SECTION 233500 WELDING FUME EXHAUST SYSTEM PART 1 - GENERAL 1.1 WORK INCLUDES Welding fume exhaust system and controls Accessories Additional System Equipment Engineering Support Commissioning 1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section 23 01 00 - HVAC General Provisions B. Section 23 03 00 - HVAC Basic Materials and Methods C. Section 23 05 13 HVAC Variable Frequency Drives D. Section 23 07 00 HVAC Insulation E. Section 23 09 00 HVAC Instrumentation and Control F. Section 23 30 00 HVAC Air Distribution 1.3 WELDING FUME EXHAUST SYSTEM GENERAL DESIGN REQUIREMENTS A. The following specifications are based on The Lincoln Electric Company Fume Extraction System. Equivalent products and systems that meet these specifications may be submitted for engineering review and approval. B. Furnish and install associated galvanized steel duct work to provide a completely engineered duct system with a balanced amount of airflow to each work station. The ductwork shall be designed in accordance with Industrial Ventilation A Manual of Recommended Practice For Design by ACGIH and designed and installed in accordance with Accepted Industry Practice for Industrial Duct Construction by SMACNA 1.4 QUALITY ASSURANCE A. Single source responsibility: Welding Fume Exhaust System equipment and accessories shall be manufactured and furnished by a single manufacturer. B. Manufacturer s qualifications 1. Modern plant with proper tools, dies, fixtures and skilled workmen to produce high quality equipment; and shall meet the following minimum requirements: 2. Five years or more experience in the manufacture of welding exhaust systems and equipment of type specific. 3. Ten installations of equal or larger size and requirements. Provide contact and references for each. C. Installer s qualifications PROJECT NO. 2161037 233500-1
1. Factory certified by the manufacturer. Provide outline of certification program. 1.5 SUBMITTALS A. Refer to Section 23 01 00. PART 2 - PRODUCTS 2.1 MANUFACTURER A. Design, materials, construction, and finish of welding extraction system specified, is the minimum acceptable standard of quality. B. Manufacturers, subject to comply with requirements for the welding extraction system, are approved for bidding, provided they meet the contract document specifications, include the following: 1. Lincoln Electric or equivalent C. Products: Product Number listed is for Lincoln Electric use only. Approved equivalents shall provide the product numbers as required to identify product and product specifications. Quantity Product Number Product Description 10 K1655-7 LTA 2.0-CW Wall mounted telescopic articulating fume extraction arm with 360 deg. rotating hood. The working radius ranges from 3 to 7. The nominal diameter of the arm is 8 inches. Spring balance and counterweight allow arm to maintain position. Adjustable throttling valve is in hood. The arm is designed to be positioned 6-12 away from the welding process. 10 S23267-1 ENV, CUT S23267 TO 8" DIAMETER MARK Eight inch tapered connection flange used to adapt an extraction arm to a weld fume control central system. 10 S23385-41 MANUAL DAMPER, MD200MM The manual damper is used to balance the air flow at each fume extraction arm. It is located between the arm and the duct main. The damper is made from galvanized steel, and is 200mm in diameter with EPDM rubber seal. 1 XCUSTOM_ITEM AUTOMATIC CONTROLS & ELECTRONICS Equipment required to convert the system to fully controlled automatic operation using lamp/arc sensor technology. These items include: (10) AD1221 LAMP/ARC SENSOR KIT (10) S23385-39 AUTOMATIC DAMPERS (1) S23385-IF15 INTERFACE CONTROL Automatic control provide energy efficiency and energy use savings by means of on demand operation and reduces maintenance through reduction in activation as compared to a typical on-off manual system or a 100% PROJECT NO. 2161037 233500-2
constant system operation. Specifics on each component are listed below. 10 AD1221 LAMP/ARC SENSOR KIT This kit incorporates a lamp, sensor, and on/off switch; such that an operator may turn the fan on/off manually or automatically right at the end of the arm. The sensor will turn the fan on when it detects the arc, and off when it no longer detects the arc. The following items are included in the kit: Work lamp, arc sensor, 36-3 wire - 20 AWG, control box, and thermal relay. Specs. Voltage 24 VAC Bulb Halogen, 35W Weight 7.7 lbs 10 S23385-39 AUTOMATIC DAMPER, AD 200MM Motor operated damper, 200mm in diameter with galvanized steel structure and EPDM rubber seal. Damper is equipped with Kenlock seals for easy duct mounting. The working range is 0 to 90 degrees. Electrical Data: Drive Torque 8 Nm Running time 8 sec Input Power 24V AC Frequency 50-60 Hz Power consumption 7 W (13VA/3.4A@2ms) 1 S23385-37 IF-15 INTERFACE CONTRL, STATIFLEX 6000 The IF-15 works in conjunction with the VFD to regulate the fan speed based on the number of arms that are demanding air flow. The IF-15 receives a signal from the fume extraction arm to turn the fan on/off, and/or to change its frequency (speed). The signal output to the VFD is 4-20mA. The input power required to the IF-15 is 24V AC. The IF-15 can serve up to 15 arms. More than one IF-15 can be wired to the VFD as necessary. 10 XCUSTOM_ITEM ENV, ARM MOUNT (7.625 CINDER BLOCK) Mild Steel Bracket for mounting the LTA 2.0-CW arm above a 7.625 inch cinder block. Finish is flat black. Hardware/lags are not included but are required in order to secure the bracket to the block. 1 AD1389-2 FILTER, PRESSURE DIFFERENTIAL KIT Monitors the saturation level of the filter cartridges and adjusts the air volume rate based upon a predetermined setpoint. As filter cartridges become saturated, the controller adjusts the fan speed to maintain the required air volume determined by the air volume setpoint. Kit shall include (1) S23385-48 Pressure Gauge Gauge enclosure NEMA 4X 1 M18464-29 SF15000, 11KW, EXTRACTION FAN, LEFT Mechanical Specifications: Fan Steel Housing Steel with aluminum profiles Motor design IEC 132 Discharge position RD 0 PROJECT NO. 2161037 233500-3
Fan type Radial Speed 2850 RPM sound absorbing case approx. 10 db(a) Inspection Cover Left Electrical Specifications: Voltage 208/3ph/50Hz Horsepower 15 HP 1 AD1283-44 ENV,POWERFLEX 400,15HP, IP54VFD The variable frequency drive (VFD) regulates the fan input voltage based on either a differential pressure signal or a signal from the IF-15 control box. UL listed to UL508C, NEMA ICS 3.1, IEC 146. Electrical Specifications: Voltage Tolerance 200-240V +or- 10% 380-480V +or- 10% Frequency Tolerance 48-63 Hz Input phases 3 phase = full rating. De-rate for single phase. Displacement pf 0.98 across entire speed range Efficiency 97.5% @ rated amps, nominal line voltage Environment: Altitude 3300ft without derating Air Temp IP20,NEMA/UL type open = -10 to 50 deg C. Humidity 0-95% non-condensing 1 AD1283-35 ENV,POWERFLEX 400, CONDUIT BOX Supports the connection of electrical connections to the Powerflex 400 1 XCUSTOM_ITEM ON/OFF PUSH BUTTON CONTROLLER Kit includes the following: (1) S21118-91 Enclosure (1) S21130-76 Push Button, Green LED, Ilum (1) S21130-46 Red Push Button, AB (1) S22628-5 Push Button, contact block, 2 N.C. Assembly is required. See below for component specifics. 1 S21118-91 ENCLOSURE, 2 ELEMENT, STEEL 30.5mm, Heavy-Duty, Pilot Device Enclosure, Gray, Steel, Surface Mount, 2 Element, 1 Contact Block Depth, NEMA 12, 13. 1 S21130-21 PUSH BUTTON, GREEN, AB Push button, 30.5mm, Illuminated, Green, Type 4x, IP65 wateright/oiltight panel, Double nickel plated terminal screws, Contact material: Silver 1 S21130-46 PUSHBUTTON, RED, AB Flush pushbutton, 30.5mm, Non-Illuminated, Red, 800T, NEMA Rating: 4/13, 1 NO 1 S22628-5 30mm CONTACT BLOCK, 1 N.C. PROJECT NO. 2161037 233500-4
1 N.C. Contact Block, 30.5 mm, Base Mount, Non- Metallic, 800T Series 1 S23281-43 90deg SILENCER Dual walled, inline, straight duct silencer. O.D is 29, I.D is 24, length is 47. The sound reduction is 12 dba. Duct connection inserts included. D. ENGINEERING SUPPORT 1. Provide engineering and installation phone support for the electrical and mechanical contractors. Lincoln Electric does not provide spiral ductwork nor the installation of the system which includes and is not limited to any HVAC components, electrical connections, equipment handling and mounting, and compressed air connections. 2. Lincoln Electric will provide one system installation manual. This manual is included with the purchase of the quoted system and will be shipped with the equipment. Additional hard copies are available for an additional charge of $100.00 for each copy. Electronic versions will be provided upon request from Lincoln s customer. E. COMMISSIONING 1. Provide system start-up, commissioning, and technician support to test and tune the system at initial system operation. Commissioning includes manual damper adjustment, airflow set point, extraction system operation and maintenance. Post installation commissioning include a point-to-point checklist and sign-off procedure. A minimum of two weeks is required prior to commission date to establish a travel itinerary. One factory technician will be provided. 2. Lincoln Electric requires that the technician be on-site and present at the time of start-up of the system. The system shall not be used to test the leakage of ductwork or to test electrical connections, wiring or compressed air system. 3. Commissioning data and reports are done for the purpose of warranting the system. Created reports are not intended to be used for any official use. If a certified report is required in your area, contact Lincoln Electric prior to purchase. PART 3 - EXECUTION 3.1 INSTALLATION A. Install welding fume extraction system and equipment in accordance with the manufacturer s instructions. B. Install equipment plumb, square, and straight with no distortion and securely anchored as required. C. Secure equipment components with material and procedures recommended by the manufacturer. D. Install ductwork in accordance with Accepted Industry Practice for Industrial Duct Construction by SMACNA. E. Accessory installation: Install all accessories and fittings in accordance with manufacturer s recommendations. 3.2 FIELD QUALITY CONTROL TESTING OF WELDING FUME EXTRACTION SYSTEM A. Perform tests in field to verify proper operation of the system before they are put in use, using only PROJECT NO. 2161037 233500-5
qualified personnel. B. Correct any unsafe conditions disclosed by these tests before request of test procedures. C. Commissioning and balancing of the fan, VFD, and fume extraction arms shall be completed by a Lincoln Electric service technician. 3.3 ADJUSTING A. Repair or remove and replace defective work, as directed by the Engineer (G.C., or entity in charge of the project) upon completion of installation. B. Adjust fixtures, accessories and other moving or operating parts to function smoothly. 3.4 CLEANING A. Clean equipment, touch up as required. 3.5 PROTECTION OF FINISHED WORK A. Provide all necessary protective measures to prevent exposure of equipment to other construction activity. B. Advise contractor, of procedures and precautions, for protections of material and installed system, from damage by work of other trades. END OF SECTION PROJECT NO. 2161037 233500-6