DESIGN A/E NOTE - GUIDE SPECIFICATION CONVENTIONS

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Rev 19JUN09 j:\Projects\Active\com-deca_design_criteria_revisions-04071\Guide Specifications\TJG Innformation

SECTION 15682

AIR COOLED WATER CHILLERS

PART 1 - GENERAL

1.1SUMMARY

1.1.1.Section Includes:

  1. Chiller package.
  2. Charge of refrigerant and oil.
  3. Controls and control connections.
  4. Chilled water connections.
  5. [Remote air cooled condenser.]
  6. Refrigerant piping.
  7. Starters.

1.2Related Sections:

  1. Section 01042 - Mechanical, Refrigeration, Food Service Equipment and Electrical Coordination.
  2. Section 01400 - Quality Control.
  3. Section 01720 – [Phased Turnover and] Contract Closeout.
  4. Section 15170 Motors.
  5. Section 15245 Vibration Isolation.
  6. Section 15510 Hydronic Piping.
  7. Section 15535 Refrigeration Piping and Specialties.
  8. Section 15540 HVAC Pumps.
  9. Section 15990 Testing, Adjusting, and Balancing.
  10. Section 16180 Equipment Wiring Systems: Electrical characteristics and wiring connections.

1.3QUALITY CONTROL

1.3.1.The following publications form a part of this specification to the extent they are applicable:

  1. Section 01400 – Quality Control.
  2. ARI 590 Reciprocating Water Chilling Packages.
  3. ASHRAE 15 Safety Code for Mechanical Refrigeration.
  4. ASHRAE 90A Energy Conservation in New Building Design.
  5. ASME SEC 8 Boiler and Pressure Vessel Code.
  6. NEMA MG 1 Motors and Generators.
  7. UL 465 Central Cooling Air Conditioners.

1.4SUBMITTALS FOR REVIEW

  1. Section 01300 Submittals: Procedures for submittals.
  2. Shop Drawings: Indicate components, assembly, dimensions, weights and loadings, required clearances, and location and size of field connections. Indicate valves, strainers, and thermostatic valves required for complete system.
  3. Product Data: Provide rated capacities, weights, specialties and accessories, electrical requirements and wiring diagrams.
  4. Operation and Maintenance data.

1.5SUBMITTALS FOR INFORMATION

  1. Section 01300 Submittals: Procedures for submittals.
  2. Submit manufacturer's installation instructions.
  3. Manufacturer's Certificate: Certify that components of package not furnished by manufacturer have been selected in accordance with manufacturer's requirements.

1.6SUBMITTALS AT PROJECT CLOSEOUT

  1. Operation and Maintenance Data: Include startup instructions, maintenance data, parts lists, controls, and accessories. Include troubleshooting guide.
  2. The Contractor shall submit all certifications and testing data as a supplement to previously submitted O & M manuals at contract closeout.

1.7QUALITY ASSURANCE

  1. Manufacturer Qualifications: Company specializing in manufacturing the Products specified in this section with minimum three years experience.

1.8REGULATORY REQUIREMENT

  1. Products Requiring Electrical Connection: Listed and classified by Underwriters Laboratories Inc. as suitable for the purpose specified and indicated.

1.9DELIVERY, STORAGE, AND PROTECTION

  1. Section 01600 Material and Equipment: Transport, handle, store, and protect products.
  2. Comply with manufacturer's installation instructions for rigging, unloading, and transporting units.
  3. Protect units from physical damage.

PART 2 - PRODUCTS

2.1INDOOR LIQUID CHILLER WITH REMOTE AIR COOLED CONDENSER

  1. Acceptable Manufacturers:

(1)Trane.

(2)Carrier

2.1.2.Efficiency

  1. EER shall not be less than 9.5

2.1.3.Manufactured Units:

  1. Provide factory assembled and tested indoor air cooled liquid chillers consisting of compressors, remote air cooled condenser, evaporator, thermal expansion valve, refrigeration piping and accessories, and control panel. Construction, testing, and ratings shall be in accordance with ARI 590.
  2. Conform to UL 465 code for construction of reciprocating water chillers and provide UL label.
  3. Conform to ASME SEC 8 Boiler and Pressure Vessel Code for construction and testing of reciprocating water chillers.
  4. Conform to ASHRAE 15 code for construction and operation of water chillers.

2.1.4.SemiHermetic Compressors:

  1. Reciprocating Compressors:

(1)Unit: Serviceable hermetic reciprocating motorcompressor with positive displacement oil pump lubrication system, spring loaded heads and replaceable cylinder liners, crankcase heater, suction inlet screen, discharge service valves. and control panel.

(2)Automatic Capacity Reduction Equipment: Suction valve unloaders with lifting mechanism solenoid operated. Provide for unloaded compressor start.

(3)Motor: Constant speed 1800 rpm, suction gas cooled with electronic overheating protection in each phase, reduced voltage starting.

(4)Crankcase Heater: Energize when compressor is not operating.

(5)Controls:

(a)Starter: Part winding, with manual reset current overload protection, starter relay, control power transformer, terminal strip for connection to interface equipment.

(b)Safety Controls: Manually reset, adjustable high and low pressure cutouts, low oil pressure cutout.

(c)Panel Face: Compressor run light, startstop switch, circuit breaker or disconnect switch, demand limit switch, elapsed time meter, crankcase heater startstop switch and light.

2.1.5.Evaporator:

***Designer shall provide space to rod or pull the tube handle.

  1. Provide shell and tube type evaporator, seamless or welded steel construction with removable cast iron or fabricated steel heads, seamless copper tubes or red brass tubes with integral fins, rolled or silver brazed into tube sheets. [Provide multiple refrigerant circuits on multiple compressor units.]
  2. Design, test, and stamp refrigerant side for 225 psig (1550 kPa) working pressure and water side for 150 psig (1034 kPa) working pressure, in accordance with ASME SEC 8.
  3. Insulate with 0.75 inch (20 mm) minimum thick flexible expanded polyvinyl chloride insulation with maximum K value of 0.28.
  4. Provide water drain connection and thermometer wells for temperature controller and low temperature cutout.

2.1.6.Remote Air Cooled Condensers:

***A/E Edit fin material – copper for coastal sites.

  1. Construct condenser coils of [copper] [aluminum] fins mechanically bonded to seamless copper tubing. Provide subcooling circuits with liquid accumulators. Air test under water to 425 psig (2900 kPa).
  2. Provide vertical discharge direct or belt driven propeller type condenser fans with fan guard on discharge. Provide factory mounted, louvered, galvanized steel coil guard panels.
  3. Provide fan motors with permanently lubricated ball bearings and builtin current and overload protection. Refer to Section 15170. Provide disconnect and starters in weatherproof panel.

2.1.7.Enclosures:

  1. House air cooled condenser components in welded steel frame with galvanized steel panels with weather resistant, baked enamel finish.
  2. Mount starters and disconnects in panel provided with full opening access doors. Provide mechanical interlock to disconnect power when door is opened.

2.1.8.Refrigerant Circuit:

  1. Provide refrigerant circuits, factory and field supplied and piped. Refer to Section 15535.
  2. Provide for each refrigerant circuit:

(1)Liquid line solenoid valve.

(2)Filter dryer (replaceable core type).

(3)Liquid line sight glass and moisture indicator.

(4)Thermal expansion valve sized for maximum operating pressure.

(5)Charging valve.

(6)Insulated suction line.

(7)Discharge line check valve.

(8)Compressor discharge service valve.

(9)Condenser pressure relief valve.

(10)Suction line accumulator.

2.1.9.Controls:

  1. On chiller, mount steel control panel, containing starters power and control wiring, molded case disconnect switch, factory wired with single point power connection.
  2. For each compressor, provide part winding starter, nonrecycling compressor overload, starter relay, and control power transformer or terminal for controls power. Provide manual reset current overload protection.
  3. Provide safety controls with indicating lights with terminations for connection to controls system arranged so any one will shut down machine and require manual reset:

(1)Low chilled water temperature switch.

(2)High discharge pressure switch for each compressor.

(3)Low suction pressure switch for each compressor.

(4)Oil pressure switch.

(5)Flow switch in chilled water line.

(6)Relay for remote mounted emergency shutdown switch.

(7)Phase loss, Phase reversal, low voltage and voltage spike protection, factory or field installed on three phase units. (SymCom Inc., Motor Saver).

  1. Provide operating controls:

(1)Multistep chilled water temperature controller which cycles compressors and activates cylinder unloaders.

(2)Five minute off timer prevents compressor from short cycling.

(3)Periodic pumpout timer to pump down on chilled water flow and high evaporator refrigerant pressure.

(4)Solenoid valve between heat recovery condenser and receiver to limit refrigerant level in condenser.

(5)Load limit thermostat to limit compressor loading on high return water temperature.

(6)Low ambient control consisting of external damper assembly, controls head pressure for operation down to 30 degrees F (-1 degrees C).

(7)Hot gas bypass sized for minimum compressor loading on one compressor only, bypasses hot refrigerant gas to evaporator.

  1. Provide prepiped gage board with pressure gages for suction and discharge refrigerant pressures, and oil pressures for each compressor.

2.2OUTDOOR AIRCOOLED PACKAGED LIQUID CHILLER

2.2.1.Acceptable Manufacturers:

  1. Trane.

2.2.2.Manufactured Units:

  1. Provide factory assembled and tested outdoor air cooled liquid chillers consisting of compressors, condenser, evaporator, thermal expansion valve, refrigeration accessories, and control panel. Construction, testing, and ratings shall be in accordance with ARI 590.
  2. Conform to UL 465 code for construction of reciprocating water chillers [and provide UL label].
  3. Conform to ASME SEC 8 Boiler and Pressure Vessel Code for Construction and testing of reciprocating water chillers.
  4. Conform to ASHRAE 15 code for construction and operation of water chillers.

2.2.3.Semi-Hermetic Compressors:

  1. Reciprocating Compressors:

(1)Unit: Serviceable hermetic reciprocating motor-compressor with positive displacement oil pump lubrication system, [spring loaded heads and replaceable cylinder liners,] crankcase heater, suction inlet screen, discharge service valves and control panel.

(2)Automatic Capacity Reduction Equipment: Suction valve unloaders with lifting mechanism [solenoid] [gas pressure] operated. Provide for unloaded compressor start.

(3)Motor: Constant speed 1800 rpm, suction gas cooled with electronic overheating protection in each phase, [full] [reduced] voltage starting.

(4)Crankcase Heater: Energize [continuously] [when compressor is not operating].

(5)Controls:

(a)Starter: [Full] [Part winding], with manual reset current overload protection, starter relay, control power transformer, terminal strip for connection to interface equipment.

(b)Safety Controls: Manually reset, adjustable high and low pressure cutouts, low oil pressure cutout.

(c)Panel Face: Compressor run light, start-stop switch, circuit breaker, demand limit switch, elapsed time meter, crankcase heater start-stop switch and light.

[OR]

  1. Screw Compressors:

(1)Unit: direct drive, semi-hermetic 3600 RPM, fixed compression, rotary screw compressor with control panel.

(2)Features: Differential refrigerant pressure oil pump, oil heater, oil separator and filter, oil charging valve.

(3)Motor: Suction gas cooled hermetically sealed, squirrel cage induction.

(4)Controls:

(a)Non-Fused molded case disconnect switch.

Single point power connection and grounding lug.

Anti-Recycle timer.

Solid state overload relay for each compressor.

Phase loss/reversal monitor.

Cycle counter and hour meter per compressor.

Low and high pressure control.

Automatic shutdown compressor overload and low and high refrigerant pressure.

(b)Automatic Capacity Reduction: Continuously variable slide valve with infinitely variable control to 25 percent of full load.

2.2.4.Evaporator:

  1. Provide shell and tube type evaporator, seamless or welded steel construction with cast iron or fabricated steel heads, seamless copper tubes or red brass tubes with integral fins, rolled or silver brazed into tube sheets. [Provide multiple refrigerant circuits on multiple compressor units.}
  2. Design, test, and stamp refrigerant side for 225 psig (1550 kPa) working pressure and water side for 150 psig (1034 kPa) working pressure, in accordance with ASME SEC 8.
  3. Insulate with [0.75 inch (20 mm)] [1.5 inch (40 mm)] minimum thick flexible [expanded polyvinyl chloride] [polyurethane foam] insulation with maximum K value of [0.28.] [0.26.] [0.15.] Provide heat tape to protect evaporator to [-20 degrees F (-29 degrees C).] [ ] degrees F ([ ] – 29 degrees C).]
  4. Provide water drain connection and thermometer wells for temperature controller and low temperature cutout.

2.2.5.Condensers:

  1. Construct condenser coils of aluminum fins mechanically bonded to seamless copper tubing. Provide sub-cooling circuits with liquid accumulators. Air test under water to 425 psig (2900 kPs).
  2. Provide vertical discharge [direct] [belt] driven propeller type condenser fans with fan guard on discharge. [Equip with roller or ball bearings with grease fittings extended to outside of casing.] Provide factory mounted louvered, galvanized steel coil guard panels [with lint screens].
  3. Provide fan motors with permanently lubricated ball bearings and built-in current and overload protection. Refer to Section 15170.

2.2.6.Enclosures:

  1. House components in [welded steel frame with] galvanized steel panels with weather resistant, baked enamel finish.
  2. Mount starters and disconnects in [NEMA ICS 6] weather proof panel provided with full opening access doors. Provide mechanical interlock to disconnect power when door is opened.

2.2.7.Refrigerant Circuit:

  1. Provide refrigerant circuits, factory supplied and piped. Refer to Section 15535.
  2. Provide for each refrigerant circuit:

(1)Liquid line solenoid valve.

(2)Filter dryer (replaceable core type).

(3)Liquid line sight glass and moisture indicator.

(4)Thermal expansion valve sized for maximum operating pressure.

(5)Charging valve.

(6)Insulated suction line.

(7)Discharge line check valve.

(8)Compressor discharge service valve.

(9)Condenser pressure relief valve.

(10)Suction line accumulator.

2.2.8.Controls:

  1. On chiller mount [NEMA ICS 6] weather proof steel control panel, containing starters power and control wiring, [molded case disconnect switch,] factory wired with single point power connection.
  2. For each compressor, provide [across-the-line] [part winding] starter, non-recycling compressor overload, starter relay, and control power transformer or terminal for controls power. Provide manual reset current overload protection.
  3. Provide safety controls [with indicating lights] [with terminations for connection to controls system (refer to Section 15980),] arranged so any one will shut down machine and require manual reset:

(1)Low chilled water temperature switch.

(2)High discharge pressure switch [for each compressor].

(3)Low suction pressure switch [for each compressor].

(4)Oil pressure switch.

(5)Flow switch in chilled water line.

(6)Relay for remote mounted emergency shut-down switch.

  1. Provide operating controls:

(1)Multi-step chilled water temperature controller which cycles compressors [and activates cylinder unloaders].

(2)Load limit thermostat to limit compressor loading on high return water temperature.

(3)Low ambient control consisting of external damper assembly, controls head pressure for operation down to [0] [ ] degrees F ([-18] [ ] degrees C).

(4)Hot gas bypass sized for minimum compressor loading [on one compressor only], bypasses hot refrigerant gas to evaporator.

  1. Provide pre-piped gauge board with pressure gauges for suction and discharge refrigerant pressures, and oil pressures [for each compressor].
  2. For multiple units, provide remote mounted sequence panel to allow operation in [series] [parallel] with lead-lag switching.

PART 3 - EXECUTION

3.1INSTALLATION

  1. Install in accordance with manufacturer's instructions.
  2. Align chiller package on concrete foundations.
  3. Install units on vibration isolation. Refer to Section 15245.
  4. Complete Refrigerant Piping from chiller to remote air cooled condenser. Pipe pressure relief device full size to out of doors.
  5. Connect to chilled water piping. Refer to Section 15510.

(1)On outlet, provide:

(a)Thermometer well for temperature controller.

(b)Thermometer well for temperature limit controller.

(c)Flexible pipe connecter.

(d)Shutoff valve.

(e)Temperature and Pressure Station.

(2)On inlet, provide:

(a)Flexible pipe connecter.

(b)Balancing valve.

(c)Temperature and Pressure Station.

  1. Arrange piping for easy dismantling to permit tube cleaning.
  2. Securely fasten units to housekeeping pads on roof mounting rails to withstand wind and seismic loading specified in Section 01000.

3.2MANUFACTURER'S FIELD SERVICES