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SECTION 23 09 16
REFRIGERATION MONITORING AND CONTROL SYSTEMS (RMCS) (Edited from DeCA December 2016 Design Criteria)
PART 1 - GENERAL
0.1 SUMMARY
A. Section Includes:
1. Refrigeration Monitoring and Control System.
B. Related Sections:
1. Division 01 Section Mechanical, Refrigeration, Food Service Equipment and Electrical Coordination. 2. Division 01 Section Environmental procedures for Refrigerants. 3. Division 01 Section Quality Control. 4. Division 01 Section Closeout Procedures. 5. Division 23 Section Product Refrigeration Systems. 6. Division 23 Section Packaged, Outdoor, Air-Handling Units. 7. Division 23 Section Mechanical Dehumidification Units. 8. Division 23 Section Convection Heating and Cooling Units. 9. Division 23 Section Instrumentation and Control Devices for HVAC. 10. Division 26 Electrical.
0.2 SCOPE OF WORK
A. General:
1. Provide a monitoring and control system (RMCS) to monitor and control product refrigeration and HVAC equipment designated for control by RMCS. Items which shall be controlled by the RMCS include:
a. Product Refrigeration System:
1) Compressors: Each new multiplex compressor system compressor indicated in the Contract Drawings. 2) Condensers: Each new multiplex compressor system condenser fan indicated in the Contract Drawings. 3) Defrost Contactors: Each new refrigeration defrost contactor. 4) Solenoid Valves: Each new refrigeration liquid/suction solenoid. 5) Heat Reclaim: Each new heat reclaim 3-way valve (both air and water). 6) Display Case Lighting: New display case lights.
b. Heating Ventilation and Air Conditioning (HVAC):
1) All HVAC devices indicated for control by RMCS on Contract Drawings
c. Sales Area and Outside Lighting:
1) All lights indicated for control by RMCS on Contract Drawings
d. Warranty: Provide warranty service specified in paragraph 3.6 "Warranty". e. Close Out Items: Provide close out items specified in paragraph 3.5 "Close Out Items". f. Training: Provide training of Commissary personnel as specified in paragraph 3.1 "General Requirement, Training". g. Parts and Labor: All labor and equipment necessary for Contractor to meet the requirements stated herein this Section shall be Contractor Furnished and Contractor Installed. h. Coordination: The refrigeration monitoring and control system and its installation shall be approved by and coordinated with the display case manufacturer and the RMCS manufacturer. 2. The RMCS system must be capable to do the following: a. Communicate via serial and Ethernet connectivity. b. Provide centralized access to all devices from a single location. c. Provide remote broad band access via cellular communication device. d. Be capable of future remote accessibility via http using public infrastructure. e. Provide graphical display of store information including all temperatures, alarms and data points managed by RMCS. f. Provide secure logged authentication for all users. Provide multiple levels of password protected access to include view only, Lighting Schedule override, set point changes, and programming changes.
0.3 SUBMITTAL
A. Furnish under the provisions of Division 01 Section Quality Control.
B. Contractor shall furnish a RMCS construction submittal for review and approval as herein indicated.
1. Distribution:
a. One (1) copy of RMCS construction submittal to the Contracting Officer’s technical representative. b. One (1) copy of submittal to Parson Jacobs’s DeCA core team support, Lackland AFB TX 78236-1039. c. Date Required: Within 90 days after receipt of Notice to Proceed.
2. Equipment Cut Sheets: Provide manufacturer's cut sheets indicating Contract compliance of the following system components:
a. Thermistors, transducers, and dewpoint sensors. b. ICU. c. Phase loss protector. d. Pulse meters. e. Cellular modem. f. Lighting control hardware.
3. Installation Manuals: Provide system installation manual and instructions. 4. Drawings: Provide Drawings showing components locations in commissary and required wiring between components. 5. User Manuals: Provide user's manual on system describing how to use the system and the software. 6. RMCS Manufacturer's Resume: Provide resume of control system manufacturer's experience in supermarket refrigeration. A minimum of ten successful installations using hardware model being provided. 7. Startup Technician's Resume: Provide resume of Startup Technician(s) indicating participation in startup of a least 5 systems using the same hardware as that being provided. 8. RMCS Manufacturer Approval of Startup Technician: Provide letter from RMCS manufacturer indicating their approval of the proposed Startup Technician(s), or, their intent to provide their own startup technician for startup and certification of the RMCS. 9. Display Case/Compressor Manufacturer Coordination: Provide a letter from the manufacturer of the display cases and the manufacturer of the compressor systems, verifying their approval of the RMCS equipment selection and indicating their intent to review all operating setpoints for the RMCS. 10. RMCS Installer's Resume: Provide resume of lead on site technician's experience indicating that he has installed a minimum of 3 control systems of same brand and model as the one being installed on this Project. Lead technician shall be on site during installation and shall install and or supervise all aspects of the RMCS field installation.
C. Operation and Maintenance data.
PART 2 - REQUIRED EQUIPMENT
0.1 REQUIRED HARDWARE QUANTITIES
A. Modem: Quantity required (1).
B. Laptop Computer with Padded Carrying Case: Quantity required (1).
C. Desktop Computer: Quantity required (1).
D. Printer: Quantity required (1).
E. Refrigeration Alarm Annunciator: Quantity required (1).
F. Phase Loss Protector: Quantity required (1).
G. Individual Control Unit(S): See paragraph 3.2 for quantity required.
H. Sensors: See paragraph 3.2 for quantity required.
0.2 HARDWARE DESCRIPTIONS
A. Cellular broad band modem.
B. Laptop Computer: Laptop shall be compatible to communicate with RMCS and shall have the following minimum features: modem, read/write CD drive, 100 GB hard disk.
C. Desktop Computer: Desktop Computer monitor and keyboard with the following minimum features: R/W CD Drive, 100 GB Hard disk.
D. Printer: Sheet feed Ink jet printer.
E. Refrigeration Alarm Annunciator: Shall have an audible alarm and reset button.
F. Phase Loss Protector:
1. Phase Unbalance Trip: Shall be adjustable 5 percent to 10 percent. 2. Under Voltage Trip: Shall be adjustable 10 percent to 20 percent of normal voltage. 3. Phase Loss Trip: Trip shall be within 50 msec. 4. Phase Reversal: Trip shall be within 50 msec. 5. Restart: Automatic restart upon return to normal. 6. Product Reference: TimeMark Model 2644 or approved equal.
G. ICU'S: Individual control units (ICUs) shall have the following minimum features:
1. Independent Operation: Each ICU shall operate independent of the other ICUs. If one ICU is taken out of operation, the other ICUs shall continue normal operation. The ICU unit shall retain all setpoints during a "power down" or "power up" and shall automatically reboot and commence normal operation. 2. Memory Storage: System programs shall be stored in EPROM or CMOS memory. If CMOS memory is provided, the contents of memory shall be maintained for a minimum
of 1 year by battery. The system shall have battery back up for retention of system clock of at least 1 year. 3. Voltage/Surge Protection: System shall operate from 100V AC to 130V AC 60 HZ power. Power supply to ICU shall have surge protection which meets the following.
a. EMI/RFI filtering. b. Meets Government and military specs for fire panel applications. c. User replaceable fusing. d. LEDs to indicate protection status, ground presence, ground fault indication, fuse status. e. Tested to meet UL 1449 approved. f. 120/240 VAC, 20 amp continuous rating. g. 10 year limited warranty. h. DITEK Model DITEK D-50-120/2401 or approved equal.
4. Analog Control Features:
a. The outputs shall be controlled by either; computer automatic operation or manual keyboard on/off (100 percent/0 percent). b. The power supply for the control voltage on the control relays shall be fused to protect it from overloading. c. The outputs shall be fused for over-current protection.
5. Digital Control Features:
a. Control relays shall be controlled by computer automatic. b. The digital outputs shall be designed so that if high voltage is applied to the contacts of one control relay, then the other points are not damaged. c. The power supply for the control voltage on the control relays shall be fused to protect it from overloading. d. The contacts on the control relays shall be rated to carry at least 5 amps 220 VAC. e. The contacts on the control relay shall be fused to protect the relay from exceeding the current capacity of the contacts. f. Control relays on digital outputs shall have SPDT contacts with a; normally open, and normally closed terminal. 6. Basis of design: Danfoss AK-SM 880 (Baltimore, MD) or approved equal.
H. Sensors: RMCS sensors/inputs shall be furnished and shall meet or exceed the following required features:
1. Analog Inputs:
a. Temperature sensors shall be thermistors.
1) The thermistor temperature probes shall be interchangeable in the field with no required calibration. 2) The thermistor temperature accuracy shall be (+ or -) 2 deg F. 3) Analog dewpoint temperatures shall be measured from -30 deg F to 79 deg F with an accuracy of 2 deg F.
b. Pressure sensors shall be transducers.
1) The range for the compressor low pressure side shall be 0 psig to 200 psig with +or - 1 psig. 2) The range for the compressor high pressure side shall be 0 psig to 500 psig with accuracy of + or - 5 psig.
c. Dewpoint sensor. Measurement method is non-dispersive infra-red dual channel, non-interactive, non-saturating. Rated life of 15 years. Design standard is Telaire Vaporstat 9002. d. Refrigerant vapor detection sensors shall meet or exceed the following minimum requirements:
1) Shall measure 0 to 1000 parts per million of all refrigerants provided in this project. Shall operate from 0 deg F to 120 deg F. 2) Shall not require maintenance more often than every 6 months in order to operate properly.
e. Outdoor temperature.
f. Outdoor light sensor module.
g. Indoor light sensor module where day lighting is used.
I. Limit Switches: Provide magnetic switches to monitor walk-in freezer doors. Provide a local audible and visual alarm at the door which will alarm after 30 minutes of open time.
J. Three (3) Phase KWHR Transducer/CT: (3) phase KWHR (pulse) transducer, with current transformers (see paragraph 3.2.E). Hawkeye Series H-8050 or approved equal. Veris Industries Inc. 1-800-354-8556.
0.3 SYSTEM CONTROL FEATURES/STRATEGY
A. General: System software shall be furnished, installed, tested, and debugged to provide; control/functions described herein this Specification Section. Control Variables/Setpoints: Setpoints shall be remote selectable by user via "laptop computer" on modem. This portion of the software shall be resident on site in the RMCS ICU's. This software shall be protected from loss during power failure.
B. Software Configuration: System software shall allow user to add/remove: digital outputs/inputs, analog inputs, schedules and programs. This software may be either transient or resident. If software is transient, it shall be compatible with q MS Windows based PC and shall allow user to re configure software then downloaded the new configuration to the ICU's at the Commissary (Via modem).
C. Data Base Features: Data base features of system software shall provide the following features:
1. Downloading Capability: This database software shall allow downloading of on-site data base to an offside location via broad band cellular modem. Data-base shall contain; setpoints, names, tables, etc. 2. Unattended Phone Line Disconnect Feature: Master controller communication software shall force the modem to hang up the phone line if no data is transferred for 5 minutes.
Also, when the modem on the RMCS cannot detect a carrier signal for a period of time (8 to 40 seconds), the RMCS software shall make the modem hang up the phone line. 3. Downloading Software: P.C. software on CD shall be provided which shall allow the data base to be edited off-site then reloaded via phone line to commissary. This software shall be user friendly and shall have error checking features. This software shall take care of all output data formatting and shall be formatted for 80 column output. A copy of this software shall be provided to DeCA/LEED Lackland AFB TX along with a letter granting the Government the right to use this software.
D. Phase Loss Protector Features: When a phase loss/unbalance occurs, all RMCS controlled 3 phase loads shall be shutdown until power is restored. Systems shall automatically restart upon return of all three phases. Monitor power at panel "CP" on dedicated breaker.
E. Alarm Features:
1. Types Of Alarms: RMCS shall provide for the following types of alarms:
a. Alarm (A): When an alarm occurs, the audible buzzer in commissary sounds and the alarm dial out begins. b. Alarm Logs (N): These are events that are recorded in the system and do not produce any dial out or buzzer.
2. Alarm Dial Out Sequence: The RMCS shall execute the following dial out actions upon each Alarm (A) event:
a. Alarm To: Remote 3rd party alarm monitoring center via broad band cellular modem. b. Alarm to Printer/Modem: Dial to modem with printer at phone address previously selected by the user. c. Alarm to Fax Machine: Dial facsimile machine (fax) at phone address previously selected by user. d. Message Description: The Master controller shall send a message (store name, date, time, sensor name, and sensor number that caused alarm), to each printer and facsimile called during dial out.
3. User Selection/Configuration Of Alarm Dial Out Actions: The RMCS software shall provide the user with the following alarm dial out configuration options:
a. Phone Numbers To Be Called: Allow user (via keyboard) to enter a minimum of four separate phone numbers/addressees which shall be called during Alarm Dial Out Sequence. b. Type of Devices To Be Called: Allow user to select which devices (pager, fax, printer) are at the phone addresses selected in "PHONE NUMBERS TO BE CALLED." c. Pauses During Dialing: Allow user to be able to select time delays to be entered into the phone address selected in "PHONE NUMBERS TO BE CALLED." d. Attempts to Reach a Number: Allow user to select the number (1 to 4) of times the Master Controller shall dial the phone number of each pager. e. Alarm Test Time: Allow user to select the time of day that the Master controller shall dial out a test refrigerant alarm.)
F. History Logging Features: The RMCS software shall collect data from the ICUs and shall provide the following features:
1. Alarm History: Log the last 100 alerts and last 100 alarms. 2. User Configuration: Allow user (via keyboard) to, select items to: log, select logging interval (seconds or minutes), select number of samples. The items which shall be logged in this manner shall be all; analog inputs (AI), analog outputs (AO), digital outputs (DO), digital inputs (DI). 3. Compressor Runtime: The compressor cycles per day and total run time per day shall be logged for a period of not less than 14 days. 4. Condenser Runtime: The condenser fan cycles per day and total run time per day shall be logged for a period of not less than 14 days. 5. Refrigeration Runtime: The refrigeration circuits defrost cycles per day and total run time per day; shall be logged for a period of not less than 14 days. 6. Log history of data points at one minute intervals. Provide capacity to retain a minimum of six months data for each data point.
G. Security/Access Features: Software shall require a password(s) in order to access the system. Password shall be for user identification and shall not be echoed on printer or terminal. The system shall be capable of using a password of 4 or more characters. At least four levels of access shall be provided. One level of access shall be provided to view data/setpoints. One password will only permit lighting override and lighting schedule changes. The other two levels shall provide access to change, setpoints and system programs.
H. Compressor Control Features: RMCS control of refrigeration compressors shall incorporate the following features:
1. User Access: Software shall allow the user to select and adjust all setpoints. 2. Control Strategy: Software shall control the compressors on each multiplex compressor system by the following method:
a. Rate of Change with Temperature Modification: As the refrigerated fixtures get colder than required, the target pressure is raised in increments so as to raise the compressor system operating suction pressure. The reverse takes place as refrigerated fixture temperature increases. For each compressor a minimum ON time and minimum OFF time shall be provided.
I. Subcooler Control Features: The RMCS shall control 2 normally closed liquid line solenoids, one sized for 25 percent subcooler operation, one sized for 75 percent and both open for 100 percent operation. A temperature sensor shall be mounted on the subcooled liquid outlet to maintain the subcooled liquid at a temperature of 50 degrees F.
J. Electronic Evaporative Pressure Regulator Valve Control Features. The RMCS shall control the Electronic Evaporative Pressure Regulator (EEPR) via an interface board which will provide low voltage power (24VDC) and control to the motor in the EEPR.
K. Defrost Temination Control Features: The RMCS shall control the defrost termination of all frozen and ice cream display cases.
1. When all defrost termination Klixons Provided by Case OEM are closed or the RMCS Coil Sensors reach the RMCS Defrost Termination setpoint, the RMCS shall terminate defrost and return circuit to normal refrigeration.
L. HVAC Control Features:
1. Sales Area Dual Path Air Handling Unit(s):
a. Space temperature and humidity shall be controlled by a minimum of three individual cooling stages utilizing two air paths. The outside air path will process all of the outside air (no bypass) and provide most of the dehumidification required for the space. An outdoor air precooling coil and dehumidification coils (6-row minimum) shall be used. The return air path will have a cooling coil to cool the return air as required to provide the remaining cooling required for the space. Some return air may be bypassed. The air paths will then mix heating will be accomplished by utilizing reclaimed refrigeration heat through heat reclaim coils, supplemented by a two stage gas fired power burner. The reclaimed heat will be used for reheat if required, and will provide the main heat as reclaimed heat is available. The gas heating will only be used if additional capacity is required. b. Fan operation shall be continuous. Fan shall run at high speed (100 percent) in occupied mode and for cooling dehumidification operation and at low speed (50 percent) at all other times. c. Compressors shall be sized to match the cooling/dehumidification requirements of the two paths with the evaporator coils. d. Multiple Condenser fans shall be controlled from liquid temperature and shall be cycled to maintain a target liquid temperature. e. Heat reclaim will be used for reheat and for initial stages of heat. f. Control the gas heating section from space temperature only after maximum utilization of heat reclaim has been realized. Auxiliary heat shall not be used for reheat control. Mount a temperature probe on the supply line within 12” of the heat reclaim coil inside of the AHU for proof of reclaim operation. g. The dehumidification coil in the outdoor air path is stage 1 and the outside air precooling coil is stage 2. The return air cooling coil is stage 3. Stage 1, 2 and 3 coils shall be controlled from space humidity in that order to maintain 52 deg F dewpoint. Precooling coil shall be locked out below an ambient temperature of 72 deg F. h. Outside air and return air motorized dampers shall be provided. The outside air (or night setback) damper shall be open during the occupied cycle and closed in the unoccupied cycle. The outside air (or night setback) damper shall be mechanically linked to the return air damper so the return air damper shall open when the outdoor air (or night setback) damper closes, allowing return air to follow both air paths. i. To allow the specified air flow rates in the two paths, an array of static pressure probes shall be positioned to monitoring internal air pressure drops through key elements of the dual path system. Each air path shall have built-in balancing dampers for air volume adjustment. j. Provide a differential pressure switch to monitor the operation of the main blower. k. The temperature and humidity set points shall be:
Function Day Night
Heat 70 deg F 65 deg F Cool 75 deg F 75 deg F Humidity 52 deg F dew point 52 deg F dew point
l. Cooling operation shall be locked out below 45 deg F ambient.
2. Other Conditioned Rooms: Air conditioning systems indicated on Contract Drawings
a. One stage cooling and [one stage heating.] [2 stage heating for heat pump units with electric heat.] b. Night set back. c. Fractional Horsepower AHU fans shall only operate during heating or cooling demand. AHU fans (1) horsepower and greater, shall operate continuously during daytime and on demand at night. d. Shall have a schedule for user to select on/off hours. e. Close outdoor air dampers in unoccupied mode f. Monitor for proof of run.
3. Refrigeration Equipment Room Exhaust Fans: Exhaust fans EF
ventilation, and EF
M. Lighting Control Features:
1. The RMCS shall provide contact closures and wiring to the contactors for the following lighting functions:
a. Sales Area Lighting: contactors as required for the following controls (1/2 lighting intensity level for Sales Area including checkouts, 1/2 lighting intensity for Sales Area, including Checkout area, and Sales Area track, mass display, etc.). See the Sales Area Lighting Control, Detail Sheet E
b. For stores with day lighting and dimmable ballasts provide analog control to dim the sales area lighting as light from the day lighting features increases. Control to 80 fc during sales hours and 40 fc during stocking and cleaning hours. c. Exterior Lighting: 3 contactors (Patron Parking, Employee Parking, and Receiving Pole Lights). See Exterior Lighting Control Details, Sheet E
2. Division 23 Section Refrigeration Monitoring and Control Systems (RMCS) shall provide a 3 wall switch gang box in the Store Director's office, Cover plate, and conduit to the RMCS HVAC system ICU for Division 23 Section Refrigeration Monitoring and Control Systems (RMCS) to install 3 momentary contact override switches and the necessary wiring to connect these switches to 3 input terminals in the HVAC RMCS system. Division 23 Section Refrigeration Monitoring and Control Systems (RMCS) shall program the system such that:
a. When any of the momentary contact switches is closed for 6 seconds, the contactor controlled by that switch shall energize the lighting circuit controlled by that switch for 240 minutes. .
b. When the same button is closed again for 6 seconds, the contactors shall revert to the original mode of operation. c. Label all switches with the lighting control function, i.e. "Sales and Checkout", "Case and Supplementary Lighting," "Outside Lighting". d. Outdoor lighting shall be turned off when the light sensor senses daylight.
N. Condenser Control Features: The RMCS shall provide the following refrigeration condenser control functions.
1. Control Point: Control fan speed to meet target condenser pressure. 2. Parallel Fan Operation: Parallel condenser fans shall be controlled with a variable speed drive. 3. "ON" "OFF" Delays: Pre delays and post delays shall be provided for each stage. 4. 50 percent / 50 percent Split: Shall control split condenser valves for condensers provided with such valves. Control shall be based on outdoor ambient setpoint and reset deadband.
PART 3 - EXECUTION/INSTALLATION REQUIREMENTS
0.1 GENERAL INSTALLATION REQUIREMENTS
A. Guide Lines: The entire system shall be installed in accordance with RMCS manufacturers' recommendations and the requirements of these specifications. Where the Contract requirements are in conflict with those of the manufacturer, the more stringent requirement shall be followed.
B. N.E.C. The entire system shall be installed in accordance with the current National Electric Code and the requirements of these Specifications.
C. Lead Technician: Lead technician shall be on site during installation and shall supervise install and or supervise all aspects of the RMCS field installation. Lead technician experience shall have installed a minimum of 3 control systems of same brand and model as the one being installed in this Project, along with being capable of programming and starting up the equipment.
D. Inspection/Certification of Installation:
1. Startup Technician Responsibilities:
a. The manufacturer approved Startup Technician shall personally be on site at the Commissary for at least 3 days to perform operational checkouts of the system. b. The Startup Technician shall personally inspect the installation of the system to ensure that the RMCS system is installed in accordance with the RMCS manufacturer recommended methods. c. The Startup Technician shall provide a "Startup Inspection Report" listing all incomplete work and incorrectly installed equipment. This list shall be provided to the Contracting Officer, the RMCS manufacturer, and the display case manufacturer.
2. Certification of Installation: The following installation certifications shall be provided:
a. Startup Technician Certification: The Startup Technician shall provide a letter certifying that all items indicated in the "Startup Inspection Report" have been corrected. This letter shall be provided to DeCA/LEED Lackland AFB TX. 78236- 1039, the RMCS manufacturer, and the display case manufacturer. b. RMCS Manufacturer Certification: The Contractor shall submit a letter from the RMCS manufacturer certifying that the installation meets the manufacturer's recommendations. Letter shall be addressed to the Contracting Officer with a copy to DeCA/ LEED, 2250 Foulois Ave, Lackland AFB TX 78236-1039. c. Display Case Manufacturer Certification: The Contractor shall submit a letter from the Display Case Manufacturer certifying that the installation is correct. The letter shall be addressed to the Contracting Officer with a copy to DeCA/ LEED, 2250 Foulois Ave, Lackland AFB TX 78236-1039.
0.2 HARDWARE INSTALLATION REQUIREMENTS
A. Individual Control Units (ICU's): ICU's shall be provided for the following equipment.
1. Quantity And Location:
a. Refrigeration Compressor Systems: Provide one dedicated ICU for each multiplex refrigeration compressor system. b. HVAC: Provide at least one dedicated ICU for controlling of the HVAC. This ICU shall be mounted on the RMCS HVAC enclosure located in the mechanical center/room.
2. Installation/Testing: ICUs shall be installed and tested at the respective factory of the compressor system manufacturer.
B. Analog Temperature Sensors: Analog temperature sensors shall be furnished and installed at the following locations:
1. Storage Rooms: One temperature probe in each refrigerated walk-in box and refrigerated processing room. Probes shall be in the return air to the unit coolers. 2. Sales Area: One temperature and one dewpoint probe for each sales area air handler being controlled. Mount these probes 2 feet above store shelving product line. Also provide one temperature sensor in the return air stream and one in the supply and one on the suction line if system is a single compressor DX. Mount supply sensor downstream of all coils. Mount return sensor after outside air intake. 3. Refrigerated Display Cases: Factory mount one Supply Air Temperature Sensor per evaporator coil in each refrigerated display case. 4. Probes on Compressor Systems: On each compressor system, provide a temperature probe on the bottom side of the suction header and one on the drop leg to the receiver. 5. Low Temp Circuits: Provide one suction temperature sensor on each suction circuit operating below 10 deg F SST. Install at compressor suction header. 6. Outdoor Temp: One temperature probe to measure outside air temperature. This probe shall be mounted on ACC-1 out of the sun, in the condenser air stream, and not more than 8 inches below the bottom of the condenser coil. 7. Subcooling Temperature: One temperature probe to measure subcooled liquid temperature shall be mounted on the subcooled liquid outlet of each subcooler. 8. Chilled Water: On chilled water systems, one temperature probe on chilled water supply from chiller and one temperature probe on chilled water return to chiller.
9. Boiler Water: On systems with a hydronic boiler, mount one sensor in boiler supply and one in boiler return. 10. Other Conditioned Rooms, HVAC: Install Wall Mounted Zone temperature sensors 6 feet above finished floor. Also install supply and return air sensor and suction temperature sensors on all units indicated for RMCS control on Contract Drawings
C. Analog Pressure Sensors: Analog pressure sensors shall be furnished and installed at the following locations:
1. Multiplex Systems: On each multiplex compressor system, provide a pressure transducer for the following: system suction pressure, system discharge pressure, system condenser pressure, and suction pressure for any satellite or escort compressors. 2. Single Systems: On single compressor systems, provide a suction pressure transducer when indicated by drawing control notes.
D. Analog Receiver Level Sensors: Connect to and monitor refrigeration equipment OEM supplied liquid level sensors. Calibrate and validate readings are correct.
E. Analog Dew Point Sensors: Field calibrate using NIST certified calibration techniques.
F. Digital Sensors: Digital inputs shall be furnished and installed to monitor the following electrical loads:
1. Compressors: On each refrigeration compressor monitoring the compressor operation. 2. Freezer Doors: on each walk-in freezer door. 3. Condenser Fans: On each condenser fan motor monitoring the fan motor operation. 4. AHU Fans: On each sales area, Air handler and Desiccant supply fan motors being controlled. 5. Phase Loss Protector: Provide dedicated breaker in panel "CP". Connect protector sensor inputs to breaker. Connect N.C. output contacts in protector to RMCS input. 6. Electrical Energy Consumption: Provide split core current transformers with monitoring interface equipment and wiring to monitor each of the following:
a. Sales Area Lighting - monitor panel feeder. b. Sales Area Accent Lighting - monitor panel feeder. c. Processing Area/Staging Area Lighting - monitor individual lighting circuit. d. Sales Area HVAC - both indoor and outdoor units, DHU and ACCU. e. Refrigeration - monitor feeder circuit at the manual transfer switch. f. External Lighting. g. Total building power - Monitor building electrical service.
G. Digital sensors: Digital inputs shall be furnished and installed to monitor the following utility consumption: 1. Water and Gas Consumption Monitoring: Connect to the digital pulse meters provided under Division 22, Plumbing Specialities. 2. Water heater operation.
H. Refrigeration Alarm Annunciator and Computer Terminal: Furnish and install the Computer terminal in the Store Manager's office. The Alarm Annunciator will be installed near the Store Managers office, but located in the sales area 7’-0” above finished floor.
I. Wiring: All RMCS wiring shall as a minimum meet the following requirements.
1. Routing:
a. All Factory and field installed wiring shall be in EMT. b. Analog input (AI) and Analog output (AO) wiring shall not be routed in conduits with conductors which carry alternating current. c. The wiring and EMT for space sensors shall be routed and concealed inside of stud walls.
2. Wire Size: All field wiring shall be at a minimum #18 AWG shielded/stranded wire. 3. Connections: All splices/connections shall be made in junction boxes and shall utilize either terminal strips or Siliconed filled connnectors, such as 3M-314 connectors or approved equal. 4. Labeling: Control cables shall be labeled at all junction boxes and at the origination and termination of each cable. The Cable number/letter indicated on the submittal drawings shall be specified on this label.
J. Cellular modem: Before the refrigeration system is tested, the Contractor shall have a commercial broad band data modem installed for use with the RMCS system. Coordination for installation of the modem is as follows:
1. Installation: Identify a broad band cellular provider with clear strong signal at the local area.
2. Identify a physical location for the cellular modem with good signal reception.
3. Provide a minimum one year service contract. 4. Transfer of Billing: Upon final acceptance of this system, the Contractor shall notify the Contracting Officer that the billing for the cellular modem to be transferred to the Commissary not less than 90 days after the date of final acceptance. The Contractor shall pay all costs on the cellular modem up until 90 days after the date of final acceptance.
0.3 INITIAL SETPOINTS
A. Initial Software Setpoints: Initially, the RMCS shall be set to maintain the following setpoints:
1. Walk-In Boxes: Walk-in boxes shall be initially adjusted to maintain the temperatures indicated on the unit cooler schedule of the Contract Drawings. 2. Display Case Temperatures: The display case discharge temperatures shall be initially adjusted to maintain the following or the case manufactures recommended discharge temperature settings:
CASE ITEM DISCHARGE TEMPERATURE Deg F 1B06 BAKE 34 to 38 1B08 FZBX -8 to -5 1B32 BAKE 34 to 38 1D00 DELI 34 to 38 1D01 MDDI 28 to 30 1D02 MDGD 30 to 34
1D24 MDDL 30 to 34 1F00 FISH 30 to 34 1F01 FISH 30 to 34 1G00 DYCS 30 to 36 1G02 DYCS 30 to 36 1G07/06 SDFF -10 to -5 1G10 FZGD -8 to -5 1G12/13 ICGD -15 to -20 1M02 MTCS 22 to 26 1M04 MTCS 28 to 30 1M07 MDDI 25 to 28 1M05 MTCS 28 to 30 1P02/03 PRCS 36 to 40 1P07 PRCS 36 to 40
3. HVAC Setpoints: The HVAC setpoints controlled by RMCS shall be initially set as follows:
a. Sales Area: Sales Area shall be set as follows:
DEHUMIDIFICATION "ON" at 51 deg F dewpoint "OFF" at 49 deg F.
Deg F Cooling Stage 1 75/73 Cooling Stage 2 76/74 Ht Rec Stage 1 69/70 Ht Rec Stage 2 68/69 Aux Ht Stage 1 66/67 Aux Ht Stage 2 65/66
b. Bakery/Deli Setpoints:
CUTIN/OUT Deg F Cooling 75/73 5/5 Heating 69/70 5/5
c. Administration Areas and Breakrooms:
CUTIN/OUT Deg F Cooling 78/76 5/5 Heating 68/70 5/5
d. Staging Area and Receiving Area unit heater and radiant heater temperature setpoints:
CUTIN/OUT Deg F 58/60
e. Exhaust Fans: The Compressor Room exhaust fan temperature setpoints:
CUTIN/OUT Deg F Ventilation Stage 1 (EF <#>) 75/70 Ventilation Stage 2 (EF<#>) 80/75 Ventilation Stages 1 & 2 (EF<#>) 75/70 80/75
f. ***** A/E shall edit as necessary Exhaust Fans: The Staging Area and Receiving Area exhaust fan temperature setpoint:
CUTIN/OUT Deg F Ventilation Stage 1 (EF <#>) 75/70 Ventilation Stage 2 (EF<#>) 80/75 Ventilation Stages 1 & 2 (EF<#>) 75/70 80/75
4. Alarm Setpoints: The RMCS alarm setpoints shall be initially set as follows with alarm inhibited during defrost:
ALARM SETTINGS AND ACTIONS DEFROST SETTINGS ITEM HIGH TEMP/TIME LOW #PER/LENGTH/TERM ABB. TEMP/ TIME RESULT RESULT OF MIN OF MIN A * 1B06 BAKE 45OF/120 A 28OF/120 L * 1B08 FZGD 10OF/90 A - A * 25OF/120 1B32 BAKE 45OF/120 A 28OF/120 A * 1D00 DELI 40OF/90 A 24OF/120 A * 1D01 MDDI 40OF/90 A 24OF/120 A * 1D02 MDGD 40OF/90 A 27OF/120 A * 1D17 DELI 40OF/90 A 25OF/120 A * 1D24 MDDL 40OF/90 A 25OF/120 A * 1F00 FISH 40OF/90 A 27OF/120 A * 1F01 FISH 40OF/90 A 27OF/120 A * 1G00 DYCS 40OF/60 A 25OF/120 A * 1G02 DYCS 40OF/60 A 25OF/120 A * 1G03 DYCS 40OF/60 A 25OF/120 A * 1G06 FZCS 10OF/90 A - L * 25OF/120 1G07 FZCS 10OF/90 A - L * 25OF/120 1G09 FZCS 10OF/90 A - L * 25OF/120 1G10 FZGD 10OF/90 A - L * 25OF/120 1G11 MIGD 40OF/90 A - A *
32OF/120 1G15 DYCS 40OF/60 A 25OF/120 A * 1G12 ICGD 5OF/90 A - L * 25OF/120 1G24 GDMT 45OF/90 A 32OF/120 L * 1M02 MTCS 34OF/90 A 15OF/120 A * 1M04 MDDI 34OF/90 A 15OF/120 L * 1M05 MDDI 34OF/90 A 15OF/120 L * 1M07 MTCS 34OF/90 A 15OF/120 A * 1M09 MTCS 34OF/90 A 15OF/120 A * 1P02 PRCS 45OF/90 A 32OF/120 L * 1P03 PRCS 45OF/90 A 32OF/120 L * 1P06 PRCS 45OF/90 A 32OF/120 L * 1P07 PRCS 45OF/90 A 32OF/120 L * 1P09 PRCS 45OF/90 A 32OF/120 L * 1P11 PRCS 45OF/90 A 32OF/120 L * 1P17 PRCS 45OF/90 A 32OF/120 L *
(ROOMS) BKBX 45OF/150 A 32OF/120 A 4/45 BKFZ 10OF/150 A - L 3/45/50 25OF/120 PRBX 45OF/150 A 32OF/120 A 3/40 PRPR 70OF/150 A 32OF/120 A 1/70 "&" DLBX 40OF/150 A 28OF/120 A 3/45 MTBX 40OF/150 A 25OF/120 A 3/45/50 POBX 40OF/150 A 25OF/120 A 3/45/50 HDBX 40OF/150 A 25OF/120 A 3/45/50 MTWR 55OF/120 A 40OF/120 L 1/60 "&" MTPR 55OF/120 A 40OF/120 L 1/60 "&" FRZV 40O F/120 A 25O L 1/60 "&" F/120 FZBX 10OF/150 A - L 3/45/50 25OF/120 DYBX 38OF/120 A 32OF/120 A 4/45 CTBX 72OF/180 A 32OF/120 A 1/70 "&" Sales Temp 78OF/180 L 32OF/120 A 1/70 "&" Sales DP 55OD/180 L FZDR OPEN/30 A Liquid. 10 percent/120 A Level. PHASE OFF/05 L LOSS MON /05 L PROOF MT Suct 60PSI/30 A 30PSI/90 A PR LT Suct PR 25PSI/30 A OPSI/90 A HIGH 270/03 A 125/120 L HEAD Vapor Detectors Alarm on Sensing of Refrigerant vapor levels exceeding a preset value.
NOTES: A=Alarm N=Log (Record Only) *= Per manufacturer's published data "&"= Defrost between 10PM and 4AM
0.4 RMCS SENSORS
A. The RMCS sensors shall be identified as follows:
1. Names: The "Standard RMCS Point Names" shall be used/indicated in the system software (see list, item #5). 2. Inputs: All analog inputs shall have an identification tag at input sensor/transducer to identify input. Except for pressure transducers, tags shall be secured with fasteners (screws or rivets). On pressure transducers, tags can be secured with wire. Identification tags shall be metal or laminated plastic (minimum thickness of 1/16 inch) and the letters on the tag shall be 1/4 to 3/8 inch in height. Typical identification tags shall reflect "Standard RMCS Point Names", input example; MDFF , for Analog Input on Multideck frozen food case # . On display cases, the identification tags shall be mounted at locations shown on Drawings. 3. Probe Layout Sheet: Probe layout sheet shall indicate "Standard RMCS Point Names" which shall match software and analog input identification tags. 4. Cabinets: All system panel/cabinets that contain microprocessor units or circuit boards shall have a tag on outside of panel/cabinet to identify the panel/cabinet number. 5. The "STANDARD RMCS POINT NAMES" shall be as follows.
Refrigeration
Cases and Walk-In Boxes:
Cases/WIB Abbreviations Bakery Case BAKE Dairy Case DYCS Fish Case FISH Deli Case DELI Multi Deck Deli Case MDDI Single Deck Frozen Food SDFF Frozen Food with Gl Dr FZGD Ice Cream with Gl Dr ICGD Meat Case MTCS Produce Case PRCS Dairy Box DYBX Poultry Box POBX Freezer Vestibule FRZV Freezer Box FZBX Bakery Box BKBX Frozen Baked Box FZBX Controlled Temp (Candy) CTBX Meat Cutting Room MTCU Meat Wrapping Room MTWR Meat Holding Box HDBX Produce Box PRBX
Produce Prep PRPR Deli Box DLBX Fish Box FIBX Compressor Systems SYS##X (where ## is the system number and X is the compressor letter.) Defrost DEF## .XX (where ## is system numbered XX designates refr circuit number.) Air Cooled Condensers ACC##X (where ## is the condenser number and X is the stage number on the condenser.) Liquid Line Solenoid LLSV ## (where ## is the refr circuit number).
Heating, Ventilating and Air-Conditioning (HVAC) Names:
Names Abbreviations
Main Air Handler AHU ## (where ## is Air Handler 1, 2, etc. the AHU number) Cooling Stages Cool# (where # designates the stage number. When more than one AHU is present, designate as COOL### where ## is for AHU and the 2nd # is for stage.) Heat Reclaim Stages (HR) HR### (where ## is AHU number and # is the stag number.) Auxiliary Duct Heat (AH) AHEH### (electric) AHGH### (gas) AHOH### (oil) AHSH### (steam) AHWH### (water) (where ## is AHU number and # is stage number.) Dehumidification DHUM.## (where ## is the desiccant sys#) Humidity HUMD## (where ## is the AHU number.) Dewpoint DEWPT## (where ## is the AHU number.) Condensing Water Temp COND WTR Mezzanine Room Temp MEZ TMP Outside Air Temperature OTSD TMP Pan Water Temperature PAN WTR Stock Room Temperature STCK TMP Store Temperature INSD TMP (when only one zone) INSIDE X (where X =zone when more than one.) Supply Air Temperature SP## AIR (where X is AHU number) Compressor Suction / SYS##ST# or SYS##DT## (where ## is system number and Discharge Temperature # is compressor letter.) Oil Pressure Monitor OPMXXX (where ## is system number and # is compressor letter.) Refrigerant Level SYSXXLQD (where XX is the system number.) Chill Water Supply CWSTMP Chill Water Return CWRTMP System Suction Pressure SYS##SP (where ## is the system number.) System Discharge Press SYS##DP (where ## is the SYS number.) System Condenser Press SYS##CP (where ## is the SYS number.)
0.5 CLOSE OUT ITEMS
A. O & M MANUALS: Contractor shall furnish O&M manuals and information as herein indicated.
1. Distribution: a. Provide two (2) CD ROM copies to DeCA / LEED, 2250 Foulois Ave, Lackland AFB, TX 78236-1039. b. Provide one CD ROM copy to the Contracting Officer’s technical representative (to be forwarded to Commissary). 2. Date Required: Prior to final acceptance. 3. Table of Contents: Each set shall have a table of contents identifying the contents. 4. Contents: Each shall contain hardware and software information indicating the following:
a. The names, addresses, and telephone numbers of; the manufacturer of the system and of the nearest service representatives for the system. b. Shall describe the specifications and capabilities of all equipment provided, including:
1) General description and specification. 2) Installation and checkout procedures. 3) Descriptions of maintenance and repair of defective components (temperature probes, humidity or dewpoint sensors, control relays, digital input sensors, power supplies, etc.). 4) Installation drawings and sketches indicating locations of: analog inputs, control relays, digital outputs, digital inputs, and panels. 5) Computer specifications and peripherals. 6) Use of: system and applications software. 7) Use of Alarm system.
B. CADD Files: Provide CADD files (DWG and DXE format) on CD ROM indicating; analog probe locations, and point to point electrical interface drawings between RMCS connections and other equipment.
1. Distribution of CADD CD: CD shall be mailed to HQ DeCA/LEED Lackland AFB, TX 78236-1039.
C. Control Task Manual: Provide a booklet attached by chain to each ICU and one attached to the Desk Top Computer. Each manual shall contain the following:
1. Control Task Description: Provide a written description of each and every control task. Description shall clearly describe at length, how each relay point is affected by changes in the input. 2. Wiring Diagram: Provide a half sized As-Built drawing that folds into booklet, indicating physical location in store of all relays, relay boards, and sensors. Provide one full sized As-Built with same information and mount on equipment room wall with other As-Built drawings.
D. Training: The startup technician give the following training sessions each of which shall be: coordinated with the commissary, scheduled during week days, scheduled at a minimum of 14 days in advance, and coordinated through the Contracting Officer. During these sessions, Commissary Store Personnel shall be instructed on accessing the RMCS temperatures and alarms using the laptop computer. Additionally during these sessions, Commissary Personnel shall be instructed on changing the lighting schedules by means of using the lighting password.
1. First Training Session: A four hour training session (to a minimum of four Commissary Store Personnel) within 14 days after final acceptance and all RMCS final inspection
punch list items are resolved. This training session should be considered in conjunction with 3 day commissioning start up visit. 2. Second Training Session: A second four hour training session (to a minimum of four Commissary Store Personnel) at least 30 days after but no more than 45 days after the final acceptance.
E. Videos: Provide each video described below:
1. User Video: This video should be tailored to equipment installed on this project and will explain to commissary management how to determine what causes a refrigeration alarm and how to change lighting schedules using the Desktop Computer. Video length should be from 15 to 25 minutes. 2. Service Video: Video training tape on "Basic Service Procedure": This video should be tailored to repairing equipment (, ICUs, and sensors) installed on this project. The video should be on the level that would enable a journeyman refrigeration mechanic to make most repairs to the system. Video length shall be 45 to 70 minutes. 3. Distribution of Videos: Provide one copy of each DVD video to: HQ DeCA/LEED Lackland AFB TX 78236-1039.
F. Database Software: Provide the following items:
1. CD ROM: Data base downloading software CD ROM described in 2.3-d (1). 2. Authorization Of Use: Letter granting Government rights to use this software. 3. Distribution: Mail to DeCA/LEED, Lackland AFB TX, 78236-1039.
G. Data Backup: Provide the following items:
1. CD ROM: CD ROM containing backup of all RMCS name, and setpoints for site. 2. Distribution: Mail to DeCA/LEED, Lackland AFB TX, 78236-1039.
H. Spare Parts: The following spare parts shall be provided at least 30 days prior to final acceptance.
1. Probes: Four temperature sensing probes for each type. 2. Transducers: One pressure transducer for each type. 3. Boards: One circuit board of each type; DI, AI, RO, AO, communication. 4. Fuses: Twenty fuses of each type. 5. ICU: One spare individual control unit (ICU) complete with all printed circuit cards, circuit chips, and power supply. 6. Location for parts: These parts shall be located in the mechanical equipment room in a Contractor furnished cabinet with lockable door.
I. Final Acceptance: Prior to final acceptance, the following shall be accomplished.
1. Temperatures Maintained: All RMCS equipment shall be maintaining Contract specified control. 2. Punch List Complete: All pre final and final punch list items shall have been corrected by the Contractor and their correction approved by DeCA/LEED Lackland AFB TX. 3. O&M Info Received: All O&M information shall have been received by the Government. 4. Warranty Received: Warranty letters from the RMCS and Display case manufacturers shall have been received by the Government.
5. Certification of Installation Received: Certification of installation letters from the RMCS and Display Case Manufacturers shall have been received by the Government (see 3.1.2-b). 6. Transfer of Billing for cellular modem: (See 3.2-H (2)). 7. Alarm Monitoring and Notification: Alarm monitoring and notifications service shall be activated.
J. Alarm Monitoring and Notification: Manufacturer shall provide a 24 hour a day Alarm monitoring and notification service during the first 90 days of the warranty after final acceptance. See 3.6 Warranty.
1. General: RMCS shall dial out alarms to a monitoring service using a toll free (1-800) phone number. Monitoring company shall evaluate all alarms and shall notify designated Commissary personnel as necessary to inform them of refrigeration problems which warrant the store's attention.
0.6 WARRANTY
A. Provide Warranty Guarantees and Services as follows:
1. The manufacturer of the RMCS shall guarantee that the RMCS equipment/software, shall operate and provide specified control without failure for the periods indicated below beginning on the date of final acceptance.
a. First 90 Days: During the first 90 days of the warranty, the Manufacturer shall provide 24 hours a day, 7 days per week (including holidays), service to the Commissary. A technician shall arrive at the Commissary within 2 hours of receipt of a telephone call for warranty service. All parts and labor shall be provided by the Manufacturer at no cost to the Government during this period. Additionally, manufacturer shall provide a 24 hour a day Alarm Monitoring and Notification service. b. 91 To 365 Day: During the 91st day through the 365 day of the warranty, the Manufacturer shall provide free exchange of parts within 24 hours of notification. Shipping costs shall be paid by the Manufacturer. These parts will be installed by a Maintenance Contractor whose services are provided for under a separate Contract. No installation cost shall be paid by the RMCS Manufacturer for replacement of these parts. Additionally, manufacturer shall provide a 24 hour a day Alarm Monitoring and Notification service. c. First Five Years: Additionally, during the 91st day through the first five years of the warranty, the manufacturer of the RMCS shall provide assistance (via telecon at no cost to the Government nor Government Contractor) in helping the Government or Contractor personnel locate any problem with the RMCS system. During this warranty period, the manufacture of the RMCS shall unconditionally provide software maintenance at no cost to the Government or Government Contractor.
END OF SECTION