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Chrysler LLC - ME Building Group Construction StandardsProject & Bid Package Reviewed : Oct. 2010

SECTION 15681 – AIR COOLED ROTARY-SCREW CHILLERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. The requirements of the General Conditions, Supplementary Conditions, Division 1, and Drawings apply to all work herein.

1.2 SUMMARY OF WORK

A. Provide Microprocessor controlled, twin-screw compressor, air-cooled, liquid chillers of the scheduled capacities as shown and indicated in this specification section, including but not limited to:

1. Chiller package2. Master Control System3. PC and software for monitoring and control4. Charge of refrigerant and oil5. Electrical power and control connections6. Chilled water connections7. Factory start-up

B. Factory Test: Chiller shall be pressure-tested, evacuated and fully charged with refrigerant and oil, and shall be factory operational run tested with water flowing through the vessel.

C. Chiller manufacturer shall have a factory trained and supported service organization that is within a 50 mile radius of the site.

1.3 PROJECT MILESTONE DATES

A. Milestone date is as follows:

Deliver all Chillers no later than December 14, 2007.

1.4 GENERAL NOTES

A. All work shall conform to applicable federal, state and local codes and regulations.

B. All work shall conform to all applicable DaimlerChrysler Corporation requirements. It is understood and agreed that this Supplier is familiar with all applicable DaimlerChrysler Corporation requirements.

C. Submit shop drawings showing in sufficient details all items pertaining to this Work to the Owner and obtain said approval prior to fabrication. See paragraph 1.6.

D. Whenever in the following specifications an article, material, or equipment is defined by describing a proprietary product or the use of the manufacturer or vendor, it shall be the basis of bid. Any offered equal must have Owner approval prior to submission of bid.

AIR COOLED CHILLERS 15681 - 1 of 18


1.5 ELECTRICAL

A. Unit manufacturer shall provide a control panel containing unit package power wiring, main disconnect switch, motor starters, main drive motor including terminal boxes, oil pump separator, oil pump, oil heater, control devices and auxiliaries, together with over-current protective devices, control transformers and control wiring system.

B. Wiring for external connections shall be brought to readily accessible terminal strips for connection thereto.

C. Electrical work excluded.1. Motor control centers for chillers,.2. Power wiring to chiller package will be furnished and

installed by the installation Contractor.3. Interlock and interface wiring from the chiller master

system control panel to the chiller unit microprocess control panels, to energy center PC, and to the motor control center will be furnished and installed by the installation Contractor. Design of all power and control wiring 480 V, 115 V, etc., however is the responsibility of the chiller manufacturer.

1.6 QUALITY ASSURANCE

A. ARI Compliance: Rate chiller according to ARI 550.

B. ASHRAE Compliance: Conform to ASHRAE 15 for chiller design, construction, leak testing, and installation.

C. ASME Compliance: Comply with ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, for construction and testing of evaporator pressure vessel. Label evaporator with ASME mark.

D. NEC Compliance: Comply with applicable NEC requirements for electrical power and control wiring.

E. UL Listing label.

F. Factory Test: Chiller shall be pressure-tested, evacuated and fully charged with refrigerant and oil, and shall be factory operational run tested with water flowing through the vessel.

G. Provide sound data for refrigerant compressors measured in accordance with ARI 530 and DaimlerChrysler Sound Level Specification.

1.7 DELIVERY AND HANDLING

A. Unit shall be delivered to job site fully assembled and charged with refrigerant and oil by the Manufacturer. If not practical, minimize shipping split and field connections all fluids shall be factory charged. NOTIFY OWNER OF SHIPPING REQUIREMENTS AT TIME OF BID.

B. During shipment, provide protective covering over vulnerable components. Fit nozzles and open ends with plastic enclosures.

C. Protect the chiller and its accessories from the weather and dirt exposure during shipment.



D. Provide services of local manufacturer’s representative for supervision of rigging, unloading and setting of units.

E. For Mexico, units are shipped free of refrigerant and oils; refrigerant and oils are to supplied separately.

1.8 SUBMITTALS

A. Product data for each chiller, including the following1. Chiller refrigerant and quantity.2. Chiller capacity at design conditions.3. Condenser pressure drop.4. Cooler pressure drop.5. Furnished accessories.6. Installation and start-up instructions.7. Chiller APLV in accordance with ARI rating procedures.8. Chiller power consumption per ton at design conditions.9. Part load performance data.

B. Shop drawings detailing fabrication and installation of chiller, including plans, elevations, sections, component details, attachments, and other construction elements including dimensions, weight loadings and distribution, maintenance and operational clearances, field connections, structural supports, lockout tagging, and field mounted device tagging.

C. Chiller performance ratings conforming to and reported in accordance with ARI-550/590 and to include capacity (tons), energy efficiency (kW/ton), water pressure drop (ft of water), Integrated Part Load Value (IPLV) efficiency or Non-Standard Part Load Value (NPLV).

D. Include additional power or water sources for auxiliaries (water for oil coolers, etc.) and the effect of compressor motor heat losses to the refrigerant stream in all rating calculations.

E. NPLV calculated to ARI Standard 550/590 equation.

F. Statement of Compliance with ASHRAE 90.1.

G. Sound power and pressure level ratings expected from measurements performed in accordance with ARI-370 and DaimlerChrysler Sound Level Specification. Include estimates for each octave band at each of the four standard ARI points.

H. Unit Drawing: Indicate overall unit dimensions, key component locations and dimensions, required clearances and field connection details for piping and electrical wiring and unit access.

I. Floor layout drawing: Indicate centerlines; Indicate locations and dimensions of chiller points of contact with the floor.

J. Other Diagrams: Thermal insulation requirements diagram and vibration isolator diagrams.

K. Weights: Shipping weight loadings and distribution, operating weight, weight of each major component, weight load at each vibration isolator.

L. Capacities and Charges: Refrigerant and Oil.

M. Electrical and Control Wiring Drawings1. General Requirements: A complete set of control wiring drawings and physical

layout of the multi-chiller system (P & ID drawing) and associated control and



sensing devices (temperature, pressure, flow sensors, end switches, etc. on the chiller unit and/or in the field piping) shall be submitted to the Owner and engineer prior to start of fabrication. Drawings shall include:

a. Schematic and interconnection diagrams shall have each point numbered including the schematic of the starter and annunciator panel and internal wiring of relays. Wire sizes to be indicated.

b. Bill of material showing the manufacturer, rating, catalog number and identification symbol of each component, including relays, meters, fuses, timers, contactors, resistors, capacitors, control and sensing devices, etc. Supplier to include in the bill of materials whether the control and sensing devices are "furnished and installed", or "furnished by chiller manufacturer and installed by others", or "furnished by others and installed by others".

c. A complete sequence of operation.d. Electrical and control drawings are to be presented in ladder logic format to JIC

and DaimlerChrysler standards.e. Drawings are to be done with a DaimlerChrysler approved title block and

numbering sequence.f. Electrical and control drawings shall incorporate all aspects of the chiller plant

including the chiller, all field devices (pressure temperature and flow transmitters, etc.), pumps, starters plus monitoring of certain aspects of the system including interface to the PC workstation.

g. Electrical and control drawings shall include power wiring, 480 Volts, and control wiring 115, and 24 Volt etc., AC and DC.

2. Drawings Required:a. Chiller unit electrical and control drawings.b. Master control panel, field wiring, and starter drawings.c. Low voltage 480 volt starter drawings.d. Electrical/control riser diagrams.e. Sequence of operation.f. Input/output list and addresses.

N. Software: Manufacturer shall provide the following software packages:1. System Graphics2. System Graphics - PC 3. Program for Intellution PC

O. Certification of performance from the factory.

P. Certification letter from manufacturer stating that the chiller has been through start-up procedures and that it is functioning properly.

Q. Material Safety Data Sheet (MSDS) for any refrigerants used that is NOT classified as ‘A1’ for flammability and toxicity by ASHRAE 34. MSDS for Mexico shall be in Spanish.

R. Manufacturer’s warranty certificate.

1.9 OPERATION AND MAINTENANCE MANUALS

A. 90 days prior to start-up of equipment, submit to the Owner with 10 copies of operating and maintenance instruction manuals bound in durable stiff covers.

B. Instruction manuals shall contain the following:1. Index on book form of component and diagram data

sheets.2. Description and assembly drawings of each item of

equipment.



3. Parts nomenclature.4. Wiring and piping drawings.5. Procedures for start-up and operation of unit.6. Instructions for disassembly and reassembly of all items of

equipment furnished, as required for normal operation and maintenance.

7. Sequence of operation for the equipment.8. Normal set points and limits for controls.9. Final settings and adjustments established for start-up

tests.10. Preventative maintenance schedule and checklist including

daily, weekly, monthly, and annual schedules.11. Operating checklists.12. Spare parts list.13. Special tools list.

C. In addition to the folded insert drawings, (11 inches by 17 inches) and data sheets incorporated in each copy of the manual, large diagrams and schematics shall be furnished in as-built condition on mylar reproducible sheets and electronically on disc.

D. Provide software and related back-up diskettes for control systems.

1.10 SPARE PARTS LISTS

A. Supplier shall submit a list of parts recommended to maintain units in full operation under normal operating conditions, including long lead time items in excess of 1 week delivery such as vacuum contractors, spare motors and spare compressors. List should include expected life and recommended replacement schedule for furnished equipment. Selection shall take into account vulnerability to normal wear, availability and expected shelf life. Supplier shall also advise special devices and tools required for maintenance and calibration of all equipment furnished. Lists shall indicate current total prices of recommended and optional parts and materials.

1.11 REFRIGERANT AND LUBRICATING OIL CHARGE

A. Refrigerant and lubricating oils needed to satisfy the initial start-up and testing needs of the equipment shall be provided.

1.12 WARRANTY

A. Warranty: Manufacturer shall Warrant in writing and signed all equipment and material of its manufacture against defects in workmanship and material for a period of twenty-four (24) months (August 1,2010) from date of start up or substantial completion, whichever occurs later.

B. Perform warranty work with manufacturer’s factory-trained and factory-employed service technicians.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide chillers by one of the following:1. Trane Company (The)2. United Technologies Corp.; Carrier Corporation Subsidiary3. York International Corporation



4. McQuay5. Thermal Care

2.2 MANUFACTURED UNIT

A. Description: a packaged factory assembled, charged and operational tested air-cooled screw chillers as specified herein. Chiller shall include, but is not limited to: a complete system with multiple independent refrigerant circuits, semi-hermetic twin screw compressors, shell and tube type evaporator, air-cooled condenser, R134a refrigerant, lubrication system, interconnecting wiring, safety and operating microprocessor controls including capacity controller, control center, motor starting components, and special features as specified herein or required for safe, automatic operation.

B. Operating Characteristics: 1. Provide low ambient control and high ambient options as

required to ensure unit is capable of operation from 0F to 125F (-18C to 52C) ambient.

2. Provide capacity control system capable of reducing unit capacity to 10% of full load. Compressor shall start in unloaded condition. Application of factory installed hot gas bypass shall be acceptable as required to meet specified minimum load.

3. Sound pressure level, resulting from centrifugal refrigeration machine operation, shall not exceed 80 dBA. When measured in accordance with ARI Standard 575 and the National Machine Tool Builders Association (NMTBA) Noise Measurement Techniques latest edition. Data shall comply with the requirements of DaimlerChrysler’s sound level specification for industrial machinery and equipment.

4. Bids shall clearly state exceptions regarding the ability of the proposed vendor in complying with this requirement.

5. If Bidders cannot meet the specified noise level and the manufacturer of the proposed equipment is capable of demonstrating that engineering solutions have been fully explored without positive results, the bidder shall furnish with the bid, the minimum sound level that can be achieved (not to exceed 85 dBA), manufacturer's complete octave-band analysis, together with his identification of probable noise sources. Data shall include readings at each test point from each load condition in sufficient detail to permit calculation of associated noise exposure. Furnish manufacturer's information as to nature, construction type, and expected noise reduction for corrective schemes such as enclosures and include cost of such corrective schemes in bid.

6. Compressor and compressor inlet and discharging piping shall have sound blanketing as required to meet the specified criteria.



7. Pressure Limiting and Relief Devices: Manufacturer's standard complying with ASHRAE 15, including rupture disc. Provide refrigerant charging and transfer connections, pressure relief device (per BSR/ASHRAE 15 safety code) on the evaporator to prevent over-pressurization of the refrigerant, and to sense refrigerant pressure or temperature. System shall incorporate as a minimum the following indicating, warning and shut-down protective devices and shall include wiring:

Sensor Warning Shutdown

Oil pressure X X

High lube oil temperature X X

Low lube oil temperature X X

High condenser head pressure X X

High evaporator head pressure X X

Low evaporator temperature X X

Vibration X X

High electrical motor current X -

Hours run totalizing meter - -

Compressor bearing temperature sensor X X

Surge X X

Compressor contactor failure X X

C. Refrigerant Flow Control Devices: Provide refrigerant flow control devices between evaporator and condenser (and as required elsewhere) to regulate refrigerant flow at volume and pressure required to maintain evaporator liquid refrigerant at level sufficient to keep cooler tubes adequately wetted through full range of chiller operation.

D. Cabinet: Unit panels, structural elements, control boxes and heavy gauge structural base shall be constructed of galvanized steel. Unit panels, control boxes and structural base are finished with a baked on powder paint. All painted surfaces shall be coated with baked on powder paint which, when subject to ASTMB117, 1,000 hour, 5% salt spray test, yields minimum ASTM 1654 rating of “6”.

E. Unit shall ship in one piece and shall require installer to provide only a single evaporator inlet and outlet pipe connection. Chiller model that ships in multiple pieces shall NOT be acceptable. Trim kits and multiple evaporator inlet and outlet pipe connections shall NOT be acceptable to meet the single piece shipment requirement of this specification.

2.3 COMPRESSORS AND MOTORS

A. Compressors: Shall be direct drive, semi-hermetic, rotary twin-screw type, including: muffler, temperature actuated ‘off-cycle’ heater, rain-tight terminal box, internal discharge check, discharge and suction shut-off service valve, and precision machined cast iron housing. Design working pressure of entire compressor, suction to discharge, shall be 450 PSIG (31 bar). Compressor shall be U.L. recognized.

B. Motors: Refrigerant suction gas cooled accessible hermetic compressor motor, full suction gas flow through 0.006” maximum mesh screen, with inherent internal thermal overload protection and



external current overload on all three phases. Power factor 0.95 minimum at all load points. Provide power factor capacitors.

C. Lubrication: External oil separators with no moving parts, 450 PSIG design working pressure, and UL listing. Refrigerant system differential pressure shall provide oil flow through service replaceable, 0.5 micron, full flow cartridge type oil filter internal to compressor. Filter bypass, less restrictive media, or oil pump not acceptable.

D. Capacity Control: Compressors shall start at minimum load. Capacity control range from 100% to 10% of chiller full load. Provide Microprocessor control to command compressor capacity to balance compressor capacity with cooling load. When required to meet minimum load, hot gas bypass shall be factory installed and integrated into standard control system.

2.4 REFRIGERANT CIRCUIT COMPONENTS

A. Each independent refrigerant circuit shall include: liquid line shutoff valve with charging port, low side pressure relief device, removable core filter-drier, sight glass with moisture indicator, and electronic expansion valve.

B. Chiller manufacturer shall provide independent circuit for each compressor to provide maximum redundancy.

C. Refrigerant: Chiller shall be delivered with a nitrogen charge. Any leaks identified shall be repaired prior to refrigerant charge. Non-Ozone Depleting, such as HFC-134a full operating charge of refrigerant and oil shall be furnished with each chiller. Charging of chillers by the chiller manufacturer, including handling of refrigerant containers.

2.5 HEAT EXCHANGERS

A. Evaporator: 1. Shell and tube type; refrigerant in shell; water in tubes.

Carbon steel plate shell with individually replaceable seamless externally finned high efficiency copper tubes expanded into tube sheets. Carbon steel water boxes, removable.

2. Constructed, tested, and stamped in accordance with applicable sections of ASME pressure vessel code. Refrigerant side working pressure 350 psig. Water side working pressure 150 psig.

3. Provide vent and drain fittings, and thermostatically controlled heaters to protect to -20F ambient in off-cycle.

4. Mist Eliminators: Metal screen-mesh eliminators to prevent carryover into the compressor.

B. Insulation: Factory-insulate cooler, suction lines, and other surfaces where condensation might occur with flexible elastomeric insulation of the following thickness:

1. Thickness: 3/4 inch, conductivity not exceeding 0.28 BTU-inch/hour-foot-deg F and shall conform to UL Standard 94, Classification 94HBF.

2. Performance: Insulation shall prevent condensate drip to floor in all weather conditions from all chiller surfaces.

C. Mist Eliminators: Metal screen-mesh eliminators to prevent carryover into the compressor.

D. Air Cooled Condenser:



1. Factory assembled wired and tested consisting of casing, air cooled condenser coils, fans and controls integrated with compressor operation.

2. Casing, weatherproof constructed of hot-dipped galvanized steel with factory applied finish.

3. Coil, internally enhanced seamless copper tubes with mechanically banded aluminum alloy fins with full height collars. Sub-cooling coil shall be an integral part of condenser. Design working pressure shall be 450 psig.

4. Fan discharge arrangement: vertical.5. Low sound fans; shall be dynamically and statically

balanced, direct drive, corrosion resistant glass fiber reinforced composite blades molded into low noise full airfoil cross section, providing vertical air discharge from extended orifices. Guards of heavy gauge, PVC coated or galvanized steel.

6. Fan motors: High efficiency direct drive 3 phase totally enclosed air-over (TEAO) weatherproof with permanently lubricated ball bearings, class “F” insulation, current protected. Power factor: 0.95 minimum.

2.6 POWER AND ELECTRICAL REQUIREMENTS

A. Power/Control Panel:1. NEMA (IP65), powder painted steel cabinets with hinged,

latched, and gasket sealed outer doors equipped with wind struts for safer servicing. Provide main power connections(s), compressor starters and fan motor contactors, current overloads, and factory wiring.

2. Panel shall include control display access door.

B. Single Point Power:1. Provide single point power connection to chiller, shall be 3

phase of scheduled voltage, with independent system compressor switches.

2. Circuit breaker shall be provided at point of incoming single point connection to provide disconnecting means AND be sized to provide the motor branch circuit protection, short circuit protection and ground fault protection for the motor branch-circuit conductors, the motor control apparatus and the motors. Circuit breaker shall be equipped with lockable operating handle that shall extend through power panel door so that power may be disconnected without opening any panel doors.

C. Control Transformer: Power panel shall be supplied with a factory mounted and wired control transformer that will supply all unit control voltage from the main unit power supply. Transformer shall utilize scheduled line voltage on the primary side and provide 115V/1PH on secondary.

D. Short Circuit Withstand Rating of the chiller electrical enclosure shall be 460V: 65,000 Amps Rating shall be in accordance with UL508.

E. Motor:1. Motor shall be hermetically sealed, refrigerant cooled

continuous duty, constant speed 480 volt, 3 phase, 60 Hz, squirrel cage, induction type or open drive (ODP). Full load



operation of the motor shall not exceed nameplate rating. First critical speed shall be well above the operations speed. Provide for removal of the motor or starter without breaking the main refrigerant piping connections. Motor shall have a 1.5 service factor.

a. Voluntary Alternate: Provide variable speed in lieu of continuous speed.2. A permanently attached stainless steel nameplate shall be

provided stating the motor horsepower, speed, voltage and current phase, NEMA torque design, temperature ratings, full load and locked rotor amps, together with a metal direction arrow to indicate proper direction of rotation, when applicable.

3. Chiller electric drive motor includes the following:a. Terminal box-run motor leads into a large NEMA-12, JIC terminal box having a

gasketed cover, brass or stainless steel fastening hardware and mounted at the refrigeration machine. Oversize the terminal box to accommodate the following accessories to be furnished and mounted by the motor manufacturer and to permit easy training and termination of the motor leads.

b. Ensure quick disconnect for testings. Provide provisions for meggering motor easily.

c. Ground bus.d. Current transformer(s) for the compressor manufacturer's load control scheme

with the secondary leads connected to suitable terminal strips. Provide a minimum of three (3) current transformers for differential protection to be connected with CTs at starter and to differential relay.

e. 6 leads in motor terminal box for CTs.f. Provisions for connection of the 480 volt service.

4. Insulate motor leads for the voltage class utilized and maintain proper air clearances between phase conductors, phase to neutral conductors, phase to ground, and neutral conductors to ground. Provide double indent type lugs, design terminal box for top, entry of cable.

5. Compressor Motor Variable Speed Drive - Alternate:a. Provide variable speed drive factory installed to automatically adjust compressor

motor speed in conjunction with compressor vane position to maximize part load efficiency. Include disconnect or circuit breaker, with an electronic protection system to monitor and protect against three-phase overload, phase unbalance, and over and under voltage.

b. Power supply shall be 480 volt.c. Drive shall be PWM type, utilizing IGBT's with a power factor of 0.96 or better at

all loads and speeds. Drive efficiency shall be 97 percent or better at full load and full speed.

d. Variable speed drive shall be unit mounted.e. Variable speed drive shall include the following features:

1) A minimum 3 KVA control transformer with 115V secondary.2) Door interlocked circuit breaker capable of being padlocked; UL listed

ground fault protection; over voltage and under voltage protection; 3-phase sensing motor over current protection; single phase protection; insensitive to phase rotation; over temperature protection.

3) Digital readout at the chiller unit control panel of output frequency, input voltage, 3-phase output current, input kilowatts, self-diagnostic service parameters. Separate meters for this information will not be acceptable.

4) KW Meter: Unit's input power consumption shall be measured and displayed digitally via the unit's control panel. The KW meter accuracy shall be ± 3 percent of reading.



5) Ammeter: Simultaneous three-phase true RMS digital readout via the unit control panel. Three current transformers shall provide isolated sensing. Ammeter accuracy shall be ± 3 percent of reading.

6) Voltmeter: Simultaneous three-phase true RMS digital readout via the unit control panel. The voltmeter accuracy shall be ± 3 percent of reading.

7) Elapsed Time Meter: Digital readout of the unit's elapsed running time (0 - 876,600 hours, resetable) shall be displayed via the unit control panel.

f. A harmonic filter, power conditioner or "LRC's with filter" shall be provided to limit current distortion to be in no case more than five percent (5 percent) as measured at the variable speed controller electrical power connection lugs. Line reactors will not be acceptable. Harmonic filter, power conditioner or "LRC's with filter" shall be unit mounted within the same NEMA 1 variable speed drive enclosure and shall be UL listed. The following digital readouts shall be provided at the chiller unit control panel as part of the harmonic filter, power conditioner or "LRC filter" package; input KVA, total power factor, 3 phase input voltage, 3 phase input current, 3 phase input voltage total harmonic distortion (THD), 3 phase current total demand distortion (TDD), self diagnostic service parameters. Separate meters for this information will not be acceptable. Filter shall be factory mounted on the chiller. Manufacturer shall provide wiring and conduit between filter, motor and variable speed drive. Installing contractor provides single point power feed.

F. Supports and Vibration Isolator Base: Machine shall be provided with integral steel supports and anchor bolts, complete with ribbed 1/4 inch thick neoprene vibration isolator pads, sandwiched between 2 steel plates and sized for a surface loading of from 40 to 50 pounds per square inch. Jack screws and leveling pads shall be provided.

G. Power Factor: 1. Provide equipment with a power factor of 95%.2. Power factor shall be same at full load and throughout part

load operation. Designs that produce a power factor that reduces during part load operation will not be acceptable.

3. Externally mounted power factor correction capacitors will not be acceptable.

H. Motor starters: Motor starters shall be inrush type (Wye-Delta or Solid State) for minimum electrical inrush. Across the line type starters will not be acceptable.

I. Exposed compressor and fan motor power wiring shall be routed through liquid tight conduit.

2.7 CONTROL SYSTEM

A. Master Control System:1. General: Chiller manufacturer shall provide a master

control panel and overall system control design to monitor and control the following:

a. Chiller System1) Chillers2) Variable speed primary water pumps

b. Other Systems: Chiller manufacturer’s master control panel shall also transmit operating conditions, set points and alarms for monitoring and display at the remote PC station.

c. Motor Control Center:1) Chiller manufacturer’s master control panel shall also control and monitor

the chilled water system pumps, through the master control panel.2) Monitored points shall be transmitted through to the remote PC station.3) The following points shall be monitored on each starter:



a) Currentb) Field device open (field and MCC disconnect)c) Overload trippedd) Motor run mode - both high and low speed on tower fanse) VFD fault - on VFD drivers (chilled water pumps)

2. System Integration - Electrical controls Contractor shall:a. Incorporate chiller manufacturers chiller unit controls into the overall system design

and present in a format acceptable to DaimlerChrysler (JIC/ladder logic).b. Design power wiring (480 V) through to and including motor starters.c. Design control wiring (115 V, 24 V, etc.) digital and analog as described herein

including the master system control panel and field wiring.d. Fabricate the master control panel.e. Provide field mounted sensors (pressure, temperature, and flow) and transmitters

as indicated on the system P&IDs.f. Design 480 V starter controls for pumps MCC. MCC shall be provided by the

installing contractor.g. Design PC monitoring system and interconnection, with full trending capability.h. Provide software and programming.i. Integrate PC software in conjunction with chiller manufacturer.j. Integrate systems design into a single design drawing package.

3. General:a. Furnish and install a unit mounted automatic operating and automatic warning,

protective and continuous monitoring system enclosed in a NEMA 12 panel for each chiller. Unit control panel shall be mounted at eye level on the machine. System shall be micro-computer based on real time, multi-variable, multi-level function unit, designed for operation as a stand-alone processor capable of implementing the control sequences, communications network, alarm and monitoring functions listed. Unit shall contain not less than 2 kilobytes of 16 bit words on Random Access Memory with the addition of 2 kilobytes of on-board EPROM. A battery back-up shall be provided capable of retaining the on-board memory for up to 1 year. Unit shall have the capacity to handle not less than 12 discrete digital inputs, 6 discrete digital outputs, 32 analog inputs. (4 to 20 mA 2-wire type), and 2 analog outputs (4 to 20 mA). System shall incorporate a communication port for interfacing to the master control panel and the PC operator workstation..

b. Voluntary Alternate: Chiller controls shall automatically adjust variable speed drive (and motor speed)

4. Operational Functions and Displays:a. Microprocessor shall have operational function keys with integral LCD program

display memory and alpha-numeric display. Descriptions in English numeric data in English units for Trenton, USA units; and metric and Spanish for Mexico units. System shall provide for time, lube oil function, and motor power functions with capacity to scan, set operating mode, reset, calibrate and monitor all functions, including provision of alarm and control outputs. Temperature sensors shall be 100 OHM RTDs. Pressure sensors shall be strain gauge type with 4 to 20 mA output signal.

b. Chiller unit microprocessor control panel shall incorporate as a minimum the following operational devices, functions, and display and set-up capabilities.1) Local/manual/auto start/stop.2) Remote stop and remote alarm annunciation.3) Solid state malfunction trip contacts.4) Solid state latch seal in contacts.5) Auxiliary trip contacts.6) Run hour meter.7) Unload/modulate control mode.8) Chilled water temperature reset.



9) Motor current transducer.10) Pressure level - oil supply.11) Pressure level - evaporator refrigerant.12) Pressure level - condenser refrigerant.13) Temperature indicating - entering chilled water.14) Temperature indication - leaving chilled water.15) Temperature indicating - evaporator refrigerant.16) Temperature indicating - condenser refrigerant.17) Running - normal operation.18) Oil pump control - auto/on.19) Provide NEMA-1 type pushbuttons.20) Date and time of day.21) Chiller operating hours.22) Oil differential pressure.23) Oil sump temperature.24) Percentage of motor full load amps (FLA).25) Evaporator pressure.26) Condenser pressure.27) Bearing oil supply temperature.28) Compressor bearing temperature.29) Quantity of compressor starts.30) Control point setting (high, low, present).31) Discrete output status of devices.32) Schedule function:

a) Start-up and shutdown shall be manual or automatic.b) Chiller can be started and stopped remotely by the chilled water

system master system control panel.33) Demand limit set-point.34) Alarm history file containing up to 25 alarm/alert messages with time and

date stamp.35) Capacity control - load modulation shall be from 10 percent to 100 percent

of full load without hot gas bypass. Guide vanes shall be precisely positioned by the P.I.D. (proportional, integral and derivative) control algorithm to ensure precise control (± 0.5 deg F or 0.3 deg C) of desired chilled water temperature.

36) Microprocessor shall be capable of accepting remote maximum load set point from the master system control panel.

37) Accept start/stop command from the master system control panel.38) Motor winding temperatures39) Sensor faults40) Evaporator freeze protection and low limit control. Design this control to be

used to avoid low evaporator refrigerant temperature trip-outs during critical periods of chiller operation.

5. Master System Control Panel:a. Control Panel Components: Master system control panel shall be provided for

overall system control and monitoring. Panel shall contain the following:1) Control panel shall house associated equipment (I/O modules, analog

modules, control relays, main disconnect, operator interface screen, terminal strips, fuses, pilot lights, pushbuttons, alarm horn and rotating beacon, etc.).

2) Control panel shall house required controls necessary for a safe and completely functional chilled water system.

3) Sufficient space to accommodate controls for three chillers (2 plus 1 spare chiller) and their auxiliary equipment (pumps, fans, sensors, etc.) including program memory, shall be furnished.

4) Safeties for shutdown shall be hard wired.



5) Manufacturer shall provide a network drawing showing components and location. Manufacturer shall provide software for a functional system.

6) Control panel shall include a modem for remote monitoring and trouble-shooting by the manufacturer.

b. Control functions shall include:1) Sequence control of each chiller based on flow demand and chilled water

temperatures.2) Chiller lead/lag designation and automatic start of standby unit upon failure

or trouble of operating unit; or when system process cooling demand exceeds the design rating of a single chiller.

3) Primary chilled water pump variable frequency drive control.4) System pressure, temperature and flow monitoring.5) Interface with chiller microprocessor control panels to accept chiller

parameters (temperature, pressure, flow, status, alarms, etc.).6) Sequence automatic valves.7) Provide common current load reset for chillers.8) Automatic/manual operation.9) Lead/lag selection and sequencing to equalize equipment wear.10) Select and adjust assignment of individual primary pumps to each chiller.

c. Operator Interface1) Master control panel shall incorporate an operator interface. Operator

interfaces are to be capable of independently invoking password protection of the entire display and keypad, operator settings (e.g. chilled water set point, machine configuration settings, and service start-up settings).

2) This operator interface shall include graphics for control and monitoring of:a) Chilled water system.b) Primary chilled water pumps.

3) At least one page of graphics shall be devoted to each of the above.4) Graphics shall illustrate:

a) Ready/start/run/stop/fault status of chillers.b) Run/stop status of pumps. MCCs will have off/hand/auto selection

for each starter with auxiliary contacts for status indication back to the master system control panel.

c) Temperature, pressure, flow and level indication for system parameters.

d) Alarm display e.g. chiller fault, system chilled water temperature low and high.

e) Valve status with limit switch verification for actuated valves.f) Control, monitoring and alarm of any other system parameters

required to provide reliable, efficient and safe chilled water plant operation.

g) Individual chiller operating parameters must also be displayed at this panel.

d. Manual Control1) Each automatic valve shall have manual selector switch control to permit

system operation without the system controller and/or PC interface. Valve open and close position shall be indicated on the PC display. A single open/close/auto selector switch shall be provided for each valves function control. Trenton chillers shall automatically reset to normal chiller operation after power failure. Mexico is to have manual resets.

2) Panel is to have sufficient space for manual control of future chillers valves.3) Chillers must be capable of running in manual and independently on their

unit microprocessor control panels only.e. Automatic Control

1) Master system control panel will provide fully automatic control with systems being automatically started and stopped by program logic after the master start button is depressed and until a master stop button is depressed.



2) Filter gallery heat exchanger control will be through two-way valves (by others) in which case flow rate to the system loads will vary. Remote differential pressure sensor will be provided as part of the installation contract with 4 to 20 mA analog input to the Master Control Panel. This differential pressure indication shall be used to vary the speed of primary pumps to maintain pressure setpoint, +/- 2 psi.

3) Chiller load/turndown and primary pump speed sequence shall be controlled by any of the following control strategies:a) Chilled water supply temperature only (must be held constant).b) Chilled water return temperature only.c) A combination of the above.d) System differential pressure.

4) After enabled, operating chiller will only start if system chilled water supply temperature is above minimum shut down set point and only stop if system chilled water supply temperature is below minimum shutdown setpoint.

5) Primary chilled water pump will start and stop in conjunction with its MCP assigned chiller. Manual reassignment will be accomplished at the systems MCC.

6) If a chiller trips on fault, an alarm will be indicated and the standby chiller will automatically start. Chiller lead/lag sequence shall be automatically changed during non-production hours based on Chiller run time or by operator input.

7) Primary chilled water flow rate and temperatures shall be used to calculate and display a running tonnage for the system.

6. Input/Output Summary: Master control panel shall contain the following inputs and outputs as a minimum:

a. Analog Inputs (minimum) to Master Control Panel DDC1) Primary chilled water flow GPM.2) Primary chilled water supply temperature.3) Primary chilled water return temperature.4) Primary chilled water supply pressure.5) Primary chilled water return pressure.6) Chilled water loop differential pressure.7) Chilled water loop remote temperature.

b. Analog Inputs (minimum) to Master Control Panel PLC1) Six are to be determined.

c. Discrete Inputs (minimum) to Master Control Panel DDC1) Chiller chilled water primary pump run status. Quantity of 3.2) Chiller on/off. Quantity of 3.3) Chilled water chiller isolation valve open/close. Quantity of 3 each.4) Alarm acknowledge pushbutton.5) Chiller operating mode. Quantity of 3.6) Equipment room refrigerant monitor (3 alarm levels, plus fault status, three

sensing points).d. Discrete Inputs (minimum) to Master Control Panel.

Chiller PumpsPrimary

Current 3

Field device open 2

Motor running 2

Motor running high --

Motor running low --

Run mode 2



Up to speed 2

VFD Fault 3e. Discrete Inputs (minimum) to Master Control Panel.

1) Four are to be determined.f. Analog Outputs (minimum) from Master Control Panel DDC

1) Chilled water supply temp set-point. Quantity of 3.2) Chiller demand load limit set-point. Quantity of 3.3) Primary pump VFD control. Quantity of 3.

g. Discrete Output (minimum) from Master Control Panel DDC1) Chiller start/stop. Quantity of 3.2) Chilled water pumps primary pumps start/stop. Quantity of 3.3) Chilled water isolation valve open/close. Quantity of 3 each.4) Global alarm output.

7. Personal Computer (PC) Operator Interface: Furnished by the Owner with software programming and loading of software is by the chiller manufacturer.

a. PC shall contain a series of screens that monitor status alarm conditions, process variables, adjustable setpoints, etc. It is the only means by which the operators can maintain the parameters of the system through set point adjustments. Stored variables associated with compared analog signals or limit comparative values shall be indicated on the PC and changed where appropriate.

b. Monitoring parameter capabilities on the chiller unit microprocessor control panel, master system control panel DDC controllers, and motor starter chiller microprocessor based protection system shall be observable at the PC. It is a means in which 1 operator can monitor any of the chillers he desires at the PC (see "Unit Microprocessor Control Panel," "Motor Starter Microprocessor Based Protection System" section, and “Master Chilled Water Control System”).

c. PC operator interface shall contain screens showing the overall chilled water process (chillers, primary water pumps) and their associated points of monitoring (temperature, pressure, GPM, flow, pump, current power and fans status), in graphic format.

d. Overall screen shall be broken down into smaller sections or subsystems. There shall be a screen for each chiller and their associated points of measurement (pressure, GPM, chilled water in/out temperature, lube oil temp., evaporator temp., compressor motor current, voltage, fault, etc.).

e. There shall be a separate screen for each set of pump and fan motors (primary chilled water pumps), and their associated monitoring points, such as motor running, vibration fault, auto/manual, hi/low speed, up to speed, current, run mode, VFD fault, etc.

f. As a minimum, the PC shall monitor and trend all functions as indicated in input/output summary and functions of the individual chiller unit Microprocessor Control Panel. Chiller PC shall also be capable of logging alarms and faults. Alarms are to automatically printed at the PC printer. Chiller PC is to be capable of historical trending, status, and system variables, and print out. Provide a daily log of the list of points recommended in ASHRAE Guideline 3.

8. Miscellaneous Control Devices and Subsystemsa. Pressure sensors and gauges for condenser, evaporator inlets and outlets, and

lubricating oil.b. Thermometers and temperature sensors for condenser, and evaporator inlet and

outlet and lubricating oil.9. Equipment Performance Schedule:



Location Trenton, Michigan Saltillo Mexico

Site Elevation

Site Latitude

Summer drybulb

Summer wetbulb

Winter drybulb

Per ASHRAE

Per ASHRAE

Per ASHRAE

Per ASHRAE

Per ASHRAE

4950 ft

25.2 Degrees

96.8 F

71.6 F

17.6 F

Tonnage 550 550

Quantity 3 3

Evaporator EWT 65 deg F

Evaporator LWT 50 deg F (Capable of 42 deg F)

Evaporator GPM 762.9

Condenser GPM 1200 1200

Motor Voltage 480 V/3 Phase 480V/3 Phase

Glycol content 30% 10%

BIN data 20hrs /day, 6 day /wks, 300 day/ yr balance of remaining hours at 110 tons

20hrs /day, 6 day /wks, 300 day/ yr balance of remaining hours at 110 tons

10. Lockout Tagging: Provide a lockout placard on each chiller panel and the master control panel, and lockout tagging on all ancillary equipment such as pumps, and cooling tower controlled by the chiller system. Lockout tagging shall comply with applicable DaimlerChrysler safety requirements.

11. Equipment Tagging: All chiller and field mounted devices, such as valves,, transmitters, sensors, and major components, shall be provided with lamacoid tags to identify the component function and its number reference on the system electrical control schematics.

2.8 ACCESSORIES AND OPTIONS

A. Flow Switch (Field Mounted): Vapor proof SPDT, NEMA 3R switch, 150 PSIG (10.3 bar), -20F to 250F (-28.9C to 121.1C).

B. Vibration Isolation (Field Mounted):1. Neoprene Isolators.

C. Provide suction service shut-off valve for each compressor (Factory Mounted).

PART 3 - EXECUTION

3.1 MANUFACTURER’S SERVICES

A. Provide services of a factory-authorized service representative to:1. Assist in the field assembly of components and installation

of chillers;



2. Provide start-up services, test and adjust controls and safeties;

3. Train Owner’s operating and maintenance personnel on operation and maintenance of chillers.

4. Review data in operation and maintenance manuals.5. Owner will require seven days advance notice for

scheduled training.

END OF SECTION


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