UNIVERSITY SERVICES ANNEX James Madison University Harrisonburg, Virginia State Project Code: Architect s Project Number:

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1 SECTION CONDENSING BOILERS PART 1 - GENERAL 1.1 RELATED DOCUMENTS A. Provisions of the Contract and of the Contract Documents apply to this Section. 1.2 ACTION SUBMITTALS A. Product Data: Include performance data, operating characteristics, furnished specialties, and accessories. B. Shop Drawings: For boilers, boiler trim, and accessories. Include plans, elevations, sections, details, and attachments to other Work. 1. Wiring Diagrams: Power, signal, and control wiring. 1.3 INFORMATIONAL SUBMITTALS A. Manufacturer Seismic Qualification Certification: Submit certification that boiler, accessories, and components will withstand indicated seismic forces. Include the following: 1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation. B. Warranty: Warranty specified in this Section. 1.4 CLOSEOUT SUBMITTALS A. Operation and Maintenance Data: For boilers to include in emergency, operation, and maintenance manuals. 1.5 QUALITY ASSURANCE A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use. B. ASME Compliance: Fabricate and label boilers to comply with ASME Boiler and Pressure Vessel Code. C. ASHRAE/IESNA Compliance: Boilers shall have minimum efficiency according to "Gas and Oil Fired Boilers - Minimum Efficiency Requirements." CONDENSING BOILERS

2 D. DOE Compliance: 1. Not required for boilers in excess of 300,000 BTUH 2. Minimum efficiency shall comply with 10 CFR 430, Subpart B, Appendix N, "Uniform Test Method for Measuring the Energy Consumption of Furnaces and Boilers." E. UL Compliance: Test boilers 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 COORDINATION A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified with concrete. 1.7 WARRANTY A. Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of condensing boilers that fail in materials or workmanship within specified warranty period. B. Warranty Period: 1. Boiler: Two years from date of Substantial Completion. 2. Pressure Vessel / Heat Exchanger: Ten years from date of Substantial Completion for corrosion, thermal stress failure, material defects or workmanship. PART 2 - PRODUCTS 2.1 CONDENSING BOILERS A. Basis of Design: 1. The basis of design shall be as indicated. B. Manufacturers: 1. Aerco International 2. Fulton Boiler Works, Inc. 3. Lochinvar Corporatrion C. Description: Factory-fabricated, -assembled, and -tested condensing boiler with heat exchanger sealed pressure-tight, built on a steel base; including insulated jacket; flue-gas vent; combustion-air intake; water supply, return, and condensate drain connections; and controls. D. Fabricate base and attachment to pressure vessel with reinforcement strong enough to resist boiler movement during a seismic event when boiler base is anchored to building structure. CONDENSING BOILERS

3 E. Condensing Boiler Components: 1. Heat Exchanger: Type 316L stainless-steel or duplex alloys of stainless steel, primary and secondary combustion chamber. 2. Burner: a. Pre-mix type b. Fuel: 1) Refer to drawings. c. Blower: 1) Variable speed throughout operating range of the burner d. Motor: Refer to section Motors 3. Gas Train: a. Combination gas valve with manual shutoff and pressure regulator. Provide separate gas regulator for each boiler. Include 100 percent safety shutoff with electronic flame supervision. 4. Ignition: Spark ignition with 100 percent main-valve shutoff with electronic flame supervision. 5. Casing: a. Control Compartment Enclosure: NEMA 250, Type 1A. b. Finish: Factory standard protective finish. c. Insulation: Minimum 2 thick. Surrounding the heat exchanger. d. Combustion-Air Connection: Inlet duct collar and sheet metal closure over burner compartment. 6. Condensate Neutralization: a. Non-metalic container filled with lime stone chips or other neutralizing media. b. Neutralization container shall act as a trap. c. Neutralization container shall drain through an air gap to a floor drain. d. Neutralization container may serve multiple boilers. 2.2 BOILER TRIM A. Include devices sized to comply with: 1. ANSI B31.1, "Power Piping when boiler operating pressure exceeds 160 psig. 2. ANSI B31.9, "Building Services Piping." when boiler operating pressure is equal to or less than 160 psig. B. Electronic Controllers: 1. Operating. 2. Firing rate. 3. High limit. 4. Sequence capability 5. BAS communication capability 6. Diagnostics and alarm history C. Safety Relief Valve: ASME rated to limit pressure in the boiler. Pressure setting shall be as recommended by the boiler manufacturer. D. Drain Valve: Minimum ¾ hose-end ball valve. CONDENSING BOILERS

4 2.3 BURNER OPERATING CONTROLS UNIVERSITY SERVICES ANNEX A. Description: To maintain safe operating conditions, burner safety controls shall limit the operation of the burner. 1. High Temperature and Pressure Cutoff: Independent of the high limit controller an automatic reset shall stop the burner if operating conditions rise above maximum boiler design pressure or temperature. 2. Low-Water Cutoff Switch: Electronic probe shall prevent burner operation on low water. Cutoff switch shall be automatic reset type. 3. Alarm Bell: Factory mounted on control panel with silence switch shall sound alarm for above conditions. 2.4 BOILER OPERATING CONTROLS A. Refer to Section "Building Automation System B. Control Panel: Electric, factory-fabricated, and field-installed panel or integral to the boiler controller to control burner firing rate to maintain input rate required by BAS. C. Building Automation System Interface: Factory-installed hardware and software to enable building automation system to monitor and control set point and display boiler status and alarms. 2.5 ELECTRICAL POWER A. Single-Point Field Power Connection: Factory installed other electrical devices necessary to provide a single-point field power connection to boiler. 1. House in NEMA 250, Type 1enclosure. 2. Wiring shall be numbered and color-coded to match wiring diagram. 3. Install factory wiring outside of an enclosure in a metal raceway. 2.6 VENTING KITS A. Kit: 1. Approved by boiler manufacturer. 2. Horizontal/vertical vent terminal as indicated, wall/roof passage thimble as indicated, indoor plate, vent adapter, condensate trap, and sealant. B. Combustion-Air Intake: Horizontal/vertical vent terminal as indicated with screen, inlet air coupling, and sealant. C. Chimney and Vent Adapter: Vent adapter and sealant. CONDENSING BOILERS

5 2.7 SOURCE QUALITY CONTROL UNIVERSITY SERVICES ANNEX A. Test and inspect boilers prior to shipping in accordance with the ASME Boiler and Pressure Vessel Code: Section I, for high-pressure boilers and Section IV, for low-pressure boilers. B. 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 test. PART 3 - EXECUTION 3.1 EXAMINATION A. Before boiler installation, examine concrete housekeeping pads, anchor-bolt sizes and locations, and piping and electrical connections to verify actual locations, sizes, and other conditions affecting boiler performance, maintenance, and operations. 1. Boiler locations indicated on Drawings are approximate. Determine exact locations before roughing in for piping and electrical connections. B. Examine mechanical spaces for suitable conditions where boilers will be installed. Proceed with installation only after unsatisfactory conditions have been corrected. 3.2 BOILER INSTALLATION A. Install boilers level on concrete housekeeping pad. B. Concrete Bases: Anchor boilers to concrete base as recommended by boiler manufacturer. 1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise indicated, install dowel rods on 18 centers around full perimeter of base. 2. Place and secure anchorage devices using setting drawings, templates, diagrams, instructions, and directions furnished with the boiler and items to be embedded. C. Vibration Isolation: Rubber pads with a minimum static deflection of D. Install gas-fired boilers according to NFPA 54. E. Assemble and install boiler trim. F. Install electrical devices, vent kit, and other accessories furnished with boiler but not factory mounted. 3.3 CONNECTIONS A. Drawings indicate general arrangement of piping, fittings, and specialties. CONDENSING BOILERS

6 B. Connect piping to boilers, except safety relief valve connections, with flexible connectors of materials suitable for service. 1. Exception: Boilers included as part of an HVAC Packaged Pumping System. C. Connect gas piping full size to boiler gas inlet with union, valve, and full size eight inch long dirt leg. D. Connect hot water piping to supply and return boiler tappings with shutoff valve and union or flange at each connection. E. Install piping from safety relief valves to six inches above concrete housekeeping pad unless indicated otherwise. F. Connect vent kit to boiler as recommended by boiler manufacturer. G. Install piping adjacent to boiler to allow service and maintenance. H. Ground equipment. I. Connect wiring. J. Tighten electrical connectors and terminals according to manufacturer's published torquetightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A and UL 486B. 3.4 STARTUP SERVICE A. Engage a factory authorized service representative to test, inspect, and adjust boiler components and equipment installation and to perform startup service. B. Perform installation and startup checks according to manufacturer's written instructions. C. Leak Test: Hydrostatic test. Repair leaks and retest until no leaks exist. D. Operational Test: Start units to confirm proper motor rotation and unit operation. Adjust airfuel ratio and combustion. E. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment. F. Adjust initial temperature set points. G. Set field adjustable switches and circuit breaker trip ranges as indicated. H. Occupancy Adjustments: Within 12 months of date of Substantial Completion, and when the temperature is below forty degrees F., provide on site service. Adjust system to suit actual occupied conditions. CONDENSING BOILERS

7 I. Within two weeks of Substantial Completion prepare a written report that documents testing procedures and results. J. Within two weeks of Occupancy Adjustments prepare a written report that documents adjustments made. 3.5 DEMONSTRATION A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain condensing boilers. 3.6 ON-SITE TRAINING & TESTING A. Provide on-site training for four (4) of the Owner s staff to go over operation and maintenance of boilers at a minimum of eight (8) hours training. The boiler manufacturer s instructor shall be present to provide training and answer any technical questions. B. Provide on-site testing of the boiler to calculate boiler efficiencies at various firing levels and emissions. END OF SECTION CONDENSING BOILERS

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