemturndownwhenstagedtooperatesequentially.

Abletoregulateoverallplantoutputwithpreciseaccuracy,aboilerplantwith±2°Fheadertemperaturevariationis assuredunder normal load conditions. It offers sequential or parallel operation flexibility, 100%control ofauxiliaryequipment,anduserprogrammablemodesofoperation thatcanbechanged in thefield.TheACSautomaticallyrotatestheleadunittohelpequalizeboilerruntime.

Theruggedcontrollerisdesignedforeasyinstallationwithlowvoltage,twistedpair,shieldedwirebetweenthepanelandboilers.Faultalarmcontacts,automaticsystemstart,twointerlockcircuitsandtheabilitytostartanauxiliarypieceofequipment(atbothstartand100%load)combineallcriticalfunctionsoftheboilerplantintoonereliablecontrolcenter.

FULLYCOMPATIBLEWITHBASOREMSSYSTEMSVIAMODBUSOPENPROTOCOL

Forfacilitiesthathavetakenabuilding-wideapproachtoenergyefficiency,theACSsupportseasyintegrationwithBuildingAutomationSoftware(BAS)orEnergyManagementSoftware(EMS)programsviaModbusprotocolandRS-232interface.Astandards-basedopenprotocolusedthroughoutthebuildingscontrolsmarket,ModbusintegrationwillenablefacilitymanagerstodriveallACSoperationsfromanybuildingcontrolplatform.BASorEMSintegrationalsooffersacommunicationsgatewaytopollupto35operatingparametersfromindividualboilersthroughasingleconnectiontotheACS,including:(consultAERCOModbusCommunicationsManualGF-114andModulexE8Controller/BoilerCommunicationsModuleManualGF-115-Cforcompletelist).

ConfigurationOptions TypicalApplicationsIndoor/OutdoorResetAchangeintheoutsideairconditionresultsinaProcessApplicationproportionatechangeinheadertemperature–afunctionoftheadjustableresetratio(0.3–3.0).

Indoor/OutdoorResetHydronicHeatingProcessApplication

ConstantSetpointDeliversfixedsupplywatertemperatureatsetpointsof50°F-220°F(dependentuponboilermaximumtemperaturelimit).

WaterSourceHeatPumpDomesticWaterGenerationSupplementalHeatRecoveryEquipmentSwimmingPoolHeating

4-20mASignalHeadertemperaturerespondslinearlytoanexternal4-20mAcontrolsignal.

ComputerControlledBuildingManagementIndustrialProcessGreenhouseApplication

NetworkCommunicationsEnablesEMSorBASsystemtodriveboilerplantsettingforheadersetpointtemperatureviaModbusconnectiontoACS.AlsoprovidescommunicationlinkbetweentheboilerandtheACStoallowdirectcommunication.ThisenablestheEMS/BAStoqueryandcapturefaultsofACSandupto35operatingparametersofindividualboilers.

ComputerControlledBuildingManagementEMSDataLogging&TrendAnalysis

NOTE:ACSpackageincludesSupplyHeaderTemperatureSensor(GM-122790)

• UnitType• UnitSize• UnitStatus• DefaultMessageCodes• OutletTemperature

• RunCycles• RunHours• FlameStrength• ActiveSetPoint• High/LowLimits

• ModeofOperation• OutdoorTemperature• ValvePosition/ModulationLevel• Time• Date

ROBUSTFEATURESSIMPLIFYCONTROL• Application Flexibility – Four different configuration

optionsmeettheneedsofanyclosedloopsystemandcanbechangedinthefield;Threedomesticwaterheatingmodesallowapplicationflexibility-headertemperatureboost,DHWpriority,andDHWpriority+buildingpriority.(DHWpriority,andDHWpriority+buildingpriorityisnotapplicabletoModulexBoilers)

• Sequential or Parallel Operation – Choose tosequenceindividualboilersorrunall inparallel.Modeof operation can be changed by a simple keyboardselection.

• AutomaticSystemStart–TheACScanbringauxiliaryequipment or boilers online based on outside airtemperature.AutoStartContactswhichcanbeset tocloseatoutsideairtemperaturesbetween32°F-100°Feliminate the need for plant operator to turn auxiliaryequipmentonandoff.

• Time Delay Between Boiler Start – A fixed, thirtysecond time delay between boiler starts allows for asmoothenergyinputwithoutspikesinelectrical,gasorventingconditions.

• Automatic Allowance for Maintenance – Bycontinuouslymonitoringthenumberofboilersavailablefor operation, the panelwill automatically operate thenextboilerneededtomeetdemandifaunitmalfunctionsoristakenoff-lineformaintenance.

• AuxiliaryBoilerCapability–Contactsareavailabletooperatestand-byorback-upboilerequipmentwhentheplantisat100%load.Thesecanbeusedtocontrolanauxiliaryboilerornotifybuildingmanagementsystem.Contactsturn-offisadjustablethroughthekeyboardtoanypercentageofplantinput.

• Adjustable Off Set – The ACS includes a 7-dayprogrammable clock to support night setback and/or daily setback periods. TheACS will shift from theoriginalsetpointtoahigherorlowertemperature.

• Two InterlockCircuits–Monitorpumps,combustionair dampers, or other equipment using two interlockcircuitsthatmustbecompletedbeforeplantoperationsbegin.

• PowerOffMemory – By using non-volatilememory,programs are retained through a shut down of morethantwoyears.Nobatteriesrequired.

• SimpleInstallation–TheACScontrolsystemoperatesonstandard85-265VAC/1/60powersupply.Twistedpair,shielded wire connections to the ACS and individualboilers are required to support communications. AnRS-232interfaceisrequiredtolinkanEMSorlaptoptotheACS.RS-232communicationswiringbetween theEMSandtheACScannotexceed50feet.AnRS-485interfacecanbeusedtoconnecttheACStotheboilers.RS-485communicationswiringsupportsadistanceofupto4,000feetbetweenACSandboilers.Itispossibletouseaconverter(RS232toRS485)betweentheACSandaBAS/EMSequippedwithanRS485interface.

• Flexible&Expandable–TheACScansupportupto32AERCOboilers–whichcanbefullyintegratedwithany EMS or BAS software via the Modbus protocol.AERCOalsooffersGatewayproduct forLONBACnetandJohnsonControlsN2.

• FaultAlarmSurveillance–IntheabsenceofaBAS/EMSsystemtopollindividualboilersforfaults,analarmclosurecontactisprovidedfortheACSonly.ItcanbeusedtonotifyfacilitymanagersoffaultsassociatedwiththeACS.

• BuildingReferenceTemperature Inputs–TheACScanacceptreferencetemperaturesfromasensor,andexternal4-20signalorviaModbusfeedtoaBAS/EMSsystemandwilladjustplantoperationstoaccommodatevaryingconditions.

• Programmable Minimum/Maximum Setpoints &Building Reference Temperature – Boilers can beclampedatminimumandmaximumtemperatures,andthe building reference temperature adjusted to driveplantheadertemperature.Thisallowsawiderangeofboiler responses to outside air changes formaximumcomfort.

• Accuracy –ACSusesPID (Proportional& Integral+Derivative)andDynamicUp/DynamicDownModulationcontrolalgorithmtoprovideadynamicresponsetoallchanges in plant operation. Header temperatures, aswellaspercentageboilerinput,arepreciselycontrolledwithvirtuallynoovershootorshortcyclingofequipment.A header temperature of ±2°F is assured duringcontinualplantoperation.

• “Bumpless”EnergyTransfer–Whenstagingboilerssequentially,theACScanbringadditionalunitsonlineatanadjustablepercentageofinputselectedbytheuser.

• “First On-First Off”/”First Off-First On” RotationAlgorithm – Improved sequential operation helpsequalizeruntime.

• LeadandLastBoilersDesignation–Thesefeaturesallowovercycling/in-maintenanceboilertolag/catch-uptotheotherunits’cyclecounts.

• Lead Boiler Time Rotation – Rotates the operatingleadboileratspecifiedtimeandhelpsequalizeruntime.

• Anti-Cycling Features – These features prolong thesystem’s stay at specific state (firing/off) - reducingthe number of cycles while maintaining accuratetemperaturecontrol.• Highdeadbandset-

pointenable• Deadbandhigh• Deadbandlow• SetpointDownRate

• PlantDTLimit• Demandoffset• Maxpowerinput• Rampup%min• Rampdown%min

• SystemOverride-Modbusenable/disable–allowsyoutoremotelyturnon/offtheboilerthroughaModbuscall.

TYPICALINSTALLATION:

Required Recommended OptionalMainModeSelection

Indoor/OutdoorReset B,A H C,E,F,G,I,J

ConstantSetpoint B H C,E,F,G,I,J

4-20mASignal B,D H C,E,F,G,I,JNetworkTemperatureSetpoint B,K H C,E,F,G,I,J,L

CombinationDomestic/SpaceHeating-Componentswithde-scriptionsinparenthesisindicateDomesticHeatingfunctions

Note:DHWpriority,andDHWpriority+buildingpriorityisnotapplicabletoModulexBoilers.

HeaderTemperatureBoost BJ(aquastat)

H C,E,F,G,I

DomesticHotWaterPriority(SeeApplicationsGuideTAG_0050andO&MGF-131fordetails)

BF(aquastat)G(valveclose)I(valveopen)J(valveendswitch)

H C,E

DomesticHotWaterPriority+BuildingPriorityACSRelayPanelRequired(AvailableApril2012)(SeeApplicationsGuideTAG_0050andO&MGF-131fordetails)

BF(aquastat)G(valve#2controls)I(valve#1controls)J(valveendswitch)

H C,E

SPECIFICATIONS:Dimensions……………………………………7.25”x9.50”x4”Weight………………………………………………………3lbs.ElectricalRequirements…………………85-65VAC/1/601AMPEnclosure………………………………………………NEMA13MaximumAmbientTemperature………………………131°F

WATERHEATERS•BOILERS•PARTS&ACCESSORIESAERCOINTERNATIONAL,INC.

100ORITANIDR.•BLAUVELT,NY10913(845)580-8000•FAX(845)580-8090

www.aerco.com

RepresentedBy:

Specificationssubjecttochangewithoutpriornotice.ConsultwebsiteorcontactAERCO.ACS03/2012NY

AccessoriesAvailable:• OutdoorAirSensorKitGM-122781• RS-232toRS-485Converter124943• SupplyHeaderSensorReplacementGM-122790• OrderasecondGM-122790tousetheplantdelta

temperaturelimitfunction

PROTONODE GATEWAYSTECHNICAL DATA SHEET

AERCO/PROTONODE GATEWAYS

AERCO offers a multi-protocol, communications gateway to support integration with customers’ building control and energy management systems. The plug-n-play package supports integration with BACnet/IP, BACnet MS/TP, LonWorks, and Johnson Controls Metasys N2 systems. AERCO’s Communications Gateway is available for all AERCO boilers, *water heaters and electronically controlled indirect systems. The gateway may be installed using the mounting tabs or with the included DIN mount adapter directly into the site’s communications control panel. Confi gurations for all AERCO devices are preloaded on both gateways so the installer simply selects the protocol and confi guration via the DIP switches. BACnet gateways are BTL Marked and the LonWorks gateway is LonMark compliant simplifying the commissioning process. Both gateways are programmed to communicate up to:

• Twelve (12) C-More controlled boilers or water heaters • Four (4) AERCO Modulex boilers• Six (6) SmartPlates or electronically controlled indirect water heaters• Two (2) BMS II, one dedicated to control the C-More and another to control the Modulex systems

A list of standard control points for each category of equipment includes set point, fi re rate, outlet temperature, unit status, run cycles and run hours.

*Helitherm, U-Tube style, and SmartPlate water heaters must be equipped with the company’s Electronic Control System.

FEATURES:• Built-in translation for BACnet/IP, BACnet MS/

TP, LonWorks, Metasys N2 and Modbus TCP Protocols

• Select protocol and baud rate in the fi eld using simple DIP switch selection

• Captures alarm and trend history for faster troubleshooting

• Non-volatile memory retains point mappings and programs in the event of power loss.

• Approvals: BACnet Testing Labs (BTL) B-ASC on ProtoNode RER, CE Mark, LonMark 3.4 Certifi ed on ProtoNode LER, TUV approved to UL 916

WATER HEATERS • BOILERS • PARTS & ACCESSORIESAERCO INTERNATIONAL, INC.

100 ORITANI DR. • BLAUVELT, NY 10913 (845) 580-8000 • FAX (845) 580-8090

www.aerco.com

Represented By:

Specifi cations subject to change without prior notice.Consult website or contact AERCO.CG-1 11/2011 NY

64084: 1 - 6 pin Phoenix Connector • 1 RS-485 +/- Ground port • Power +/- Frame Ground port 1 - 3 pin Phoenix connector RS-485 • 1 RS-485 +/- Ground port 1 Ethernet -10/100 Ethernet port64085: 1 - 6 pin Phoenix Connector • 1 RS-485 +/- Ground port • Power +/- Frame Ground port 1 - 3 pin Phoenix connector RS-485 • 1 RS-485 +/- Ground port 1 Ethernet -10/100 Ethernet port 1 FTT-10 LONWORKS port

Power Requirements……………… 9-30 VDC or 9-24 VACCurrent draw @ 12V

64084…………………………… @ 12V = 150 mA64085…………………………… @ 12V = 279 mA

Operating Temp.……………… -40oF to 187oF (-40oC to 85oC)Relative Humidity ………………… 5-90% RH, non-condensing Dimensions………………………… 4.52 x 3.25 x 1.60 inchesWarranty ……………………… Two (2) years return to factory

SPECIFICATIONS:

DIMENSIONS:AERCO/ProtoNode-RER-E

(Serial Ethernet, P/N 64084)AERCO/ProtoNode-LER

(LonWorks, P/N 64085)





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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288

GF-2060 TAG-0048_0C

ELECTRICAL POWER GUIDE

Natural Gas & Propane Fired Modulating, Condensing Boiler Models: • BMK750 • BMK1000 • BMK1.5 • BMK2.0 • BMK3000 • BMK6000

04/13/2012

BENCHMARK Series Gas-Fired Boilers

Page 2 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 PR1 04/13/2012

GF-2060 TAG-0048_0C

Benchmark Boilers Electrical Power Guide

Technical Support: (Mon–Fri, 8am-5pm EST)

1-800-526-0288

www.aerco.com

Disclaimer

The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material.

PR1 04/13/2012 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 Page 3 of 8

GF-2060 TAG-0048_0C

GENERAL Benchmark (BMK) Gas Fired Boilers are fully factory wired packaged units which require simple external power wiring as part of the installation (Diagram 1). This technical guide is intended to help designers provide electrical power wiring (line voltage) to BMK units. Control wiring details are provided in other publications, depending upon unit application. This document is intended only as a guide and therefore cannot include all possible alternatives, or unit applications. In order to comply with all codes and authorities having jurisdiction, designers and installers must plan the electrical wiring carefully and execute the installation completely. Emergency shutoffs, fusible fire switches, break glass stations, and other electrical requirements should be considered and installed whenever necessary. Boiler Electrical Requirements With the exception of BMK3000 and BMK6000 models, Benchmark boilers require 120V/1∅/60 Hz electrical power. BMK3000 and BMK6000 models require 3∅ power and can be ordered with either one of the following power options:

BMK3000 BMK3000

208-230/3∅/60 Hz @ 20 amps 208-230/3∅/60 Hz @ 30 amps 460/3∅/60 Hz @ 15 amps 460/3∅/60 Hz @ 15 amps

For all Benchmark models, the power distribution block for field wiring connections is located in the upper right corner behind the unit front panel (Diagram 2). All copper wire must be connected to the terminal distribution block. For all 1∅ Benchmark models, the minimum supply voltage to the unit is 110 VAC. For 3∅ Benchmark 3000 models, the minimum supply voltages to the unit are 190 VAC for 208-230/3∅/60 Hz and 415 VAC for 460/3∅/60 Hz. Lower voltages will result in increased wear and premature failure of the blower motor. Wire size and type should be made per the National Electrical Code based on length and load.

Diagram 1:

Service Switch Typical Location

Service Disconnect Switch

Knock-Out for alternate electricalconduit to Service Switch

Control Panel


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Diagram 2: Distribution Block Location

Provisions for Service Designers must provide emergency shutoffs and other devices to satisfy electrical codes. It is also recommended to provide an electrical shutoff disconnect switch of suitable load carrying characteristics on or near each BMK boiler. No electrical boxes or field components should be mounted to the surface of the boiler or where they would interfere with the removal of the side or top panels for maintenance. The disconnect switch should be mounted near the unit as illustrated in Diagram 1. Wiring conduit, EMT, or other wiring paths should not be secured to the unit, but supported externally. Electricians should be instructed as to where the wiring conduit should be located, such as away from the relief valve discharge, drains, etc. All electrical conduit and hardware should be installed so that it does not interfere with the removal of any covers, inhibit service or maintenance, or prevent access between the unit and walls or another unit. Boiler Wiring A dedicated protected circuit should be provided from the power source to the boiler. No other electrical devices should be permanently wired on the same circuit. An emergency switch (electrical shutoff) must be in series with the power to the unit. For applicable wiring connections, refer to the following Diagrams:

• Diagram 3: 120V/1∅/60 Hz @ 20 amps • Diagram 4: 208-230/3∅/60 Hz @ 20 amps (BMK3000) • Diagram 5 208-230/3∅/60 Hz @ 30 amps (BMK6000) • Diagram 6: 460/3∅/60 Hz @ 15 amps (BMK3000, BMK6000)

Multiple Unit Wiring Whenever multiple units are installed within the same mechanical spaces, electrical code requirements call for a single electrical shutoff for emergency use. It is the responsibility of the electrical designer to comply with local codes and regulations affecting an individual installation.


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L1

GND

DISTRIBUTION BLOCKINSIDE POWER BOX

DISCONNECT SWITCH1 POLE 20 AMP

L1

GND

1 POLE 20 AMPCIRCUIT BREAKER

120VAC, 1 PHASE

NEU NEU

Diagram 3: 120VAC/1∅/60 Hz Wiring Schematic

L2

L1

L3

GND



L1

L2

L3

GND

5 WIRE208-230V/3O/60Hz


208-230 LABELL1L2 208 V/3/60 Hz, 20 AMPL3

L1 120V/1/60 Hz, 20 AMPNEU

NEUNEU

Diagram 4: BMK3000: 208-230/3∅/60 Wiring Schematic- 5 Wire

L2

L1

L3

GND



L1

L2

L3

GND

5 WIRE208-230V/3O/60Hz


208-230 LABELL1L2 208 V/3/60 Hz, 30 AMPL3

L1 120V/1/60 Hz, 30 AMPNEU

NEUNEU

Diagram 5: BMK6000: 208-230/3∅/60 Wiring Schematic- 5 Wire


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L2

L1

L3

GND



L1

L2

L3

GND


460 LABELL1L2 460 V/3/60 Hz, 15 AMPL3

L1 120V/1/60 Hz, 15 AMPNEU

Diagram 6: BMK3000 & BMK6000: 460/3∅/60 Wiring Schematic- 4 Wire


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AERCO INTERNATIONAL, INC. 100 ORITANI DRIVE, BLAUVELT, NY 10913

Visit Us at www.aerco.com

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GAS SUPPLY DESIGN GUIDE

Natural Gas & Propane Fired Modulating, Condensing Boiler Models: • BMK750 • BMK1000 • BMK1.5 • BMK2.0 • BMK3000 • BMK6000

04/12/2012



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Benchmark Boilers Gas Supply Design Guide

Disclaimer



1-800-526-0288

www.aerco.com


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General AERCO Benchmark Low NOx gas fired boilers are modulating input devices that require an adequate volume of natural gas at constant pressure for proper operation. The gas requirements specified in this document must be satisfied to ensure efficient combustion. Designers and installers must adhere to the AERCO specifications and those of the local authorities having jurisdiction. A thorough understanding and knowledge of these guidelines is required for the successful design and installation of Benchmark Low NOx series boilers.

Gas Train Components AERCO Benchmark gas-fired boilers are equipped with standard UL approved/FM compliant gas trains. These gas trains are factory tested and fired, with a minimum number of modular components. The gas train components have been designed to operate at high combustion efficiencies by closely controlling both the volume and air/fuel mixture to the burner. The major internal gas train components are:

∗ SAFETY SHUT OFF VALVE (SSOV) With BUILT-IN SUPPLY GAS REGULATOR - An electro-hydraulic gas valve, containing a proof of closure switch, is utilized to stop fuel from flowing into the gas train of the boiler. This is a 100% tight shutoff device with a visible window indicator showing valve position. Reliable, and a standard industry component, this valve is factory piped with a low gas pressure switch on the inlet side of the valve which monitors the manifold pressure for minimum supply conditions. There is also a high gas pressure switch installed on the outlet side of the gas valve, which shuts down the boiler if gas manifold pressures exceed maximum conditions. The actuator has a built-in regulator that replaces the need for an external supply regulator for installations that have supply pressure of up to 14.0” W.C. For installations that have supply pressure greater than 14.0” W.C., see the “Gas Pressure Requirements” section.

∗ AIR/FUEL VALVE - The air/fuel valve controls the volume and mixture of air and fuel in perfect proportion throughout the entire modulation range of the boiler. The valve utilizes one common shaft to simultaneously vary the gas port area and air volume. The gas portion of the valve is a slide port type valve with linear proportion-to-position characteristics. The air side uses a butterfly type valve for adjusting the air volume. The driver of the valve shaft is a precision stepping motor which provides continuous positioning from full input to minimum fire. The air/fuel valve also contains two proof-of-position switches.

∗ CAST ALUMINUM BLOWER ASSEMBLY - A cast aluminum pre-mix blower ensures the precise mixing of air and fuel prior to entering the burner thereby providing controlled combustion.

* LOW NOx BURNER – The burner provides the actual point of air/fuel contact and combustion into the cylindrical combustion/heat exchanger. Fabricated from metal fiber mesh covering a stainless steel body, the burner is stable throughout the entire input range of the boiler. The spark igniter and flame detector for the combustion supervision system are part of this assembly. The burner is easily removable from the boiler.

Gas Pressure Requirements The AERCO Benchmark Low NOx series boiler requires a stable natural gas input pressure. For Benchmark Models BMK 750 through BMK 3000, the nominal inlet supply pressure to the boiler is 7.0” W.C. The allowable gas inlet pressure range is 4.0” W.C. (min.) to 14.0” W.C. (max.) when firing at maximum input. A low supply gas pressure switch in each gas train prevents the boiler from operating without sufficient pressure. Maximum allowable gas pressure is 14.0” W.C. for BMK 750 through BMK 3000 boiler sizes. Gas pressure should be measured when the unit is in operation (firing). Measure the gas pressure with a manometer at the 1/8” NPT ball valve provided at the SSOV inlet. In a multiple boiler installation, gas pressure should initially be set for single boiler operation, and then the remaining boilers should be staged on at full fire, to insure gas pressures never fall below the supply gas pressure when the single unit was firing.

The Benchmark BMK 6000 Model requires a minimum stable gas pressure of 20” W.C. The maximum allowable gas pressure for the BMK 6000 is 2.0 psig. As with all other BMK sizes, a low supply gas pressure switch is provided in the gas train to prevent operation without sufficient gas pressure.


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An external isolation valve must be installed at each Benchmark Low NOx boiler, as shown in Diagram 1. This isolation valve is supplied with the boiler. For installations that have greater than 14.0” W.C. supply pressure, an external lock-up type regulator must be installed downstream of the isolation valve. The lock-up type regulator(s) must be sizes as follows

Boiler Size (MBH) Required CFH 750 750 – 850 1000 1000 – 1200 1500 1500 – 1750 2000 2000 – 2300 3000 6000

3000 – 3400 6000 – 6500

External gas regulators are self-contained with tapped diaphragm vent ports allowing the diaphragm to change its position as required. These vents typically require piping to the outside. For details, refer to the paragraph titled “Venting of Gas Supply Regulators” on page 4 of this guide. The SSOV/Regulator in the gas train is factory piped and does not require any vent piping.

AERCO BOILERS MUST BE ISOLATED FROM THE SYSTEM WHEN LEAK TESTING.

Drip legs are typically required at the gas supply of each boiler to prevent any dirt, weld slag, or debris from entering the boiler gas train inlet pipe. When multiple boilers are installed, some utilities and local codes require a full size drip leg on the main gas supply line in addition to the drip leg at each unit. The bottom of the gas drip leg(s) should be removable without disassembling any gas piping. The weight of the gas pipe should not be supported from the bottom of the drip leg. The drip leg(s) should not be used to support any or part of the gas piping.

CAUTION



Diagram 1. Single Boiler Gas Pipe Connections

Custom Gas Trains Some utilities, insurance carriers, and industrial customers have special requirement gas components on high input devices beyond that which are normally supplied with AERCO boilers. Secondary shutoffs, high or low pressure operators, and external regulators are typical of the requirements of gas utilities. It is mandatory that a designer or installer comply with these requirements. AERCO assumes no liability when these requirements are not satisfied for any location or installation. Contact your local gas utility for their specific requirements before installing AERCO equipment. Special gas trains with a double block and bleed (DBB) configuration (formerly IRI) are available from AERCO. Gas inlet pressure requirements for natural gas (N.G.) and propane (LPG) are as follows:

BMK 750 BMK 1000 BMK 1.5 BMK 2.0 BMK 3000 BMK 3.0 BMK 6000 Gas Train N.G. LPG N.G. LPG N.G. LPG N.G. LPG N.G. LPG N.G. LPG N.G. LPG

DBB (IRI) 4.5” W.C. N/A 4.5”

W.C. N/A 4.5” W.C. --- 5.0”

W.C. 5.0” W.C.

4.5” W.C.

4.5” W.C.

4.0” W.C.

3.5” W.C. N/A N/A

Dual Fuel N/A N/A N/A N/A 4.0” W.C.

4.0” W.C.

8.5” W.C.

8.5” W.C. N/A N/A 5.7”

W.C. 3.5” W.C. N/A N/A

Dual Fuel DBB (IRI) N/A N/A N/A N/A 4.5”

W.C. 4.5” W.C.

8.5” W.C.

8.5” W.C. N/A N/A 6.5”

W.C. 3.5” W.C. N/A N/A


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Gas Piping All gas piping and components must comply with NFPA local codes, and utility requirements minimum. Only gas approved fittings, valves, or pipe should be utilized.

Standard industry practice for gas piping is Schedule 40 iron pipe and fittings. All high and low gas pressure piping systems must comply with local utility and building codes.

Assembled piping should be clean of all debris, pipe chips, or foreign material to prevent any from entering the Innovation Low NOx series boiler gas train. Piping should be tested as prescribed in NFPA 54. Equipment should be isolated before testing any piping system over the allowable pressure. DO NOT EXCEED 14.0” W.C.on the inlet side of the Benchmark boiler at any time for BMK 750 through BMK 3000 Models. For BMK 6000 boilers, DO NOT EXCEED 2.0 PSI on the inlet side of the boiler at any time.

Gas Supply Main Sizing Gas pipe sizing, for either a single or multiple boiler installation, shall be sized for a maximum pressure drop of 0.3” W.C., from the source to the final boiler. The maximum gas flow rate required is the sum of the maximum inputs of each unit divided by the heat of combustion of the fuel supplied at the location, (approximately 1,030 BTU per cubic foot). The fuel supplier or utility should be consulted to confirm that sufficient volume and normal pressure is provided to the building at the discharge side of the gas meter or supply pipe. For existing installations with gas equipment, gas pressure should be measured with a manometer to be certain sufficient pressure is available. Before sizing gas piping, a survey of all connected gas devices should be made. Gas piping supplying more than one gas device must be able to handle the total connected input within the allowable gas pressure drop. The allowable minimum and maximum gas pressure for each device should be considered. Whenever the minimum and maximum gas pressures vary between devices, gas pressure regulators at each unit should be installed to allow regulation at any individual unit. Gas pressure must never exceed the maximum allowable rating of any connected device.

The total length of gas piping as well as fitting pressure drop must be considered when sizing the gas piping. Total equivalent length should be calculated from the meter or source location to the last boiler connected on the header. Gas piping tables 1, 2 and 3 containing data extracted from NFPA 54 should be used as a minimum guideline. (See Tables on the following pages). Gas pipe size should be selected on the total equivalent length from the appropriate pressure table. The gas volume for cfh flow will be the input divided by the calorific value of the fuel to be supplied.

Gas Header Sizing Main supply gas pipe sizing should be developed for the total plant. Boiler gas manifold piping should be sized based on the volume requirements and lengths between boilers and the fuel main. Multiple boiler manifold sizing (Diagram 2) indicates the proper sizing for units placed on the factory standard 52” centers with 2” takeoffs for each unit. Header sizes can be either full size or stepped in size as units are connected. A typical gas piping header diagram for a 3-Module Benchmark Boiler Plant is illustrated in Diagram 3.

BENCHMARK SERIES GAS HEADER SIZING

No. of Boilers 1 2 3 4 5 6 7 8

Sch. 40 Iron Pipe 1.5” 2” 4” 4” 5” 5” 6” 6”

Diagram 2. Multiple Boiler Manifold Chart



GASSUPPLY

BENCHMARK 2.0 LN BOILERS

MANUALSHUTOFF

VALVE

DIRTTRAP

MANUALSHUTOFF

VALVE

Diagram 3 Typical Multiple Boiler Manifold Construction

*Based on Table 1 on the following page, 1,000 cfh/unit, actual header sizes will vary with length of pipe run and fittings employed.

If supply gas pressure exceeds 14.0” W.C., a single header gas manifold lock-up type regulator, -or- individual lock-up regulators can be used to bring the gas pressure down to 14.0” W.C. Header should be located above or behind boiler. Gas piping should not be installed directly over top or front of any part of boiler. Sufficient clearances for maintenance are required.


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Gas Piping Tables

The data in the following pipe and vent sizing tables have been extracted from the National Fire Protection Association Article 54 (NFPA 54)

TABLE 1

Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressures of 0.5 psi or Less and a Pressure Drop of 0.3 inch Water Column

Nominal Iron Pipe

Size (Inches)

Internal

Diameter (Inches)

Total Equivalent Length of Pipe (Feet)

10 20 30 40 50 60 70 80 90 125 150 175 200 2.00 2.067 3,050 2,100 1,650 1,450 1,270 1,150 1,050 990 930 780 710 650 610 2.50 2.469 4,800 3,300 2,700 2,300 2,000 1,850 1,700 1,600 1,500 1,250 1,130 1,050 980 3.00 3.068 8,500 5,900 4,700 4,100 3,600 3,250 3,000 2,800 2,600 2,200 2,000 1,850 1,700 4.00 4.026 17,500 12,000 9,700 8,300 7,400 6,800 6,200 5,800 5,400 4,500 4,100 3,800 3,500

TABLE 2

TABLE 3

Pipe Sizing Table for 2 Pounds Pressure Capacity of Pipes of Different Diameters and Lengths in Cubic Feet per Hour for an Initial Pressure of 2.0 psi with a 10% Pressure Drop and a Gas of 0.6 Specific Gravity

Pipe Size of Schedule 40

Standard Pipe (Inches)

Internal

Diameter (Inches)

Total Equivalent Length of Pipe (Feet) 50 100 150 200 250 300 400 500

2.00 2.067 6589 4528 3636 3112 2758 2499 2139 1896 2.50 2.469 10501 7217 5796 4961 4396 3983 3409 3022 3.00 3.068 18564 12759 10246 8769 7772 7042 6027 5342 3.50 3.548 27181 18681 15002 12840 11379 10311 8825 7821 4.00 4.026 37865 26025 20899 17887 15853 14364 12293 10895 5.00 5.047 68504 47082 37809 32359 28680 25986 22240 19711 6.00 6.065 110924 76237 61221 52397 46439 42077 36012 31917

Pipe Sizing Table for 1 Pound Pressure Capacity of Pipes of Different Diameters and Lengths in Cubic Feet per Hour for an Initial Pressure of 1.0 psi with a 10% Pressure Drop and a Gas of 0.6 Specific Gravity



Internal

Diameter (Inches)


50 100 150 200 250 300 400 500 2.00 2.067 4245 2918 2343 2005 1777 1610 1378 1222 2.50 2.469 6766 4651 3735 3196 2833 2567 2197 1947 3.00 3.068 11962 8221 6602 5650 5008 4538 3884 3442 3.50 3.548 17514 12037 9666 8273 7332 6644 5686 5039 4.00 4.026 24398 16769 13466 11525 10214 9255 7921 7020 5.00 5.047 44140 30337 24362 20851 18479 16744 14330 12701 6.00 6.065 71473 49123 39447 33762 29923 27112 23204 20566 8.00 7.981 146849 100929 81049 69368 61479 55705 47676 42254



TABLE 4

Pipe Sizing Table for 5 Pounds Pressure Capacity of Pipes of Different Diameters and Lengths in Cubic Feet per Hour for an Initial Pressure of 5.0 psi with a 10% Pressure Drop and a Gas of 0.6 Specific Gravity



Internal

Diameter (Inches)


50 100 150 200 250 300 400 500

2.00 2.067 11786 8101 6505 5567 4934 4471 3827 3391 2.50 2.469 18785 12911 10368 8874 7865 7126 6099 5405 3.00 3.068 33209 22824 18329 15687 13903 12597 10782 9556 3.50 3.548 48623 33418 26836 22968 20365 18444 15786 13991 4.00 4.026 67736 46555 37385 31997 28358 25694 21991 19490 5.00 5.047 122544 84224 67635 57887 51304 46485 39785 35261 6.00 6.065 198427 136378 109516 93732 83073 75270 64421 57095

Venting of Gas Supply Regulators AERCO’s general guidelines for venting of gas regulators are listed below. AERCO recommends that these guidelines be followed to ensure the most reliable and proper operation of AERCO gas fired equipment. It is also recommended that you consult local codes and the gas regulator manufacturer for additional details. Always follow the most stringent guidelines available, including those listed below. • When venting a gas supply regulator, the vent pipe must be no smaller than the regulator vent size. • In a multiple unit installation, each regulator must have a separate vent line. • Vent lines must not be manifolded together or with any other equipment at the site that also requires atmospheric

vents.

• When sizing the vent, pipe diameters must be increased by one pipe diameter every 20 equivalent feet of pipe. Each 90° elbow is equivalent to approximately: ⇒ 2.5 feet for nominal pipe sizes of up to 3/4” ⇒ 4.5 feet for nominal pipe sizes of up to 1-1/2” ⇒ 10.5 feet for nominal pipe sizes of up to 4”

Each 45° elbow is equivalent to approximately: ⇒ 1 foot for nominal pipe sizes of up to 3/4” ⇒ 2 feet for nominal pipe sizes of up to 1-1/2” ⇒ 5 feet for nominal pipe sizes of up to 4”


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AERCO INTERNATIONAL, INC. 100 ORITANI DRIVE, BLAUVELT, NY 10913

Visit Us at www.aerco.com


Benchmark Series Venting and Combustion Air Guide Technical Application Guide

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Benchmark Series Boilers

Benchmark Series Gas Fired Boilers

For All Benchmark Series Boilers Including Dual Fuel Models:

• BMK 750 • BMK 1000 • BMK 1.5 • BMK 2.0 • BMK 3000/3.0 • BMK 6000

Revised: 06/21/2012

VENTING AND COMBUSTION AIR GUIDE

Page 2 of 40 06/21/2012


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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288


1-800-526-0288

www.aerco.com

Disclaimer The information contained in this manual is subject to change without notice from AERCO International, Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material.

06/21/2012 Page 3 of 40


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Benchmark Series Venting and Combustion Air Guide Technical Application Guide TAG-0022_0L

Table of Contents 1 General ................................................................................................................ 4

2 Materials and Approvals .................................................................................... 4

2.1 Code Required Vent Terminations ........................................................................ 4 3 Combustion Air Supply ...................................................................................... 7

4 Combustion Air from WITHIN the Building ...................................................... 8

5 Combustion Air from OUTSIDE the Building ................................................... 9

5.1 Two-Permanent-Openings Method (USA Only).................................................. 9 5.2 One Permanent Opening Method ....................................................................... 11

6 Opening a Louver Through the Benchmark Boiler ........................................ 12

7 Direct Vent/Sealed Combustion ...................................................................... 13

8 Exhaust Vent and Combustion Air Systems .................................................. 13

8.1 Gross Natural Draft ................................................................................................ 14 8.2 Acceptable Pressure Range ................................................................................ 14 8.3 Exhaust Fans .......................................................................................................... 14 8.4 Corrections for Altitude.......................................................................................... 14 8.5 Manifolded Systems .............................................................................................. 15 8.6 Elbow Quantity and Separation ........................................................................... 15

9 Exhaust Muffler And Air Inlet Attenuator Guidelines .................................... 15

9.1 Vent and Combustion Air System Design Requirements ................................ 16 10 Condensate Removal ....................................................................................... 22

10.1 Individually Vented Systems .............................................................................. 23 10.1.1 BMK 1.5 Example: ................................................................................... 23

10.2 Manifolded Sealed Combustion ........................................................................ 24 11 Common Vent Breeching (Manifolded) .......................................................... 25

12 Pressure Drop and Draft Data Tables ............................................................. 27

Reference: .................................................................................................................... 38

Page 4 of 40 06/21/2012


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General The AERCO BENCHMARK gas-fired boiler is a high efficiency, forced draft, hydronic-heating unit with unique venting capabilities. All BENCHMARK venting options (which include horizontal and vertical discharges, direct vent, and manifolded vent breeching), typically exceed the capabilities of competing combustion equipment. These and other features enable BENCHMARK boilers to provide extremely high thermal efficiencies and optimum temperature control under widely varying conditions. It is therefore critical that the flue gas vent and combustion air system be designed to maintain these objectives.

BENCHMARK’s high efficiency is achieved through air/fuel modulation and the release of energy from the moisture condensing in the combustion products. Because condensation can occur in the exhaust vent system, means must be provided to remove the moisture accumulation. Each BMK model is fitted with a condensate removal trap, as indicated in Figures 1a – 1d, which illustrate the air inlet, vent connections and condensate removal connections for the BMK750 (.75 MMBTU), BMK1000 (1.0 MMBTU), BMK1.5 (1.5 MMBTU), BMK2.0 (2.0 MMBTU), BMK3000/3.0 (3.0 MMBTU) and BMK 6000 (6.0 MMBTU) models.

The design guidelines in this bulletin provide broad latitude while meeting the objectives of safety, longevity and optimum performance.

Materials and Approvals The BENCHMARK boiler is a Category II, III, and IV appliance that requires special attention to exhaust venting and combustion air details. The exhaust vent MUST be UL listed for use with Category II, III, and IV appliances; i.e., it must be capable of operating at temperatures up to 480°F while providing positive-pressure, condensing, flue gas service. The BMK3000 can be used with polypropylene venting materials, but NOT PVC or CPVC. The smaller size BMK750 and BMK1000 boilers can be used with AL29-4C, polypropylene, PVC or CPVC vent materials, due to their lower exhaust operating temperatures. If needed, a PVC Vent Adapter is provided in the Spares Kit included with each BMK750 and BMK1000 boiler. All other BENCHMARK models (BMK1.5, BMK2.0, BMK3.0 and BMK6000) must use UL-listed vents made of AL29-4C stainless steel. Proper clearances to combustibles must be maintained per UL and the vent manufacturer requirements.

The UL, National Fuel Gas Code (ANSI Z223.1/ NFPA54)1 and CSA B149.1-10 guidelines are often the basis for state and local codes. AERCO's recommendations follow the guidelines of these agencies, unless more stringent codes govern the installation site. The venting and combustion air systems must meet all applicable code requirements.

All Canada installations must comply with CSA B149.1 installation code.

1.1 Code Required Vent Terminations The guidelines provided in this bulletin should be followed to comply with AERCO, UL, NFPA 54 (National Fuel Gas Code, ANSI Z223.1) and in Canada: CSA B149.1-10 recommendations and regulations: Vent terminations should be at least 4 feet below, 1 foot above or 4 feet removed horizontally from any window, door or gravity air inlet of a building. Such terminations should extend beyond the outside face of the wall by at least 6 inches.

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Figure 1a: BMK 750 & 1000 Figure 1b: BMK 1.5

Figure 1c: BMK 2.0

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Figure 1d: BMK 3000 Figure 1e: BMK 3.0

Figure 1f: BMK 6000

CONDENSATE TRAP

06/21/2012 Page 7 of 40


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The bottom of the vent termination should be at least 12 inches above both finished grade and any maximum snow accumulation level to avoid blocking the vent or air intake. The vent termination should be least 3 feet above any forced-air building inlet within 10 feet. Design must prevent flue gases from recirculating through the boiler air intake. Vents should not terminate over public walkways or areas where condensate or vapor could create a nuisance or be detrimental to the operation of regulators, meters or related equipment.

Discharges should not be located in high wind, wind-blocked areas or corners, or be located directly behind vegetation. Discharges in these locations may cause the flue pressures to fluctuate and result in flame instability. As a general rule, designs should minimize wind effects.

Wall and roof penetrations should follow all applicable codes and the vent manufacturer's instructions. Vents should never be installed at less than required clearances to combustible materials, as enumerated in UL, NFPA, CSA B149.1-10 or local codes "Double-wall" or 'Thimble" assemblies are required when vents penetrate combustible walls or roofs.

Vertical discharges should extend at least 3 feet above the roof through properly flashed penetrations, and at least 2 feet above any object within a 10-foot horizontal distance. Discharges that extend more than 2 feet above a roof must be supported laterally.

Vertical and horizontal discharges should be designed to prevent rain from entering the vent. Large-mesh screens can be applied to protect against the entry of foreign objects but the 'free area' should be at least twice the flue cross-sectional area.

If the vent system is to be connected to an existing stack, the stack must be UL listed for Category II, III, and IV appliances (capable of 480°F, positive pressure and condensing flue gas operation). Masonry stacks must be lined, and the vent penetration must terminate flush with, and be sealed to, this liner. Vents may enter the stack through the bottom or side. All side connections must enter at a 45-degree connection in the direction of flow and must enter at different elevations, with the smallest vent connection at the highest elevation. BENCHMARK vents must not be connected to other manufacturer’s equipment.

The exhaust vent must be pitched upward toward the termination by a minimum of ¼ inch per foot of length. Condensate must flow back to the BMK unit freely, without accumulating in the vent.

Combustion Air Supply The BENCHMARK boilers require the following combustion air volumes when operated at full capacity.

• BMK 750 165 SCFM • BMK 1000 200 SCFM • BMK 1.5 325 SCFM • BMK 2.0 500 SCFM • BMK 3000/3.0 700 SCFM • BMK 6000 1400 SCFM

These flows MUST be accommodated. Air supply is a direct requirement of NFPA, CSA B149.1-10 (Canada) and local codes that should be consulted for correct design implementation.

In equipment rooms containing other air-consuming equipment ― including air compressors and other combustion equipment ― the combustion air supply system must be designed to accommodate all such equipment when all are operating simultaneously at maximum capacity.

Combustion air intakes must be located in areas that will not induce excessive (>0.10" water column (W.C.)) intake air pressure fluctuations. Designs should take into account equipment blowers and exhausts when using room air for combustion.

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Intakes should be located to prevent infiltration of chlorides, halogens or any other chemicals that would be detrimental to the operation of combustion equipment. Common sources of these compounds are swimming pools, degreasing compounds, salts, plastic processing and refrigerants. When the environment contains these types of chemicals, the air MUST be supplied from the outdoors using direct-vent/sealed-combustion ductwork.

Air intakes must not be located in the proximity of garages, industrial and medical hood venting, loading docks or refrigerant vent lines. Boilers should not be installed in the proximity of activities that generate dust if that dust can enter the boiler intake. Boilers should be located to prevent moisture and precipitation from entering combustion air inlets.

When a boiler is used, temporarily, to provide heat during ongoing building construction or renovation, accumulated drywall dust, sawdust and similar particles can:

Accumulate in the unit’s combustion air intake and block combustion air flow

Accumulate over the burner surface and restrict flow of air/fuel mixture

In these situations, AERCO recommends that a disposable air intake filter be installed, temporarily, above the boiler combustion air inlet. Air filters may be required year-round in instances in which dust or debris can enter the combustion air tube. Consult the boiler Operations and Maintenance Manual for details.

Combustion air temperatures as low as -30°F can be used without affecting the integrity of the equipment; however, the combustion settings may require adjustment to compensate for site conditions.

Combustion Air from WITHIN the Building

Where combustion air will originate from within the building, air must be provided to the equipment room from two permanent openings to an interior room (or rooms). The sheetmetal knockout above the air inlet must remain in place to prevent debris from falling into the combustion air inlet of the boiler. (This knockout is removed only when sealed combustion is used.)

Openings connecting indoor spaces shall be sized and located in accordance with the following:

Each opening shall have a minimum free area of 1 inch2 per 1,000 BTU/hr (2,200 mm2/kW) of total input rating of all appliances in the space, but not less than 100 inch2 (0.06 m2). One opening shall commence within 12 inches (300 mm) of the top of the enclosure, and one opening shall commence within 12 inches (300 mm) of the bottom. (See Figure 2). The minimum dimension of air openings shall be not less than 3 inches (80 mm).

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BOILER

EXHAUST

Figure 2: All Combustion Air from Adjacent Indoor Spaces through Indoor Combustion Air Openings

Combustion Air from OUTSIDE the Building Outdoor combustion air shall be provided through opening(s) to the outdoors in accordance with the methods described below. The minimum dimension of air openings shall not be less than 3 inches (80 mm). The required size of the openings for combustion air shall be based upon the net free area of each opening. When the free area through a louver, grille, or screen is known, it shall be used to calculate the opening size required to provide the free area specified. For additional details, consult NFPA 54, or in Canada, CSA B149.1-10, paragraphs 8.4.1 and 8.4.3.

1.2 Two-Permanent-Openings Method (USA Only) Two permanent openings shall be provided; one commencing within 12 inches (300 mm) of the top of the enclosure and one commencing within 12 inches (300 mm) of the bottom. The openings shall communicate directly ― or by ducts ― with the outdoors, or spaces that freely communicate with the outdoors, as show on the following page:

1. When communicating directly with the outdoors, or when communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 inch2 per 4,000 BTU/hr (550 mm2/kW) of total input rating of all appliances in the space (See Figure 3 and Figure 4).

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BOILER

EXHAUST

ALTERNATEBOTTOMOPENING

VENTILATION LOUVERS FORUNHEATED CRAWL SPACE

Figure 3: All Combustion Air From Outdoors - Inlet Air From Ventilated Crawl Space and Outlet Air to Ventilated Attic

BOILER

EXHAUST

INLET AIR DUCT(ENDS 1 FT ABOVE FLOOR)

OPENING

Figure 4: All Combustion Air from Outdoors - Through Ventilated Attic

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2. When communicating with the outdoors through horizontal ducts, each opening shall have a

minimum free area of 1 inch2 per 2,000 BTU/hr (1100 mm2/kW) of total input rating of all appliances in the space (See Figure 5).

BOILER

EXHAUST

AIR DUCT

AIR DUCT

Figure 5: All Combustion Air from Outdoors Through Horizontal Ducts

1.3 One Permanent Opening Method One permanent opening shall be provided, commencing within 12 inches (300 mm) of the top of the enclosure. The appliance shall have clearances of at least 1 inches (25 mm) from the sides and back of the appliance, and a clearance of 6 inches (150 mm) from the front. The opening shall communicate with the outdoors directly or through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors (as shown in Figure 6) and shall have a minimum free area as follows:

1 inch2 per 3,000 BTU/hr (700 mm2/kW) of the total input rating of all appliances located in the space.

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BOILER

EXHAUST

ALTERNATEOPENINGLOCATION

Figure 6: All Combustion Air from Outdoors Through Single Combustion Air Opening

Opening a Louver Through the Benchmark Boiler

A louver can be opened using the auxiliary relay contacts of the BENCHMARK boiler. These contacts are provided by a single pole double throw (SPDT) relay that is energized when there is a demand for heat and is de-energized after that demand is satisfied. The relay contacts are rated for 120 VAC at 5 amps, resistive.

If the louver features a proof-of-open switch, it can be connected to the boiler’s delayed interlock. The delayed interlock must be closed for the unit to fire. If the louver requires time to open, a time-delay can be programmed to hold the start sequence of the boiler long enough for the proof-of-open switch to make (Parameter: Aux Start On Delay — programmable from 0 to 120 seconds). If the proof-of-open switch does not prove within the programmed time frame, the boiler will shut down.

For wiring connections and further details regarding the auxiliary relay, delayed interlock and the Aux Start On Delay parameter, refer to the BMK boiler’s Operations and Maintenance manual.

If an AERCO Boiler Management System II (BMS II) is being used to manage a multiple boiler installation, the louver can be opened using the System Start Relay of the BMS II. Refer to the BMS II Operations and Maintenance Manual, GF-124, for wiring connections and further details.

NOTE Do NOT power the louver directly using the Auxiliary Relay. An external relay (supplied by others) must be employed for this purpose. The boiler power cannot support external accessories.

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Direct Vent/Sealed Combustion The BENCHMARK is approved for direct vent installation; i.e., it can draw all combustion air from the outdoors through a metal or PVC duct connected between the BMK unit(s) and the outdoors. This configuration is useful for situations in which room air is insufficient or otherwise unsuitable for combustion. The minimum sealed combustion-air duct sizes for the BENCHMARK boilers are as follows:

• BMK 750 = 6-inch diameter • BMK 1000 = 6-inch diameter • BMK 1.5 = 6-inch diameter • BMK 2.0 = 8-inch diameter • BMK 3000/3.0 = 8-inch diameter • BMK 6000 = 14-inch diameter

In many installations, the combustion air duct can be manifolded for multiple unit applications.

If the system is designed around common air intake it cannot be common exhaust.

The length and restriction of the sealed combustion duct directly impact the size, length and restriction of the discharge venting. The direct vent air intake should be located at least 3 feet below any vent termination within 10 feet.

A screen with mesh size not smaller than 1” x 1” must be installed at the inlet of the sealed combustion air duct.

Exhaust Vent and Combustion Air Systems The BENCHMARK supports several venting and combustion air options, and although the application parameters vary, there are basic similarities among all systems. Tables 1 through 5 at the end of this Guide address the pressure drop of most applicable vent and duct fittings and sizes. The losses in the vent exit and air duct entrance are also included.

It should be noted that flow and vent or duct diameter have the most significant effects on overall system pressure drop. When using fittings or terminations not listed in Tables 1, 2 and 3, consult the device manufacturer for actual pressure drop values. If rectangular duct is to be used, consult Table 5 for a round diameter duct size that has the identical pressure drop per length of rectangular duct.

The pressure drop values in Table 1b and 1c are in equivalent feet of 8-inch diameter exhaust vent. Note that 1 equivalent foot of 8-inch diameter vent is equal to 0.00546-inch W.C.

The pressure drop values used in Table 1a are in equivalent feet of 6-inch diameter exhaust vent. Note that 1 equivalent foot of 6-inch diameter vent is equal to 0.00581-inch W.C.

IMPORTANT! DO NOT USE THE AERCO-SUPPLIED BOILER INLET SCREEN FOR THE SEALED COMBUSTION AIR DUCT. THIS SCREEN SHOULD BE REMOVED AT INSTALLATION OF THE SEALED COMBUSTION SYSTEM. DO NOT USE A FAN IN THE SEALED COMBUSTION

IMPORTANT! COMMON BREECHING OF AIR INTAKES CAN NOT BE COMBINED WITH COMMON BREECHING OF EXHAUSTS

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1.4 Gross Natural Draft Flue gases have a lower density (and are lighter) than air and will rise, creating "gross natural draft." Gross natural draft is created when flue gases exit the vent at an elevation above the BENCHMARK boiler. The amount of draft depends upon the height of the stack and the difference between the flue gas temperature and the surrounding air temperatures (densities). Gross natural draft values for stacks at various heights above the BMK unit are presented in Table 3, Part 1 and Part 2. These draft values are based on an installation site at sea level.

Adding the gross natural draft (negative) to the vent and air system pressure drop (positive) determines if the total system will be positive pressure or negative pressure ("net natural draft"). As with most combustion equipment, negative pressure (net natural draft) systems should be treated differently from positive pressure systems when the discharge vents are manifolded. Note that sidewall vent terminations, as well as some vertical terminations, are positive pressure systems.

Contact your AERCO sales representative or AERCO International for design assistance and approval when designing manifolded exhaust vent systems.

1.5 Acceptable Pressure Range The exhaust system must be designed so that pressure measured at every point is in the range from -0.25” W.C. to +0.81” W.C. Pressures below -0.25” W.C. (more negative) may cause flame instability. Pressures above +0.81 W.C. (more positive) will prevent flue gases from exiting.

1.6 Exhaust Fans If the BMK boiler’s exhaust system incorporates an exhaust fan, the system designer must size the vent pipe diameters, select the fan and determine the location of the fan sensor to maintain a -0.25” to +0.25” W.C. pressure range at the outlet of each boiler. Also, the designer must ensure that the exhaust fan material is acceptable for use with Category IV appliances.

1.7 Corrections for Altitude Table 4 lists correction factors for installation altitudes above sea level. These factors must be applied to both the natural draft and pressure drops of vent and air ducts. The pressure drop through vents and combustion air ducts will increase at higher elevations, while the natural draft will decrease.

CAUTION! Do NOT install a non-sealed draft control damper.

IMPORTANT! MANIFOLDED SYSTEMS CANNOT BE USED FOR BOTH COMMON BREECHING OF AIR INTAKES AND EXHAUST VENTS.. ONLY ONE TYPE OF COMMON BREECHING (AIR INTAKE OR EXHAUST) CAN BE USED; BUT NOT BOTH.

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1.8 Manifolded Systems In many instances it may be practical to connect multiple units using a manifolded vent or exhaust configuration. However, when multiple units are connected by a manifolded air intake or exhaust vent, the operation of a given unit can be affected by the others, if the venting or combustion air system is not designed properly. Properly designed common vent and air supply systems can be installed that will prevent "operational interaction" between units.

Do not use static regain method on common ductwork, but rather, use one duct size for the common run (See Figure 13).


1.9 Elbow Quantity and Separation The quantity and angle of elbows and the distances between them can influence the system’s exhaust and combustion air pressures, as well as its acoustical behavior. Designers should consider minimizing the quantity of elbows in the design and the use of angles less than 90°, whenever possible. Five or fewer elbows are recommended for individual venting/connections; five or fewer are recommended for common sections. The minimum distance required between two elbows is five feet.

Exhaust Muffler And Air Inlet Attenuator Guidelines The BENCHMARK requires an exhaust muffler when it is installed in a noise-sensitive application and when the exhaust vent ducting is relatively short in length. The following criteria should be used to determine when to include a field-installed muffler in a BENCHMARK installation:

• The exhaust is sidewall vented and the vent is terminated in close proximity to residences, offices, hotel/hospital rooms, classrooms etc.

OR

• The total vertical section of exhaust vent is less than 25 linear feet in length, and the vent terminates in close proximity to residences, offices, hotel/hospital rooms, classrooms etc.

For manifolded exhaust systems, the total vertical section includes only the common vertical; individual boiler vertical connectors are not included in the determination. For example, if the installation has a 20-foot common vertical, and each boiler has a 10-foot vertical connector, the total vertical section is only 20 feet. Because this length is less than 25 linear feet, a muffler is required.

For the BENCHMARK 1.5, an air inlet attenuator is required in addition to the exhaust muffler when the boiler is installed in a noise-sensitive application and when the sealed combustion ducting is relatively short in length. The following criteria shall be used to determine when to include an attenuator on a BENCHMARK 1.5 (field-installed) installation:

• Sidewall sealed combustion is employed and the intake is in close proximity to residences, offices, hotel/hospital rooms, classrooms etc.

OR

• The total vertical section of sealed combustion intake is less than 25 linear feet and the intake is in close proximity to residences, offices, hotel/hospital rooms, classrooms etc.

For manifolded sealed combustion, the total vertical section includes only the common vertical; individual boiler vertical connectors are not included in the determination.

For example, if a manifolded sealed combustion has 20-foot common vertical, and each boiler has a 10-foot vertical connector, the total vertical section is only 20 feet. Because this is less than 25 linear feet, an attenuator is required.

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An adapter kit is available for the BMK 750 and BMK 1000 units allowing the use of a muffler with PVC piping. When using PVC piping, it is necessary to install the muffler at the end of the vent piping, as shown in Figure 7. Part numbers for 6” and 8” kits are also shown in Figure 7.

Figure 7: Muffler Adapter Kits for BMK 750 & 1000 Using PVC Pipe Exhaust Venting

Contact your local AERCO sales representative for more information on the AERCO exhaust muffler and air inlet attenuator.

1.10 Vent and Combustion Air System Design Requirements The minimum exhaust vent and combustion air duct sizes for Benchmark Low NOx boilers models are as follows:

Benchmark Model

Minimum Exhaust Vent & Combustion Air Dust Diameter

BMK 750 6 inch dia.

BMK 1000 6 inch dia.

BMK 1.5 6 inch dia.

BMK 2.0 8 inch dia.

BMK 3000/3.0 8 inch dia.

BMK 6000 14 inch dia.

A 6-inch x 8-inch reducer, as illustrated in Figure 7d, is included with inlet air adapters to connect to an 8-inch diameter galvanized, aluminum or PVC sealed combustion air duct.

A ¼-inch NPT combustion test hole is provided on each unit’s exhaust manifold connection (See

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Figures 8a, 8b, 8c and 8d). A 24-inch length of straight vent is recommended downstream of the exhaust manifold, as illustrated in these figures.

The vent system should always be pitched up ¼ inch per foot of run towards the vent termination to enable condensate to drain back to the unit for disposal. Low spots in the vent must be avoided. Periodic inspection should be performed to assure correct drainage.

BENCHMARK vents should not be interconnected to those of other manufacturers' equipment.

Horizontal vent and ductwork should be supported to prevent sagging, in accordance with local code and the vent manufacturer’s requirements. Vertical vent and ductwork should be supported to prevent excessive stress on the horizontal runs. The exhaust manifold and inlet air adapter should never be used as weight-supporting elements. The supports should be so arranged and the overall layout designed to assure that stresses on the vent and combustion air connections are minimized.

The vents and combustion air ducts may be insulated in accordance with the vent manufacturer's instructions and local codes.

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6" MINIMUM

Figure 8a: Sealed Combustion Connection for BMK 750 & BMK 1000 Boilers

Figure 8b: Sealed Combustion Connection for BMK 1.5 & BMK 2.0 Boilers

6” MINIMUM

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8" MINIMUMAIR INLET

ALTERNATE8" MINIMUM AIR INLET(1 EACH SIDE)

Figure 8c: Sealed Combustion Connection for a BMK3000 Boiler

8" MINIMUM6x8 REDUCER

Figure 8d: Sealed Combustion Connection for a BMK3.0 Boiler

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AIR INLET14" MINIMUM DIA.

Figure 8e: Sealed Combustion Connection for a BMK6000 Boiler

EXHAUSTMANIFOLD

CONDENSATE DRAINCONNECTION

VENT PROBEPORT

UNITFRAME

PARTIAL TOP VIEW

MIN. 24" STRAIGHT VENT STARTER

6" FLUE SIZE

Figure 9a: Vent Starter Section – BMK750, BMK1000, and BMK1.5

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Figure 9b: Vent Starter Section – BMK2.0

Figure 9c: Vent Starter Section – BMK3.0

Figure 9d: Vent Starter Section – BMK3000

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Figure 9e: Vent Starter Section – BMK6000

Condensate Removal The exhaust vent system must be pitched back toward the BMK unit by a minimum of ¼-inch per foot of duct length to enable condensate to drain back to the unit for disposal. Low spots in the vent must be avoided to prevent the condensate from collecting.

The condensate trap assembly is located directly below the exhaust manifold. Plastic hose should be connected to the trap assembly and run to drain. Care should be taken to avoid hose kinks and to avoid raising the hose above the trap assembly. Condensate should flow freely to drain. The condensate-to-drain run must not be hard-piped so the trap can be removed periodically for maintenance purposes.

The BMK3.0 has a second condensate connection, a 1-inch connection port on the exhaust manifold. It may be run directly to drain or connected into the outlet of the condensate trap via a Tee, which can then be run to drain. If the condensate must be lifted above the trap assembly to a drain, it should be drained into a sump. From there, a pump can lift the condensate away.

Each unit will produce the following approximate condensate quantities in the full condensing mode:

• BMK 750 = 6 gallons per hour • BMK 1000 = 8 gallons per hour • BMK 1.5 = 9 gallons per hour • BMK 2.0 = 10 gallons per hour • BMK 3000/3.0 = 20 gallons per hour • BMK 6000 = 40 gallons per hour

Condensate drain systems must be sized for full condensing mode.

In multiple boiler applications, it is common to manifold these drains together in a plastic pipe manifold to a floor drain. Condensate manifolds must be large enough to handle the anticipated flow and must be properly secured and protected. Manifolds are generally located behind the boilers so that short runs of plastic tubing into the manifold can be used for the condensate drain. A base drain must be installed at the bottom of vertical common flue piping (see Figure 13a).

The pH level of the condensate produced by BMK boilers ranges between 3.0 and 3.2. The installation should be designed in accordance with local codes that specify acceptable pH limits. If required, any type of commercially available neutralizer may be used.

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1.11 Individually Vented Systems Systems with individual vents may be used with any of the combustion air systems described previously and illustrated in Figure 9. The maximum combined pressure drop of the vent and combustion air system must not exceed 140 equivalent feet of length.

To calculate the pressure drop:

1) Calculate the exhaust vent pressure drop. 2) Calculate the combustion duct pressure drop. 3) Divide the vent pressure drop by the altitude correction factor (CF) listed in Table 4 to correct for

installations above sea level. 4) Determine the natural draft, if any, from Table 3 and multiply it by the altitude CF. 5) Add the altitude corrected vent pressure drop (positive) and the draft (negative) to get the total

vent pressure drop. 6) Add the total vent pressure drop to the altitude corrected combustion air duct pressure drop.

The total system pressure drop must not exceed 140 equivalent feet.

1.11.1 BMK 1.5 Example: Calculate the maximum pressure drop for a single boiler installation at 500 feet above sea level having a winter design temperature of 20°F. The duct system consists of:

1) An 6-inch diameter exhaust vent with three 90° elbows, two 45° elbows, 50 feet of horizontal run, 20 feet of vertical run

2) A rain cap termination 3) A 6-inch diameter sealed combustion air duct with two 90° elbows and 50 feet of run

Calculation: 6-inch Diameter Exhaust Vent Pressure Two 90° elbows: 2 x 3.11 = 26.22 ft One 45° elbow: 1 x 9.98= 9.98 ft 35 feet total run

(5 horizontal + 20 vertical): 25 x 1.70 = 42.50 ft Rain cap exit loss: 1 x 21.95 = 21.95 ft Vent drop subtotal: = 100.65 ft Altitude correction: 100.65 = 102.49 ft 0.982 (CF) Natural draft for 20 feet @ 20°F outside temperature: = 12.6 ft Altitude correction: -12.6 x 0.982 CF = -12.37 ft Total vent drop: = 90.12 ft 6-inch Diameter Combustion Air Duct Pressure Two 90° elbows: 2 x 5.84 = 11.68 ft 50 feet total run: 20 x 1.06 = 21.20 ft Entrance loss: 1 x 8.60 = 8.60 ft Combustion air drop subtotal: = 41.48 ft Altitude correction: = 41.48 = 42.24 ft 0.982 CF Combustion air drop total: = 42.24 ft System total pressure drop Vent drop + combustion air duct pressure drop = 90.12 + 42.24 = 132.36 ft

Conclusion: Pressure drop is less than 140 equivalent feet. System OK.

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1.12 Manifolded Sealed Combustion For systems using manifolded sealed combustion ductwork, use the longest length of common duct and the individual branch to the furthest boiler to calculate the pressure drop.

Figure 9: Individual Vents

Figure 10: Individual Vents

ACCEPTABLE INSTALLATIONS

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Common Vent Breeching (Manifolded) AERCO forced draft boilers are designed for application in common vent systems.


Connections to common vent breeching or duct work must be accomplished with a 45° elbow in the direction of flow in the main breeching. “Tees” should not be used to accomplish these connections. See Figure 10.

RECOMMENDED NOTRECOMMENDED

ENTER

INDEXAL

AL

LOVE

CONTROLS

CORP.ENTER

INDEXAL

AL

LOVE

CONTROLS

CORP.

Figure 11: Recommended Connections to Common Vent Breeching Interconnection of groups of units must never be accomplished via a “tee”. As shown in Figure 11, change the direction with one of the mains and then connect the second three diameters (common section diameter) from this turn via a 45° connection.

RECOMMENDEDNOT

RECOMMENDED

45°3X DIA. MIN.

Figure 11: Required Interconnection of Groups of Units Figure 12 illustrates the preferable “transition vent section” when making the 45° connection into a main. The main can also remain at one diameter, as long as it is sized for the total number of units vented and the 45° branch connection is retained. Use of the preferred “transition” assembly will reduce the overall

NOT APPROVED

REQUIRED

NOT APPROVED REQUIRED

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system pressure drop.

RECOMMENDEDNOT

RECOMMENDED

Figure 12: Required Transition Vent Sections

The vent system should always be pitched up ¼-inch per foot of run towards the vent termination (See Figure 13). This will enable condensate to drain back to the unit for disposal. Low spots in the vent must be avoided. Inspect periodically to ensure correct drainage.

As shown in Figure 13, the unit at the end of the vent main must be connected via an elbow. An end cap must not be used as it may cause vibration and flue pressure fluctuations.

As discussed previously, the static regain method should not be used for common ductwork, but rather, the one duct size should be used for the common run.

BMK vents should never be interconnected to those connected to other manufacturers’ equipment.

NOT APPROVED REQUIRED

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PER FOOT RUN1/4" RISE

PER FOOT RUN1/4" RISE

CONDENSATEDRAIN

DRAINCONDENSATE

a. Required b. Static Regain Method Not Approved

Figure 13: Connection of Unit at End of Vent Main

Pressure Drop and Draft Data Tables

Table 1a:

Discharge Flue Vent Pressure Drop (Eq. Ft.) for Single BMK 750 MBTU Boiler (Assuming 180°F Water Temperature and 20°F Rise at Sea Level)

Flue Vent (in. Dia.)

Flue Velocity (ft/sec)

Straight Run (eq. ft / foot)

90° elbow (eq. ft)

45° elbow (eq. ft)

Exit Loss Horiz. Term.

(eq. ft)

Exit Loss Rain Cap

(eq. ft) 6 16.65 0.45 2.90 2.15 3.59 5.13 8 9.37 0.11 0.74 0.56 1.14 2.11 10 5.99 0.04 0.26 0.20 0.47 0.86 12 4.16 0.02 0.11 0.09 0.22 0.42 14 3.06 0.01 0.06 0.04 0.12 0.23

Table 1b: Discharge Flue Vent Pressure Drop (Eq. Ft.) for Single BMK 1000 MBTU Boiler

(Assuming 180°F Water Temperature and 20°F Rise at Sea Level)




90° elbow (eq. ft)

45° elbow (eq. ft)


(eq. ft)

Exit Loss Rain Cap

(eq. ft)

6 22.20 0.77 5.15 3.82 6.39 9.12 8 12.49 0.18 1.32 0.99 2.02 3.75 10 7.99 0.06 0.47 0.36 0.83 1.54 12 5.55 0.03 0.20 0.16 0.40 0.74 14 4.08 0.01 0.10 0.08 0.22 0.40

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Table 1c: Discharge Flue Vent Pressure Drop (Eq. Ft.) for Single BMK1.5 MMBTU Boiler

Table 1d:

Discharge Venting Pressure Drop for Single BMK2.0 MBTU Boiler (Assuming 180ºF Water Temperature and 20ºF Rise at Sea Level)




90° elbow (eq. ft)

45° elbow (eq. ft)


(eq. ft)

Exit Loss Rain Cap

(eq. ft) 8 26.35 0.71 5.86 4.42 9.00 16.71

10 16.87 0.23 2.08 1.59 3.69 6.85 12 11.71 0.09 0.91 0.70 1.78 3.30 14 8.60 0.04 0.46 0.35 0.96 1.78 16 6.59 0.02 0.25 0.20 0.56 1.04 18 5.21 0.01 0.15 0.12 0.35 0.65

Table 1e: Discharge Flue Vent Pressure Drop (Eq. Ft.) for Single BMK3000/3.0 MMBTU Boiler

Table 1f: Discharge Flue Vent Pressure Drop (Eq. Ft.) for Single BMK 6000 MMBTBoiler

(Assuming 180°F Water Temperature and 20°F Rise at Sea Level) Flue Vent

(in. Dia.) Flue Velocity

(ft/sec) Straight Run (eq. ft / foot)

90° elbow (eq. ft)

45° elbow (eq. ft)

Exit Loss Horiz. Term. (eq. ft)

Exit Loss Rain Cap

(eq. ft) 12 30.59 0.64 6.20 4.80 12.13 22.53 14 22.48 0.29 3.11 2.42 6.55 12.16 16 17.21 0.15 1.72 1.34 3.84 7.13 18 13.60 0.08 1.02 0.79 2.40 4.45 20 11.01 0.05 0.64 0.50 1.57 2.92

Table 2a:




90° elbow (eq. ft)

45° elbow (eq. ft)


(eq. ft)

Exit Loss Rain Cap (eq. ft)

6 34.43 1.70 13.11 9.98 15.37 21.958 19.37 0.40 3.13 2.36 4.86 9.0310 12.40 0.13 1.06 0.80 1.99 3.7012 8.62 0.05 0.46 0.35 0.96 1.7814 6.33 0.03 0.24 0.19 0.52 0.9616 4.85 0.01 0.14 0.11 0.30 0.56





90° elbow (eq. ft)

45° elbow (eq. ft)


(eq. ft)

Exit Loss Rain Cap (eq. ft)

8 37.89 1.46 11.98 9.01 18.60 34.5410 24.25 0.47 4.05 3.04 7.62 14.1512 16.84 0.19 1.76 1.34 3.67 6.8214 12.37 0.09 0.92 0.71 1.98 3.6816 9.47 0.05 0.53 0.42 1.16 2.1618 7.48 0.03 0.33 0.26 0.73 1.35


06/21/2012 Page 29 of 40


GF-2050


Sealed Combustion Air Duct Pressure Drop (Eq. Ft.) for BMK 750 MBTU Boiler

Outside Air Temperature (°F)

Inlet Duct &

No. Boilers

Duct Section

Type -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F

6" Duct Single Boiler

Straight Run 0.27 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 90° Elbow 1.18 1.23 1.29 1.38 1.47 1.57 1.68 1.79 1.91 45° Elbow 0.87 0.91 0.96 1.02 1.09 1.16 1.24 1.32 1.41 Ent. Loss 1.83 1.92 2.02 2.15 2.29 2.45 2.61 2.79 2.97



8" Duct Two

Boilers


10" Duct Two

Boilers


10" Duct Three Boilers




12" Duct Four

Boilers


14" Duct Four

Boilers


NOTES: 1) Calculation assumes 300scfm per boiler at full fire rate

2) Units for "Straight Run" pressure drop values are (eq. ft. / foot)

3) Units for "Elbows" and "Ent. Loss" are (equivalent feet / item)

Table 2b:

Page 30 of 40 06/21/2012


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Sealed Combustion Air Duct Pressure Drop (Eq. Ft.) for BMK 1000 MBTU Boiler


Inlet Duct & No.

Boilers

Duct Section Type -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F





8" Duct Two Boilers


10" Duct Two Boilers






12" Duct Four

Boilers


14" Duct Four

Boilers


NOTES: 1) Calculation assumes 300scfm per boiler at full fire rate

2) Units for "Straight Run" pressure drop values are (eq. ft. / foot)

3) Units for "Elbows" and "Ent. Loss" are (equivilent feet / item)

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Table 2c: Sealed Combustion Air Duct Pressure Drop (Eq. Ft.) for BMK1.5 MMBTU Boiler

Table 2d:

Inlet Duct & No. Boilers

Duct Section

Type -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °FStraight Run 0.98 1.00 1.02 1.06 1.09 1.13 1.16 1.20 1.2490° Elbow 4.97 5.21 5.47 5.84 6.23 6.64 7.09 7.56 8.0745° Elbow 3.78 3.97 4.17 4.44 4.74 5.06 5.40 5.76 6.14Ent. Loss 7.33 7.69 8.07 8.60 9.18 9.79 10.45 11.15 11.89

Straight Run 0.23 0.24 0.24 0.25 0.26 0.27 0.28 0.29 0.3090° Elbow 1.19 1.25 1.31 1.39 1.49 1.59 1.69 1.81 1.9345° Elbow 0.89 0.94 0.98 1.05 1.12 1.19 1.27 1.36 1.45Ent. Loss 2.32 2.43 2.55 2.72 2.90 3.10 3.31 3.53 3.76







NOTES: 1) Calculation assumes 300scfm per boiler at full fire rate2) Units for "Straight Run" pressure drop values are (eq. ft. / foot)3) Units for "Elbows" and "Ent. Loss" are (equivilent feet / item)





16" Duct Four Boilers





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Sealed Combustion Air Duct Pressure Drop for BMK2.0 MMBTU Boiler Outside Air Temperature (°F)

Inlet Duct & No.

Boilers Duct Section

Type -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F













18" Duct Four

Boilers


20" Duct Four

Boilers


NOTES : 1) Calculation assumes 600 scfm per boiler at full fire rate.

2) Units for “Straight Run” pressure drop values are (eq. ft. / foot).

3) Units for “Elbows” and “Ent. Loss” are (equivalent feet / item).

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Table 2e: Sealed Combustion Air Duct Pressure Drop for BMK3000/3.0 MMBTU Boiler

Inlet Duct & No. Boilers

Duct Section

Type -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F Straight Run 0.85 0.87 0.89 0.91 0.94 0.97 1.00 1.03 1.06 90° Elbow 4.75 4.98 5.23 5.58 5.95 6.35 6.77 7.23 7.71 45° Elbow 3.57 3.75 3.93 4.20 4.48 4.78 5.09 5.44 5.80 Ent. Loss 9.27 9.73 10.21 10.89 11.62 12.39 13.22 14.11 15.05








NOTES: 1) Calculation assumes 700scfm per boiler at full fire rate 2) Units for "Straight Run" pressure drop values are (eq. ft. / foot) 3) Units for "Elbows" and "Ent. Loss" are (equivilent feet / item)

Sealed Combustion Air Duct Pressure Drop (Eq. Ft.) for BMK 3.0MMBTU Boiler










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Table 2e: Sealed Combustion Air Duct Pressure Drop for BMK 6000 MMBTU Boiler


Inlet Duct &

No. Boilers

Duct Section

Type -30 °F -15 °F 0 °F 20 °F 40 °F

60 °F

80 °F

100 °F

120 °F





18" Duct Two

Boilers


20" Duct Two

Boilers






24" Duct Four

Boilers

Straight Run 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.23 0.24 90° Elbow 2.17 2.27 2.39 2.54 2.71 2.90 3.09 3.30 3.52 45° Elbow 1.69 1.77 1.86 1.98 2.11 2.25 2.40 2.57 2.74

Ent. Loss 7.33 7.69 8.07 8.60 9.18 9.79 10.45 11.15 11.89

26" Duct Four

Boilers


NOTES: 1) Calculation assumes 1200scfm per boiler at full fire rate 2) Units for "Straight Run" pressure drop values are (eq. ft. / foot) 3) Units for "Elbows" and "Ent. Loss" are (equivilent feet / item)

06/21/2012 Page 35 of 40


GF-2050


Table 3a- Part 1: Gross Natural Draft (Inch w.c.) for BMK 1000/750 Low NOx Boilers


Stack Height (ft) -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F

5 0.024 0.022 0.021 0.018 0.016 0.014 0.011 0.009 0.007 10 0.048 0.045 0.041 0.037 0.032 0.028 0.023 0.018 0.014 15 0.072 0.067 0.062 0.055 0.048 0.041 0.034 0.028 0.021 20 0.096 0.089 0.083 0.073 0.064 0.055 0.046 0.037 0.028 25 0.120 0.112 0.103 0.092 0.080 0.069 0.057 0.046 0.034 30 0.144 0.134 0.124 0.110 0.096 0.083 0.069 0.055 0.041 35 0.168 0.156 0.144 0.128 0.112 0.096 0.080 0.064 0.048 40 0.193 0.179 0.165 0.147 0.128 0.110 0.092 0.073 0.055 45 0.217 0.201 0.186 0.165 0.144 0.124 0.103 0.083 0.062 50 0.241 0.223 0.206 0.183 0.160 0.138 0.115 0.092 0.069 75 0.361 0.335 0.309 0.275 0.241 0.206 0.172 0.138 0.103 100 0.481 0.447 0.413 0.367 0.321 0.275 0.229 0.183 0.138 125 0.602 0.559 0.516 0.458 0.401 0.344 0.287 0.229 0.172 150 0.722 0.670 0.619 0.550 0.481 0.413 0.344 0.275 0.206 175 0.842 0.782 0.722 0.642 0.562 0.481 0.401 0.321 0.241 200 0.963 0.894 0.825 0.734 0.642 0.550 0.458 0.367 0.275

Table 3a-Part 2:

Gross Natural Draft (Eq. Ft.) for BMK 1000/750 Low NOx Boilers



5 4.1 3.8 3.5 3.2 2.8 2.4 2.0 1.6 1.2 10 8.3 7.7 7.1 6.3 5.5 4.7 3.9 3.2 2.4 15 12.4 11.5 10.6 9.5 8.3 7.1 5.9 4.7 3.5 20 16.6 15.4 14.2 12.6 11.0 9.5 7.9 6.3 4.7 25 20.7 19.2 17.7 15.8 13.8 11.8 9.9 7.9 5.9 30 24.8 23.1 21.3 18.9 16.6 14.2 11.8 9.5 7.1 35 29.0 26.9 24.8 22.1 19.3 16.6 13.8 11.0 8.3 40 33.1 30.8 28.4 25.2 22.1 18.9 15.8 12.6 9.5 45 37.3 34.6 31.9 28.4 24.8 21.3 17.7 14.2 10.6 50 41.4 38.4 35.5 31.5 27.6 23.7 19.7 15.8 11.8 75 62.1 57.7 53.2 47.3 41.4 35.5 29.6 23.7 17.7 100 82.8 76.9 71.0 63.1 55.2 47.3 39.4 31.5 23.7 125 103.5 96.1 88.7 78.9 69.0 59.1 49.3 39.4 29.6 150 124.2 115.3 106.4 94.6 82.8 71.0 59.1 47.3 35.5 175 144.9 134.5 124.2 110.4 96.6 82.8 69.0 55.2 41.4 200 165.6 153.8 141.9 126.2 110.4 94.6 78.9 63.1 47.3

Note: Based on 160°F to 180°F Boiler Water

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Table 3b-Part 1: Gross Natural Draft (Inch W.C.) for BMK1.5, BMK2.0 and BMK3000/3.0 Low NOx

Boilers

Table 3b-Part 2:

Gross Natural Draft (Eq. Ft.) for BMK1.5, BMK2.0 and BMK3000/3.0 Low NOx Boilers

Stack Height (ft) -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F5 0.024 0.022 0.021 0.018 0.016 0.014 0.011 0.009 0.007

10 0.048 0.045 0.041 0.037 0.032 0.028 0.023 0.018 0.01415 0.072 0.067 0.062 0.055 0.048 0.041 0.034 0.028 0.02120 0.096 0.089 0.083 0.073 0.064 0.055 0.046 0.037 0.02825 0.120 0.112 0.103 0.092 0.080 0.069 0.057 0.046 0.03430 0.144 0.134 0.124 0.110 0.096 0.083 0.069 0.055 0.04135 0.168 0.156 0.144 0.128 0.112 0.096 0.080 0.064 0.04840 0.193 0.179 0.165 0.147 0.128 0.110 0.092 0.073 0.05545 0.217 0.201 0.186 0.165 0.144 0.124 0.103 0.083 0.06250 0.241 0.223 0.206 0.183 0.160 0.138 0.115 0.092 0.06975 0.361 0.335 0.309 0.275 0.241 0.206 0.172 0.138 0.103

100 0.481 0.447 0.413 0.367 0.321 0.275 0.229 0.183 0.138125 0.602 0.559 0.516 0.458 0.401 0.344 0.287 0.229 0.172150 0.722 0.670 0.619 0.550 0.481 0.413 0.344 0.275 0.206175 0.842 0.782 0.722 0.642 0.562 0.481 0.401 0.321 0.241200 0.963 0.894 0.825 0.734 0.642 0.550 0.458 0.367 0.275


Stack Height (ft) -30 °F -15 °F 0 °F 20 °F 40 °F 60 °F 80 °F 100 °F 120 °F5 4.1 3.8 3.5 3.2 2.8 2.4 2.0 1.6 1.2

10 8.3 7.7 7.1 6.3 5.5 4.7 3.9 3.2 2.415 12.4 11.5 10.6 9.5 8.3 7.1 5.9 4.7 3.520 16.6 15.4 14.2 12.6 11.0 9.5 7.9 6.3 4.725 20.7 19.2 17.7 15.8 13.8 11.8 9.9 7.9 5.930 24.8 23.1 21.3 18.9 16.6 14.2 11.8 9.5 7.135 29.0 26.9 24.8 22.1 19.3 16.6 13.8 11.0 8.340 33.1 30.8 28.4 25.2 22.1 18.9 15.8 12.6 9.545 37.3 34.6 31.9 28.4 24.8 21.3 17.7 14.2 10.650 41.4 38.4 35.5 31.5 27.6 23.7 19.7 15.8 11.875 62.1 57.7 53.2 47.3 41.4 35.5 29.6 23.7 17.7

100 82.8 76.9 71.0 63.1 55.2 47.3 39.4 31.5 23.7125 103.5 96.1 88.7 78.9 69.0 59.1 49.3 39.4 29.6150 124.2 115.3 106.4 94.6 82.8 71.0 59.1 47.3 35.5175 144.9 134.5 124.2 110.4 96.6 82.8 69.0 55.2 41.4200 165.6 153.8 141.9 126.2 110.4 94.6 78.9 63.1 47.3



06/21/2012 Page 37 of 40


GF-2050


Table 3c-Part 1: Gross Natural Draft (Inch W.C.) for BMK 6000 Low NOx Boilers

Outside Air Design Temperature (°F)


5 0.024 0.022 0.021 0.018 0.016 0.014 0.011 0.009 0.007 10 0.048 0.045 0.041 0.037 0.032 0.028 0.023 0.018 0.014 15 0.072 0.067 0.062 0.055 0.048 0.041 0.034 0.028 0.021 20 0.096 0.089 0.083 0.073 0.064 0.055 0.046 0.037 0.028 25 0.120 0.112 0.103 0.092 0.080 0.069 0.057 0.046 0.034 30 0.144 0.134 0.124 0.110 0.096 0.083 0.069 0.055 0.041 35 0.168 0.156 0.144 0.128 0.112 0.096 0.080 0.064 0.048 40 0.193 0.179 0.165 0.147 0.128 0.110 0.092 0.073 0.055 45 0.217 0.201 0.186 0.165 0.144 0.124 0.103 0.083 0.062 50 0.241 0.223 0.206 0.183 0.160 0.138 0.115 0.092 0.069 75 0.361 0.335 0.309 0.275 0.241 0.206 0.172 0.138 0.103 100 0.481 0.447 0.413 0.367 0.321 0.275 0.229 0.183 0.138 125 0.602 0.559 0.516 0.458 0.401 0.344 0.287 0.229 0.172 150 0.722 0.670 0.619 0.550 0.481 0.413 0.344 0.275 0.206 175 0.842 0.782 0.722 0.642 0.562 0.481 0.401 0.321 0.241 200 0.963 0.894 0.825 0.734 0.642 0.550 0.458 0.367 0.275

Table 3c-Part 2:

Gross Natural Draft (Eq. Ft.) for BMK 6000 Low NOx Boilers



5 4.1 3.8 3.5 3.2 2.8 2.4 2.0 1.6 1.2 10 8.3 7.7 7.1 6.3 5.5 4.7 3.9 3.2 2.4 15 12.4 11.5 10.6 9.5 8.3 7.1 5.9 4.7 3.5 20 16.6 15.4 14.2 12.6 11.0 9.5 7.9 6.3 4.7 25 20.7 19.2 17.7 15.8 13.8 11.8 9.9 7.9 5.9 30 24.8 23.1 21.3 18.9 16.6 14.2 11.8 9.5 7.1 35 29.0 26.9 24.8 22.1 19.3 16.6 13.8 11.0 8.3 40 33.1 30.8 28.4 25.2 22.1 18.9 15.8 12.6 9.5 45 37.3 34.6 31.9 28.4 24.8 21.3 17.7 14.2 10.6 50 41.4 38.4 35.5 31.5 27.6 23.7 19.7 15.8 11.8 75 62.1 57.7 53.2 47.3 41.4 35.5 29.6 23.7 17.7 100 82.8 76.9 71.0 63.1 55.2 47.3 39.4 31.5 23.7 125 103.5 96.1 88.7 78.9 69.0 59.1 49.3 39.4 29.6 150 124.2 115.3 106.4 94.6 82.8 71.0 59.1 47.3 35.5 175 144.9 134.5 124.2 110.4 96.6 82.8 69.0 55.2 41.4 200 165.6 153.8 141.9 126.2 110.4 94.6 78.9 63.1 47.3


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Table 4: Altitude Correction

Site Elevation (feet above sea level)

Altitude Correction Factor (CF)

0 1 500 0.982 1000 0.964 1500 0.947 2000 0.930 2500 0.913 3000 0.896 3500 0.880 4000 0.864 4500 0.848 5000 0.832 5500 0.817 6000 0.801 6500 0.787 7000 0.772 7500 0.758 8000 0.743 8500 0.729 9000 0.715 9500 0.701

10000 0.688

Table 5: Round Duct of Identical Pressure Drop to Rectangular Duct

Adjacent Side of Duct

(in.) Side of Rectangular Duct (in.)

6 8 10 12 14 16 18 20 22 24 6 6.6 8 7.6 8.7

10 8.4 9.8 10.9 12 9.1 10.7 12 13.1 14 9.8 11.5 12.9 14.2 15.3 16 10.4 12.2 13.7 15.1 16.4 17.5 18 11 12.9 14.5 16 17.3 18.5 19.7 20 11.5 13.5 15.2 16.8 18.2 19.5 20.7 21.9 22 12 14.1 15.9 17.6 19.1 20.4 21.7 22.9 24 24 12.4 14.6 16.5 18.3 19.9 21.3 22.7 23.9 25.1 26.2

Reference: 1. National Fuel Gas Code, 2006 edition, American National Standards Institute, Inc

(ANSI Z223.1-2006) and National Fire Protection Association (NFPA54-2006)

2. CSA B149.1 (For Canada installations)

06/21/2012 Page 39 of 40


GF-2050


NOTES:

Page 40 of 40 06/21/2012


GF-2050 TAG-0022_0L


© AERCO International, Inc., 2008

GF-2070 TAG-0019_0E



For All Benchmark Series Models: • BMK 750 • BMK 1000 • BMK 1.5 • BMK 2.0 • BMK 3000 • BMK 6000 04/12/2012

BENCHMARK BOILER APPLICATION GUIDE

GF-2070 Benchmark Series Water Boilers TAG-0019_0E Technical Application Guide

Page 2 of 18 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph.: 800-526-0288 04/12/2012

Technical Support (Mon-Fri, 8am-5pm EST)

1-800-526-0288

www.aerco.com

Disclaimer


Benchmark Series Boilers GF-2070 Technical Application Guide TAG-0019_0E

PR1 04/12/2012 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 1 of 18

TABLE OF CONTENTS 1. GENERAL ................................................................................................................................................. 3 2. SINGLE AND MULTIPLE APPLICATIONS .............................................................................................. 3 3. PIPING ...................................................................................................................................................... 3

3.1 Pressure, Temperature, and Flow Restrictions: .................................................................................. 3 3.2 Multiple Boiler Piping Design ............................................................................................................... 4 3.3 Service Provisions ............................................................................................................................... 4 3.4 Hydronic System Accessories ............................................................................................................. 4 3.5 Condensate Piping .............................................................................................................................. 5

4. CONTROLS .............................................................................................................................................. 5 4.1 Safety Control ...................................................................................................................................... 5 4.2 Internal Boiler Operating Control Options ........................................................................................... 5 4.3 Field Sensor Location .......................................................................................................................... 6 4.4 Multiple Boiler Control ......................................................................................................................... 6

5. TYPICAL APPLICATIONS ........................................................................................................................ 6 5.1 Single Heating Boiler ― Heating Only ................................................................................................ 7 5.2 Four Boiler ― Heating Only ................................................................................................................ 9 5.3 Two Boiler Heating Plant ― ACS with Individual Isolation Valves .................................................... 12 5.4 Primary-Secondary Pumping ............................................................................................................ 12 5.5 Three Boiler Combination Heating and Domestic Water System ..................................................... 13

GF-2070 Benchmark Series Boilers OMM-0019_0E Technical Application Guide


This Page Is Intentionally Blank



1. GENERAL AERCO BENCHMARK (BMK) boilers can be used in any hydronic closed-loop heating system application, within the limitations of temperature and pressure ratings. Because of their extreme flexibility and precise control, they can be used to supplement any hot water system. This guide is intended to help designers apply AERCO boilers to the most common types of systems. If a special application is needed, please call your local AERCO Representative or the AERCO factory for specific application information. CAD drawing packages are available for layout specification.

2. SINGLE AND MULTIPLE APPLICATIONS AERCO BMK boilers can be applied either as stand-alone single units or in multiple batteries of boilers with unlimited input. BMK multiple boiler systems minimize floor space requirements and more importantly, modulate under partial loads to match the changing requirements of the energy input.

Actual boiler sizing and selection are the responsibility of the designer. ASHRAE standards recommend sizing equipment with a minimum of over sizing for maximum system efficiency. A multiple BMK boiler installation matches any load fluctuation from 0 to 100% without overshoot. AERCO subscribes to and recommends the methods used by ASHRAE and IBR to develop required loads and sizes.

3. PIPING 3.1 Pressure, Temperature, and Flow Restrictions: With the exception of the BMK 6000, all other BMK Series units are ASME certified for working pressures of up to 160 psig. The maximum working pressure for the BMK 6000 is 80 psig. BMK boilers cannot be used in applications where their allowable pressure ratings can be exceeded, or irreparable damage may result. Individual ASME pressure relief valves are supplied on each boiler in setpoints of 30, 50, 60, 75, 100, 125, 150, or 160 psig, as specified.

NOTE The piping connections illustrated throughout this bulletin are based on the BMK2.0. See dimensional drawings for connection locations for BMK 750, BMK 1000, BMK1.5, BMK 3000 and BMK 6000 units.

P&T

P&T

P&T

CONDENSATEDRAIN TRAP

HEATINGSYSTEM SUPPLY

HEATING SYSTEM RETURN

1-1/2" NPTDRAIN CONN.

RELIEF VALVE (TYP.)

PRESSURE & TEMPERATURE GAUGE

BALANCINGVALVE (TYP.)

ISOLATIONVALVE (TYP.)

NOTE: COMBINATION ISOLATION/BALANCING VALVE MAY BE USED IN LIEU OF SEPARATE VALVES.

(SEE NOTE)

Diagram 1: Proper Multiple Boiler Piping



AERCO BMK boilers require the following minimum flow per boiler for proper and stable boiler temperature control operation:

• BMK 750 = 25 gallons per minute


• BMK 1.5 = 25 gallons per minute

• BMK 2.0 = 25 gallons per minute


• BMK 6000 = 75 gallons per minute To prevent erosion of construction materials, maximum flows are limited to the following:



• BMK1.5 = 225 gallons per minute

• BMK2.0 = 350 gallons per minute


• BMK 6000 = 700 gallons per minute Whenever BMK boilers are employed in systems where ancillary flow devices (such as three-way valves) are not used, minimum flows must be maintained for proper boiler operation.

BMK units are applicable to systems with temperatures from 50°F to 180°F. Due to their condensing design, normal low temperature restrictions do not apply. While most common heating applications are designed with a 20°F temperature drop, BMK boilers are capable of 100°F temperature drop through the heat exchanger without thermal stress.

3.2 Multiple Boiler Piping Design For multiple boiler installations, the piping must be designed to ensure balanced flow through all the boilers. This can be accomplished by using reverse-return piping or a balancing valve at the outlet of each boiler. Failure to balance flow evenly through the boilers will prevent full delivery of boiler capability at design conditions and may cause over-cycling and unnecessary stress on the boilers.

3.3 Service Provisions For maintenance purposes, each BMK boiler should be individually valved on supply and return from the system. The BMK boiler is approved for “0” side clearance in two-unit pairs in applications where space is at a premium. Piping should be located to allow free access between boilers. Each unit has an individual factory-installed drain in the boiler shell.

3.4 Hydronic System Accessories AERCO BMK boilers must be used in conjunction with appropriate hydronic accessories, such as pumps, expansion tanks and air elimination equipment.

Normal commercial and industrial systems employ constant-speed pumping equipment. Variable-flow pumping equipment may also be employed, as long as the system is operated within the recommended minimum and maximum boiler flow limits. Controls should activate heating pumps whenever BMK boilers are in operation.

Air elimination in conjunction with pre-charged diaphragm expansion tanks is preferable to air control. Compression tanks may be used, but create a maintenance task for system operators. Make-up systems must be employed as required by codes.



Fill valves must be used with backflow preventers, as required. Traditional flow control or mixing devices (primary-secondary pumping, 3-way valves) are not required with AERCO BMK boilers. However, when such devices are employed, they should always provide the minimum flows required for a single or multiple boiler installation. When used with a refrigeration (chiller) system, the boiler must be installed so as to prevent the chilled medium from entering the boiler. Consult your local AERCO representative for application advice.

3.5 Condensate Piping Each AERCO BMK boiler has a separate indirect condensate drain and is supplied with a trap that must be permanently piped as part of the installation. BMK boilers must be installed on a 4-inch pad, minimum, to enable the condensate to drain from the exhaust outlet connection.

Each unit will produce the following approximate condensate quantities in the full condensing mode:

• BMK 750 = 6 gallons per hour


• BMK 1.5 = 9 gallons per hour

• BMK 2.0 = 10 gallons per hour


• BMK 6000 = 40 gallons per hour Condensate drain systems must be sized for full condensing mode.

In multiple boiler applications, it is common to manifold these drains together in a plastic pipe manifold to a floor drain. Condensate manifolds must be large enough to handle the anticipated flow and must be properly secured and protected. Manifolds are generally located behind the boilers so that short runs of plastic tubing into the manifold can be used for the condensate drain. A base drain must be installed at the bottom of vertical common flue piping (see Figure 13a of AERCO Technical Bulleting GF-2050).

Condensate can be drained by gravity to a floor drain, or condensate may be drained into a small condensate pump (such as used with air conditioning equipment) and pumped to a convenient drain.

The pH level of the condensate produced by BMK boilers ranges between 3.0 and 3.2. The installation should be designed in accordance with local codes that specify acceptable pH limits. If the condensate pH level needs to be raised to comply with local codes, the AERCO Condensate Neutralizer Kit may be used. See Technical Instruction TID-0029 for details.

4. CONTROLS 4.1 Safety Control BMK boilers are equipped with a manual reset high-limit aquastat. Each BMK boiler has safety controls that comply with ASME Section IV for low pressure heating boilers. These controls are factory wired and installed to simplify field installation. An internal, electric, probe-type, low water cutoff and a manual-reset high-limit temperature device comply with ASME standards. Other locally-required external safety devices (flow switches, pressuretrols, etc.) should be provided and installed locally. Designers should check with local authorities having jurisdiction to assure compliance with all applicable codes.

4.2 Internal Boiler Operating Control Options BMK boilers are shipped complete with both combustion safeguard controls and operating controls installed in each unit. When used in a single boiler application, boiler control modes must be specified and ordered with those found in the following table:



Boiler Control Modes to be Specified at Time of Order Order Code Description Output

3 Internal Setpoint Constant Discharge Temp

2 External Setpoint Outdoor Reset

4 4-20 mA Remote Signal Linear response to external applied signal 8 Modbus AERCO ACS Fire Rate Response to ACS signal 9 Network Remote Signal Discharge Temp Response to external supplied signal

Factory software and testing facilitate a simple installation, with minimum field wiring required.

When more than one BMK boiler and an AERCO Control System (ACS) are applied in a multiple-boiler application, all the modules should be specified and ordered as ACS compatible. In this configuration, simple field control wiring consisting of two twisted wires connects the ACS Panel to the individual boilers.

4.3 Field Sensor Location When a single BMK boiler is used, all water sensors are internal to the boiler unit and factory positioned. When multiple boilers and ACS are used, with common sensors such as the Header Sensor, the water sensor must be located in the field piping. It should be placed in the common supply at least 2 to 10 feet downstream of the point where the last boiler connects into the supply header.

All outdoor air sensors should be positioned on the North wall of the building served, and not in direct sunlight. The outdoor air sensor should not be placed inside the boiler air inlet duct, or near the boiler exhaust outlet connection. A sunshield is provided as part of the outdoor air sensor kit.

4.4 Multiple Boiler Control An AERCO Control System (ACS) is available for multiple boiler applications. The ACS maximizes the plant efficiency by running the boilers at their lowest possible input. It has the capability of controlling up to 32 boilers as well as auxiliary equipment. Refer to ACS specification sheet for full details of the ACS flexibility. When used with an ACS, BMK units should be specified and ordered with the ACS control configuration (see table above).

5. TYPICAL APPLICATIONS BMK boilers can be used in any closed-loop heating system within their design limitations. The following typical piping and wiring schematic diagrams represent the most common types of installation detail. These diagrams are not intended for any particular system, but are rather composites of how AERCO boilers interface with heating applications in the real world.

The designer should incorporate BMK boiler(s) in each system so as to achieve maximum operating efficiency. With ultimate control over the energy transfer process under a broad range of temperatures, the designer should first consider how the system best needs the supplied energy. The boilers should then be applied in the manner that best enables them to use their finite control and capability to supplement the system, using minimum applied energy.

The following examples illustrate typical piping and wiring diagrams with brief explanations of design considerations and sequences of operation.

The examples include:

• Single Heating Boiler ― Indoor/Outdoor Reset Control Mode. (Diagrams 2 and 3).

• Four Boiler Heating Plant ― Indoor/Outdoor Reset Mode with ACS. (Diagrams 4 and 5)

• Two Boiler Heating Plant - ACS with individual motorized isolation valves. (Diagrams 6 and 7)

• Primary/Secondary Pumping (Diagram 8).

• Two Boiler Combination Heating & Domestic Water Plant. (Diagram 9)



Designers are encouraged to work with their AERCO representative to fully explore and apply the ultimate exchange of energy with control in hydronic heating.

5.1 Single Heating Boiler ― Heating Only Sequence of Operation: Boiler plant should be activated by a system start device, such as an outdoor air thermostat or building management system.

A manual switch can be used, but it would place the burden of starting and stopping on the boiler attendant. Automatic controls are more desirable.

Using the optional BENCHMARK boiler pump relay (factory installed), the system’s circulating pump should be started with the BMK unit and should be constant run, as illustrated in Diagrams 3a and 3b. A flow switch or other method should be used to prevent the BMK unit from firing under no flow. If used, the flow switch shall be wired to the delayed interlock of the BMK C-More Controls (see C-More Manual GF-112 for details. A unit energized to fire with insufficient or no flow will trip out on high temperature limit.

Once activated, the internal boiler temperature controls will modulate the input of the boiler to match the control algorithm set.

With indoor/outdoor reset mode, the temperature of the boiler water to the system will increase as the outdoor temperature decreases. The rate of change can be varied by the adjustable reset ratio on the boiler control panel. If ordered with an internal setpoint control system, the boiler will maintain a water temperature that is constant at any adjustable setpoint from 50°F to 180°F.



AIRSEPARATOR

AUTOMATICAIR VENT

1-1/2" NPTDRAIN CONN.

LINE SIZE BYPASS

BACKFLOW PREVENTER

DIAPHRAGM TYPEEXPANSION TANK

WATER

CONDENSATE DRAIN TRAP

P&T

RELIEF VALVE (TYP.)

PRESSUREREDUCINGFILL VALVE

HEATINGSYSTEM RETURN

CHECKVALVE(TYP.)

HEATINGSYSTEM SUPPLY

ISOLATION VALVE (TYP.)

SUPPLY

SYSTEMPUMP

Diagram 2: Single Boiler Piping Schematic (BMK2.0 shown above)

(ORANGE) - N.O.

(YELLOW) - COM

POWER BOXOPTIONAL PUMP RELAY TERMINALS

HEATING PUMP

INDEPENDENT, FUSED CIRCUITS10 A RESISTIVE @ 277 VAC10 A RESISTIVE @ 28 VDC1/3 HP for N.O. @ 120/240 VAC480 VA @ 277 VAC PILOT DUTY

IF PUMP LOAD EXCEEDS THE ABOVE CONTACT RATINGS, USE A SEPARATE CONTACT RELAY - SEE DIAGRAM 3b.

H

N

A. Using the Optional BENCHMARK Boiler Pump Relay

(ORANGE) - N.O.

(YELLOW) - COM

POWER BOXOPTIONAL PUMP RELAY TERMINALS

HEATING PUMP

POWER PUMP(S) FROM INDEPENDENT FUSED CIRCUITS

H

N

CONTACT RELAY(SUPPLIED BY OTHERS)

B. Using a Separate Contact Relay in Conjunction with the Optional BENCHMARK Boiler Pump Relay

Diagram 3: Schematic – System Pump Start



5.2 Four Boiler ― Heating Only BMK multiple boiler plants provide the ultimate energy conversion for building space heating, longevity and ease of installation. Boiler plants incorporating from two to 32 boilers can be controlled from a single AERCO Control System (ACS). Boilers can be arranged in back-to-back or inline piping applications, as space permits. Boiler plant layouts should incorporate sufficient space for normal maintenance and operation.

Sequence of Operation: In a multiple-boiler plant consisting of more than two boilers, an ACS is recommended. The ACS has an Internal Plant Start adjustment that can be set for a 32°F to 100°F outdoor air temperature range. When the boiler plant is activated, the system pump should be started simultaneously. This can be controlled from the building automation system (BAS) or from the ACS via the system start relay (see Diagram 5). A flow switch or other method should be interlocked with the BAS to prevent the boilers from firing in the no-flow state.

When activated, the ACS will stage on the first boiler and increase the boiler input to increase header temperature. The first boiler will increase input, as required, until a percentage of input that is twice the boiler start level percentage (user programmed in the ACS) is reached.

At that point, the ACS will start a second boiler and run both at their start level percentage. The two boilers will continue to increase their energy input, as required by the ACS. When the two firing boilers reach a combined percentage input that is three times the boiler start percentage, the ACS will start a third boiler and run all three at their start level percentage to minimize temperature fluctuation. As the load increases as described above, the ACS will stage the fourth boiler on at the start level percentage transfer setpoint and bring input on all boilers up as needed.

Boiler inputs will modulate down in response to the ACS in a reverse manner. Each boiler will come off line at the boiler stop level percentage transfer setpoint to maximize condensing. Whether the ACS is set in a constant temperature or modulating temperature mode, it will use its modulating ability to prevent header temperature fluctuation and maximize efficiency. Also, the ACS can enable auxiliary equipment, such as system pumps and fans. Refer to the ACS Product Specification for details.



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ISO

GN

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JP6 JP5

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(NOTE 4)

(NOTE 2)

SENSORTEMP.HEADER

OUTSIDE AIRTEMP. SENSOR

JPRJPR

CIRCUITS & STARTERS AS NECESSARY.POWER PUMPS FROM INDEPENDENT

HEATING CIRC CONTACTORAND PUMP

CIRCUIT

115V/1∅/60HzCONTROL

N

H

CIRCUITBREAKER

SAFETYSWITCH

SECONDARY

BMK2.0HEATING BOILER #1

SEE NOTE 1


SEE NOTE 1

-

+


SEE NOTE 1

GRS485

-

+


SEE NOTES 1, 5

RS485-

+

NOTES:1. SEE AERCO DRAWING SD-A-890 FOR SPECIFIC WIRING DETAILS.2. ALL SENSOR WIRING TO BE IN SHIELDED CABLE.3. ALL WIRING TO COMPLY WITH NEC & LOCAL CODES.4. TERMINATE SHIELDS AT THE SOURCES ONLY, DO NOT CONNECT AT THE BOILERS.5. SEE ACS MANUAL GF-131 FOR AVAILABLE METHODS OF ACTIVATING THE BIAS AND TERMINATION OF THE RS485 LOOP.

GG-

+

G RS485RS485

Diagram 5: Four Boiler Heating Plant External Reset (I/O) Mode



5.3 Two Boiler Heating Plant ― ACS with Individual Isolation Valves Systems designed with variable speed pumps (VFD) enable plants to use less pump energy during low heating load conditions. For these types of systems, the following must be observed.

1. When idle boilers are isolated from the system during low load conditions, the VFD system must operate within the recommended minimum flow requirement of the operating boilers. As an example, consider a system with four BMK6000 boilers: when two boilers are idle and isolated from the system during low-load conditions, the flow rate to the two operating boilers must be at least 75 gpm x 2 = 150 gpm.

2. When an operating boiler is satisfied and becomes idle, operators should allow a minimum of 2 minutes before isolating it from the system flow. This ensures that heat is dissipated from the heat exchanger and prevents nuisance over-temperature conditions.

Sequence of Operation: An AERCO Motorized Isolation Valve Control Panel can be used to manage the isolation of idle boilers from the system flow. The panel is wired to the isolation valves and to the boiler auxiliary relays. During demand, the auxiliary relay signals the panel to open the corresponding isolation valve. Isolation valves MUST have proof-of-open switch. The switch shall be interlocked to the boiler (Delayed Interlock) to prevent the unit from firing until the valve is fully open.

After the boiler load is satisfied, the AERCO Motorized Isolation Valve Control Panel holds the isolation valve open for a programmed interval (default = 2 minutes) before closing it. When the system load is satisfied, the panel will open the isolation valves for all of the boilers.

Diagram 6 illustrates a typical wiring of isolation valves to the AERCO Motorized Isolation Valve Control Panel. Diagram 7 illustrates a two-boiler plant with individual motorized isolation valves.

5.4 Primary-Secondary Pumping The typical piping layouts discussed in the previous paragraphs cover most BMK applications. Ordinarily, primary-secondary pumping is not required for proper operation of BMK boiler systems. However, if the system is designed with primary-secondary pumping, Diagram 8 provides a guideline for near-boiler piping to ensure correct boiler flow rate. A water source heat pump is an example of an application in which primary-secondary pumping may be used.

If an ACS is used in a primary-secondary application (see Diagram 8), then:

1. A header sensor must be installed at A

2. The header sensor must be installed between 2 to 10 feet from the pipe junction (B).

3. If desired, individual boiler pumps may be enabled through the optional BENCHMARK boiler pump relay (see Diagram 3).

Sequence of Operation: In water source heat pump systems, the boilers supplement the loop to maintain a constant water temperature. The 60°F to 90°F temperature range is too low for conventional fossil fuel boilers because condensation will form in the firesides causing corrosion. AERCO BMK units are built with a 439 stainless steel heat exchanger to withstand condensation. BMK boilers excel in this type of application because the low return water temperature maximizes their condensing capability.

Normally, the boiler plant is activated from the Main Heat Pump Control/Sequence Panel when the system requires auxiliary heat. Once activated, the boilers will modulate independently to maintain the loop temperature. If an ACS panel is used, the Main Controls will activate the ACS, which in turn modulates the boilers to maintain the loop temperature. Extremely close tolerances to the temperature



setpoint will be maintained.

5.5 Three Boiler Combination Heating and Domestic Water System A combination heating and domestic hot water plant can be specified to share the loads among common boilers. Some benefits of combining heating and domestic load into a single plant include first-cost control, simplified venting, and simplified operation.

The heating load should be developed from ASHRAE or industry standard methods, and the domestic water load should be sized using conventional sizing criteria.

The domestic water can be generated in an external hot water storage generator (a storage tank with a water-to-water exchanger), or through an instantaneous or semi-instantaneous system. When using a hot water storage generator design for a replacement system, the size of the storage tank is fixed and sufficient recovery must be provided. For a new application, tank storage should be sized with sufficient capacity to prevent the boiler(s) from short-cycling under low loads.

When using instantaneous or semi-instantaneous systems, thermal mass must be added to the boiler water loop as a buffer to dampen out fast transitions and minimize boiler cycling. These conditions can occur either during zero load or during low load situations in which the only load is generated by recirculation piping losses.

Diagram 9 illustrates proper piping for a buffer tank and AERCO’s packaged plate heat exchanger (SmartPlate), piped as a zone with the boilers and the combination heating/domestic hot water system.

Sequence of Operation: The SmartPlate setpoint is set for the desired domestic water temperature. As domestic load occurs, the SmartPlate will open its control valve to permit boiler water to flow through the plate heat exchanger. The ACS Panel will fire the boilers as necessary to deliver the required energy (see the ACS/DHW Application Guide TAG-0050 for details). The pump between the SmartPlate and the buffer tank will constantly circulate boiler water, by-passing the plate heat exchanger when the domestic load is satisfied.



4 – BOILER /120V MODEL SHOWN ABOVE. SEE BOILER VALVE CONTROLLER O & M GF-126 FOR OTHER MODELS

Diagram 6: Multiple BMK 2.0 Boilers and Motorized Control Valves

NO

TES:

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AIRSEPARATOR

AUTOMATICAIR VENT

LINE SIZE BYPASS

BACKFLOW PREVENTER

DIAPHRAGM TYPEEXPANSION TANK

WATER SUPPLY

PRESSURE REDUCINGFILL VALVE

CHECKVALVE(TYP.)

HEATING SYSTEM SUPPLY

SYSTEMPUMP

HEATING SYSTEM RETURN

MOTORIZED ISOLATION VALVE (SEE NOTE)

NOTE: MOTORIZED VALVE WITH MANUAL OVERRIDE MAY BE USED IN LIEU OF SUPPLYING A SEPARATE MANUAL ISOLATION VALVE - VERIFY LOCAL CODES COMPLIANCE.

(SEE NOTE)

Diagram 7: Multiple Boiler Piping Schematic with Motorized Valves (BMK2.0 units shown)



P&T

P&T

MAIN LOOP FLOW

COMMON PIPE DIAMETER MUST BE SIZED FORLESS THAN 4.0 FT/SEC; COMMON PIPE LENGTHMUST BE 3 TO 5 TIMES ITS DIAMETER

{ B

A2 TO 10 FEET

ACSHEADER SENSOR

Diagram 8: Two Module Water Source Heat Pump Piping (BMK2.0 units shown)



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PPLI

ES B

OIL

ER W

ATER

TO

THE

SMAR

TPLA

TE.

9. T

HE S

MAR

TPLA

TE P

UM

P SH

ALL

BE O

PERA

TED

CON

STAN

TLY

OR

CON

TRO

LLED

BY

THE

BUIL

DIN

G CO

NTR

OLS

.

ACS

Rel

ay B

ox

BEN

CHM

ARK

BOIL

ER/S

MAR

TPLA

TE -

COM

BIN

ATIO

N

HEA

TIN

G/DH

W P

IPIN

G W

ITH

BOIL

ER S

IDE

BUFF

ER T

ANK

-DES

IGN

ATED

DHW

BO

ILER

(S) A

ND

DESI

GNAT

ED

BU

ILDI

NG

PRIO

RITY

BO

ILER

(S) A

PPLI

CATI

ON

S

AU

TOM

ATIC

AI

R VE

NT

(SEE

NO

TE 8

)

ACS

Pan

el

B1B2

B3

DRAI

N V

ALVE

STO

P VA

LVE

CHEC

K VA

LVE

LEGE

ND

UN

ION

STRA

INER

PUM

P

BALA

NCI

NG

VALV

E

P&T

3-W

AY C

ON

TRO

L

VALV

E

PRES

SURE

&

TEM

PERA

TURE

GAU

GE

AQU

ASTA

TEN

D SW

ITCH

ACS

HEAD

ER/R

ETU

RN

SEN

SOR

SYS

TEM

R

ETU

RN A

CS R

ETU

RN

SEN

SOR

Diagram 9. Three Boiler Combination Heating and Domestic Water System



© AERCO International, Inc., 2012

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