BASF Corporation Technical Standard

16-137-01
STANDARD CATEGORY: MANDATORY RECOMMENDED DESIGN AIDE
Approved: H. Zoghbi
Signed original on file Pneumatic HVAC Controls - SHEET 1 OF 9
Date: 7/10/03 Procurement and Installation

Table of Contents

1.0 Scope ..................................................................................................................................... 2

2.0 Standards ............................................................................................................................... 2
3.0 Requirements......................................................................................................................... 2
4.0 Compressed Air Source......................................................................................................... 2
5.0 Control System Components................................................................................................. 2
6.0 Acceptable Manufacturers .................................................................................................... 8
7.0 Supervision, Coordination & Instruction .............................................................................. 8
8.0 Calibration of Control Systems ............................................................................................. 8
9.0 Submittals.............................................................................................................................. 9
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 2 OF 9

1.0 Scope
This standard, together with the purchase documents and drawings, provides the basis for
the procurement and installation of a complete pneumatic automatic control system for
heating, ventilation and air conditioning (HVAC) systems. Electronic DDC HVAC
control systems are not included in this standard.

2.0 Standards and Specification Sheets

The codes, standards, and specification/data sheets listed shall be the latest edition.
Industry Standards:
• American Society of Heating Refrigeration and Air Conditioning Engineers
(ASHRAE)
• Air Movement and Control Association (AMCA)
• Underwriters Laboratory (UL)
• National Electric Code (NEC)
• National Fire Protection Association (NFPA)

3.0 Requirements
3.1 The HVAC controls Contractor shall furnish all materials and labor required to
perform the design, installation and calibration of automatic control systems to
control HVAC systems in accordance with the sequences of operation described in
the purchase documents and drawings. When practical, all the components of the
system shall be products of a single Manufacturer. All control components shall be
tagged in accordance with purchase documents.
3.2 Electrical Wiring and Components
3.2.1 All field electrical wiring (between device and control panel) and pre-wired
control panels shall be installed in accordance with the purchase documents.
3.2.2 All electric or electric-pneumatic devices mounted on or in the control
panels shall be pre-wired to numbered terminal strips.

4.0 Compressed Air Source

Unless otherwise noted, compressed air at -40°F dew point and 100 psig, will be supplied
by the Owner up to a point located inside the building. The Contractor shall connect this
existing source with appropriate matching material and size of pipe and shall provide any
necessary accessories, such as PRV (Pressure Reducing Valve) stations with inlet/outlet
gages, control valves, oil filter or air filter with an accompanying drain and desiccant
dryer.

5.0 Control System Components

5.1 Control Panel
░ 5.1.1 The Contractor shall furnish and install pre-wired control panels in fully
enclosed steel cabinets located strategically to minimize installation costs and to
control common areas. The location of all panels shall be identified in the
Contractors submittal. The panel(s) shall contain all control equipment shown to
be panel-mounted on drawings and such additional equipment required to assure a
complete control system. All internal control wiring
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 3 OF 9

shall be in accordance with the National Electrical Code. All internal

control tubing shall be Type FR (fire retardant) virgin polyethylene
instrument tubing with stainless steel or brass fittings. Tubing shall be
neatly and properly supported within cabinets and shall terminate at
numbered bulkhead fittings. Bulkhead fittings shall be so located to
facilitate connection of field run control tubing and tagged appropriately.
5.1.2 The panel(s) shall be constructed so that all indicating and recording
instruments shall be provided on the face of the panel.
5.1.3 Unless otherwise specified, the panel(s) shall be given one coat of primer
and two (2) finish coats of enamel paint. The final coat shall be oven-dried.
The panel color and finish are subject to Owner's approval.
5.1.4 The panel(s) shall be suitable for the environment and the hazardous
electrical classification specified in the purchase documents.
5.2 Control Valves:
5.2.1 Control valves shall consist of diaphragm type actuator, body, seat, disc,
plug, stem, packing, spring, and positive positioning relay where required.
(See "Positive Positioning Relays"). Two-way control valves shall be single
seated. Valves shall be supplied with valve position indicators.
5.2.2 Valve bodies 1/2 inch through 2 inches shall be threaded unless otherwise
noted. Valve bodies 2 & 1/2 inches and larger shall be flanged. Valve
bodies, seats, discs and plugs shall have pressure and temperature rating
suitable for fluids controlled. Seat leakage shall not exceed ANSI Class IV
for water service and ANSI Class V for steam service.
5.2.3 Actuators shall be equipped with replaceable, wear-resistant neoprene
diaphragms. Actuator diaphragms shall have sufficient area to close valve
against fluid pressure with lowest air pressure available at the actuator.
5.2.4 Valve packing shall be PTFE cone or V-ring.
5.2.5 Pressure drop through control valves shall be selected such that the valve
strokes approximately between 20% and 80% as the load varies through its
normal range. For steam service, valve plugs shall have linear
characteristic.
5.2.6 Refer to the Valve Schedule in the purchase documents for control valve
sizing information, including pressure - temperature rating, maximum
shutoff pressure, flow rates and pressure drops.
5.3 Positive Positioning Relays
Positive positioning relays shall be provided on control valves and/or dampers under
the following conditions:
5.3.1 Where two or more valves or dampers are operated in sequence.
5.3.2 Where the air signal to the valve comes from a controller connected to the
valve by air piping with an equivalent length in excess of 150 feet.
5.3.3 Where tight shutoff is required and additional stem thrust is needed.
5.3.4 Where it is called for on the drawings.
5.3.5 On larger valves where a large volume of air is required for operation.
5.3.6 When rapid speed of valve operation is required.
5.3.7 Where dampers or valves must be accurately positioned.
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 4 OF 9

5.4 Pneumatic Temperature Transmitters

Pneumatic temperature transmitters shall be single pipe instruments used with an
external restrictor. Duct transmitters shall have rod and tube, averaging element
with capillary, or bulb with capillary, thermal system. Room transmitters shall have
bi-metal element thermal system. Transmitter shall have pilot bleed system and
shall provide accurate linear response, directly proportional to temperature.
Pneumatic feedback shall be incorporated to assure an exact and proportional
relationship between measured temperature and transmitted signal.
5.5 Pneumatic Thermostats
Pneumatic room thermostats shall be two pipe instruments with internal restrictors.
Room thermostats shall have bi-metal element thermal systems. Duct insertion
thermostats shall have rod and tube, bulb and capillary, or averaging element with
capillary. Thermostats shall have pilot bleed system and shall provide accurate
linear response, directly proportional to deviation between setpoint and room
temperature.
Pneumatic feedback shall be incorporated to assure an exact and proportional
response between measured temperature and output signal. Thermostat setpoint
shall be adjustable from face and shall be equipped with proportional type bi-metal
thermometer and shall be calibrated at the factory. Submaster thermostat shall have
third pipe for remote setpoint adjustment. Dual temperature heating-cooling
thermostats shall have adjustable deadband between heating and cooling setpoints to
eliminate heating and cooling overlap. Throttling range shall be adjustable.
5.6 Pneumatic Humidistats
Pneumatic humidistats shall be two pipe, proportional action devices with cellulose
acetate butyrate or nylon elements, perforated removable covers, setpoint
adjustment, throttling range adjustment, mounting bracket, gasket and internal
pneumatic feedback signal to assure accurate humidity signal.
5.7 Pneumatic Humidity Transmitters
Humidity transmitters shall be single pipe devices with cellulose acetate butyrate or
nylon elements, throttling range adjustment, mounting brackets, gaskets and a
pneumatic feedback system to assure accurate transmission of humidity signal.
5.8 Freeze Protection Thermostats (Freezestats)
5.8.1 Freeze protection thermostats shall be snap-acting electric switch with
liquid-filled 20-foot flexible thermal elements. Elements shall be so
designed that thermostat will respond to the lowest temperature to which
any one-foot section of the element is subjected. Freezestats shall be
equipped with manual reset button.
5.8.2 Freeze protection thermostat element shall be installed to pass horizontally
across the face of the coil being protected with not less than two (2) complete
horizontal passes across the face of the coil. Where large coils cannot be
protected as described above by a single freeze stat, multiple freeze stats
shall be provided.
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 5 OF 9

5.9 Pneumatic Controllers (Receiver-Controllers)

Pneumatic controllers shall use miniature diaphragm technology for a high degree of
accuracy and reliability. Controllers shall have field adjustable proportional band,
reset and setpoint. Controllers shall have proportional, or proportional plus integral
control to minimize offset. Controller may be equipped with transparent covers to
provide protection while allowing easy reading of settings and gages.
5.10 Pneumatic Minimum Position Regulator
Pneumatic minimum position regulator shall be pilot operated, two-position type
with convoluted diaphragms and corrosion resistant hardware. Minimum position
regulator shall transmit a manually adjustable minimum pressure signal regardless of
input signal pressure.
5.11 Volume Booster Relays
Pneumatic volume booster relays shall be pilot operated, proportional relays with
convoluted diaphragms, corrosion resistant hardware and shall be equipped with
replaceable filters to ensure clean supply and signal air. Booster relay shall
proportionally amplify pneumatic output signal in response to input signal.
5.12 Pneumatic Switching Relays
Pneumatic switching relays shall be pilot-operated, two-position type with
convoluted diaphragms and corrosion resistant hardware. Pilot pressure shall
determine when switching occurs. Selector relays shall be equipped with
replaceable filters to ensure clean supply and signal air streams.
5.13 Pneumatic Manual Gradual Position Switches
Pneumatic gradual position switches shall have proportional action. Switches shall
be suitable for use as manual, remote set point adjustment device or minimum
position switch. Units shall be suitable for panel mounting and shall be equipped
with graduated scales indicating operation. Switches shall be capable of adjusting
branch line pressure at any pressure between 3 and 13 psig.
5.14 Electrical-Pneumatic Relays (E-P Switches)
Electric-pneumatic relays shall be solenoid valves, which open and close the air
supply to pneumatic controls. Voltage ratings shall be line voltage (120 VAC or
480 VAC), or low voltage (24 VAC), depending on application. Relays shall be UL
listed.
5.15 Pneumatic-Electric Relays (P-E Switches)
Pressure-electric switch shall convert a pneumatic signal to a two-position electric
switch action. Setpoint and fixed differential shall be factory set. Switches shall be
UL-listed.
5.16 Pneumatic Pressure Controllers
Pneumatic pressure controller shall be two-pipe device with pilot bleed relays and
pneumatic feedback. It shall produce a 3-15 psig output signal proportional to the
deviation between setpoint and the sensed gage or differential pressure.
5.17 Pneumatic Pressure Transmitters
Pneumatic pressure transmitters shall be diaphragm type, with external restrictors.
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 6 OF 9

Transmitters shall convert static or differential pressure measurement into

proportional 3 to 15 psig output signal. Units shall consist of reinforced diaphragm,
range spring with range adjustment screw, sturdy die-cast case, and compression-
type connection fittings.
5.18 Pneumatic Selector Switches
Pneumatic selector switches shall consist of rotary type multiport valve mechanism,
operating stem, knob, dial, dial plate, and where panel mounted, a surface type
switch plate. For local mounting, switches shall be equipped with wall mounting
brackets.
Switches shall have one (1) inlet port and multiple outlet ports. Unused outlet ports
shall be plugged.
Dial marking shall be as indicated on drawings. Switch plates shall bear function
description.
5.19 Load Analyzer
Load analyzers shall be diaphragm type to select the highest and/or lowest branch
pressure input from zone thermostats. It will select the highest demand for cooling
and highest demand for heating to operate final control elements. Load analyzers
shall have multiple input ports on their manifolds with logic diaphragms, integral air
filter and restrictors.
5.20 Duct-Mounted Smoke Detectors
Units shall be listed by Underwriters Laboratories, Inc. for use in air-handling
systems and shall bear the UL label. They shall be designed to provide detection of
combustion gases or smoke in air conditioning and ventilating duct systems in
compliance NFPA 90A and NFPA 72, and Underwriters Laboratories, Inc. Standard
UL 268A. Coordinate the location of the detector with the sheet metal contractor so
that he can provide an access door. Further, they shall contain an ionization-type
detector and air sampling chamber with sampling tubes extending through the width
of the air duct. Alarm-status indicating lights shall be visible on the front of the
detector. Key controller test and reset switches plus an easily accessible test jack
shall be provided. It shall include alarm relay contacts (DPDT) capable of handling
loads of up to five (5) amperes at 120 VAC or 28 VDC resistive. Unit shall have
self-contained power supply requiring 120/220/240V power. Smoke detectors shall
be interlocked with the HVAC system in accordance with the applicable Mechanical
Code and shall provide alarm in accordance with NFPA 90A.
5.21 Air Flow Control Dampers
5.21.1 The HVAC controls Contractor shall provide all control dampers as
specified on the drawings or purchase documents. Frames shall not be less
than 13-gage galvanized steel. Blades must not be over 8 inches wide nor
less than 16-gage galvanized steel roll formed. Bearings shall be oilite, ball
bearing or nylon with 1/2-inch shafts. Side seals shall be stainless steel of
the tight-seal spring type. The dampers and seals shall be suitable for
temperature ranges of -40° to 200°F. All proportional control dampers shall
be opposed or parallel-blade type and all two-position dampers shall be
parallel-blade types. Replaceable neoprene rubber or inflatable seals shall
be provided. Seals shall be installed along the top, bottom and sides of the
frame and along each blade edge. Seals shall provide a tight closure.
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 7 OF 9

5.21.2 Mixing and modulating dampers shall be equipped with linkages providing
linear flow characteristics.
░ 5.21.3 Dampers shall be positioned by single-stage diaphragm-piston type damper
operators. Operators shall be selected to position dampers through their full
range of operation and shall provide adequate force in both directions of
travel. Multiple damper operators shall be provided for larger damper sizes
requiring force beyond the capabilities of single operators. Damper
operators shall be equipped with universal mounting brackets to facilitate
installation in field under widely varying mounting conditions.
5.21.4 Where dampers are operated in sequence, damper operators shall be
equipped with positive positioning relays (see Positive Positioning Relays
above). Damper operator stroke limiting devices shall be provided as
required to limit opening and/or closing of dampers.
░ 5.21.5 All control dampers shall be standard products of the HVAC controls
Manufacturer's factory or an approved equal. Field fabrication of dampers
is not allowed.
5.22 Smoke Control Dampers
Smoke control dampers shall be furnished by the HVAC controls Contractor and
installed by the Sheet Metal Contractor in the HVAC system where shown on plans.
All smoke dampers and actuators shall be Underwriters Laboratories tested under
Standard 555S, latest revision, and classified Class II leakage at 250°F temperature
rating, unless otherwise specified, and shall bear the UL label.
5.23 Pressure Reducing Valves
Control air pressure reducing valves shall be a diaphragm type pressure regulator
with integral safety relief valve. Reducing valves shall be capable of accurately
regulating the control pressure between 0 and 25 psig with inlet air pressure between
45 and 150 psig.
5.24 Temperature Indicating Gages
All temperature gages shall have an adjustment screw on the back of the case to
permit rotation of the gage mechanism. Gages shall be equipped with dials
indicating the temperature being measured. Dials shall be selected to have proper
range for temperature being measured. Indicator accuracy shall be plus or minus 2
percent of full scale, unless otherwise specified. Minimum diameter shall be 2-1/2”.
Gages shall be suitable for panel mounting.
5.25 Pneumatic Control Tubing
5.25.1 Complete air piping shall be provided for the pneumatic control system and
is subject at all times to the approval of the Owner.
5.25.2 Pipe shall be of seamless copper tubing, aluminum tubing and/or non-
metallic tubing. All piping shall be concealed except in mechanical rooms
or areas where other piping is exposed. Hard drawn tubing will be used in
all exposed areas and either hard drawn or annealed if concealed. Where
copper
 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 8 OF 9

tubing is run exposed, each tube is to be securely fastened at regular

intervals and run parallel to the lines of the building. Only tool-made bends
will be acceptable. Fittings for copper tubing shall be brass or copper solder
joint-type except at connection to apparatus where brass compression-type
fittings shall be used.
5.25.3 Non-metallic tubing shall be type FR virgin polyethylene, ASTM Type I,
Grade 5, Class B or C, meeting the stress crack test performed for ASTM
D1693-60T. Multi-tube instrument tubing harness shall be as above, plus
mylar barrier and vinyl jacket not less than 0.062-inch thick.
░ 5.25.4 All non-metallic tubing run in mechanical or finished spaces where other
tubing is exposed shall be run within adequately supported rigid metallic
raceway, EMT or rigid PVC pipe or duct. Terminal single lines shall be
hard drawn copper or aluminum tubing except when the run is less than 12
inches in length where flexible type FR polyethylene may be used. Non-
metallic tubing in concrete block walls shall be run in EMT or PVC conduit.
5.25.5 Non-metallic tubing installed in concealed location such as pipe chases,
suspended ceilings or within walls shall be adequately supported and
installed inconspicuously in a neat and workmanlike manner. Multi-tube
instrument harness (bundle) may be used in place of single tube where a
number of tubes run to the same points. Tubing installed in concrete floor
or below concrete floor on grade may be annealed copper or non-metallic
tubing in multi-tube instrument harness. A flexible metal (Greenfield) or
EMT kickpipe shall be installed to extend six inches into the floor where the
tubing enters and leaves the floor if the tubing is otherwise exposed to
damage. Multi-tube instrument harness (bundle) may be run in floor in
place of above without kick pipe. All tubing shall be periodically tested for
leaks during installation and all tubing shall be blown out to clear
installation debris, impurities and moisture before connecting to the control
device.
5.25.6 Fittings for polyethylene tubing shall be for instrument service and may be
brass, aluminum or stainless steel of the compression or barb push-on type.

6.0 Acceptable Manufacturers

Honeywell Inc. or Johnson Controls. Prior Owner approval is required for other
Manufacturers.

7.0 Supervision, Coordination and Instruction

The following items of work shall also be included:
7.1 Supervise the installation of the automatic dampers.
7.2 Coordinate and supervise the installation of sensors, control valves, wells, etc.
7.3 Instruct Owner's operating personnel in the operation of the automatic control
systems, as described in purchasing documents.

8.0 Calibration of Control Systems

 Technical Standard
Pneumatic HVAC Controls -
16-137-01
Procurement and Installation
Date: 7/10/03 SHEET 9 OF 9

After completion of the installation, the Contractor shall calibrate and adjust all
thermostats, control valves, actuators, controllers and other equipment provided in
accordance with the Manufacturer's requirements. The controls shall be placed in a
complete operating condition subject to the approval of Owner or Owner's representative.

9.0 Submittals
Submit one (1) reproducible of schematic control diagrams to the Owner for his review and
approval. Drawings shall show all components of the control system, properly identified
with catalog numbers, with all pneumatic and electrical connections shown. Schematic
drawings shall show setpoints for the various instruments and shall indicate operational
modes, transmitter ranges, operating pressure ranges of all controlled devices, normal
position of all ports (C, NO, NC), type of action, etc. A detailed description of the
sequences of operation, written in layman's language, shall be included on schematic
drawings.
Submittals of schematic diagrams shall be accompanied by catalog cuts of all material
furnished together with valve and damper schedules. Valve schedules shall indicate valve
sizes, flow coefficients and pressure drops (at design flow).
Furnish terminal-to-terminal wiring diagrams.
Following completion and acceptance of the HVAC controls installation, the following
shall be issued to BASF:
9.1 "As-built" schematic diagrams (not “red-lined”).
9.2 Installation drawings.
9.3 Complete vendor manuals for each instrument as needed for calibration and/or
repair.
9.4 Certification of completion and controls calibration sheets.
9.5 Spare parts list.