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MPS Master SECTION 23 64 16

CENTRIFUGAL WATER CHILLERS

PART - GENERAL

SUMMARY

Section Includes: Include labor, materials, skills, and related services necessary to furnish and install the complete installation of water chilling equipment described in this section including the following:

Direct Drive Hermetic Centrifugal and Rotary Water ChillersChiller Plant Control System

Chiller Includes: Chiller shall include, but not be limited to, the following:

Chiller PackageCharge of Refrigerant and OilElectrical Power, Controls, and Control ConnectionsChilled Water ConnectionsCondenser Water ConnectionsAuxiliary Water ConnectionsVariable Frequency Drives and Circuit BreakerFactory Start-UpExtended Maintenance Agreement

SUBMITTALS

General Requirements:

Acceptable refrigerants on which chiller performance is based are HCFC-123 and HFC-134a.All proposals for chiller performance shall include an AHRI approved selection method for the specified refrigerants.Shop Drawings: Indicate components, assembly, dimensions, weights and loadings, required clearances, and location and size of field connections. Submit Product Data, indicating options and specialties, electrical requirements, and wiring diagrams and connections. Indicate accessories, valves, strainers, and thermostatic valves required for the complete system.Submit rigging, installation, and start-up procedures. Include location, size, and type of field piping connections.Submit performance data indicating energy input versus cooling load output from 100 to 25 percent of full load with constant entering condenser water temperature.Submit compressor and product data in table form indicating impeller speed (RPM), number of bearings, type of bearings, high speed impeller shaft RPM, sound pressure level per AHRI 575 (dB), number of stages, number of sets of inlet guide vanes, amount of refrigerant charge (pound), and amount of oil required (gallon).Manufacturer Certificate: Certify that components of package not furnished by manufacturer have been selected in accordance with manufacturer=s requirements.

23 64 16 - 1Centrifugal Water Chillers


Operation and Maintenance Data: Include start-up instructions, maintenance data, parts lists, controls, and accessories. Include troubleshooting guide.Warranty: Submit manufacturer=s warranty and ensure forms have been filled out in Owner=s name and registered with manufacturer.

QUALITY ASSURANCE

Regulatory Requirements:

State Building CodeNational Electric CodeLocal Codes and OrdinancesLocal Authority having jurisdiction

Existing Site Conditions: Contractor shall field verify space limitations for new equipment in existing mechanical spaces, including all required clearances (i.e. height, width, length).

Any required modifications required to existing services to accommodate new equipment shall be performed at no additional expense to the Owner.

Factory Test:

Chiller shall be pressure-tested, evacuated, and fully charged with refrigerant and oil.

Chiller shall be factory operational run tested with water flowing through the vessel.

Factory Requirements:

Chillers shall be manufactured in a facility registered to ISO 9002.

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

WARRANTY

General Requirements: When warranties are required, verify that special warranties stated in this Section are not less than remedies available to the Owner under prevailing local laws.

Special Warranty: Manufacturer’s standard form in which manufacturer agrees to repair or replace components of chillers that fail in materials or workmanship within specified warranty period.

Extended warranties include, but are not limited to, the following:

Complete Chiller; including refrigerant and oil chargeComplete Compressor and Drive Assembly; including refrigerant and oil charge



Refrigerant and Oil Charge5-Year Parts and LaborLoss of Refrigerant Charge; for any reasonStart-Up and Shut-Down for 2 Years

Fall 20XX Shut-Down; Spring 20XX Start-UpFall 20XX Shut-Down; Spring 20XX Start-Up

Warranty Period: (5) years from date of Substantial Completion.

DELIVERY, STORAGE, AND HANDLING

Shipment: During shipment, manufacturer shall provide protective covering over vulnerable components. Chiller and accessories shall be protected from the weather and dirt exposure during shipment. Fit nozzles and open ends with plastic enclosures.

Delivery: Unit shall be delivered to site fully assembled and charged with refrigerant and oil by manufacturer. Unit shall be delivered to Contractor who is under separate contract.

Storage: Unit shall be stored off-site in an insured warehouse until delivery to the site and handled in accordance with manufacturer’s instructions.

MAINTENANCE SERVICE


All inspections and service of units shall be accomplished by factory trained and authorized servicing technicians.All labor for leak checking the chiller in accordance with the manufacturer's IOM and documentation shall be included.In conjunction with, and supporting of factory warranty, OEM shall furnish complete factory authorized service and maintenance for applied chillers for 1 year from the date of Substantial Completion. All work shall be done by manufacturer's commercial warranty agent.OEM shall provide and report quarterly, semiannual, and annual maintenance in compliance with, or better than, ASHRAE Standard 180.Include maintenance items as recommended in manufacturer's operating and maintenance data.Submit copy of service call work orders and summary report to the Owner, including description of work performed, operating performance status, and noted exceptions.

PART - PRODUCTS

MANUFACTURERS

Acceptable Manufacturers for Water Cooled Centrifugal Chillers: Subject to compliance with requirements of the Contract Documents, acceptable manufacturers are as follows or Owner approved equal:



TraneYork

Acceptable Manufacturers for Refrigerant Monitor: Subject to compliance with requirements of the Contract Documents, acceptable manufacturers are as follows or Owner approved equal:

Trane, Model RMWCMine Safety Appliance, Model "Chillgard IR"

CHILLER REBATE

Requirements: Chiller shall operate at .50 KW/ton or less, and must conform to Xcel Energy Chiller Rebate Program. The manufacturer's representative shall take the appropriate steps to ensure that the Xcel rebate is processed on the district and regional level.

Each chiller shall be factory witness run-tested at 100 percent load with 85-degree ECWT and at 25 percent load at 55-degree ECWT for a minimum of 1 hour on an AHRI 550 certified test stand with evaporator and condenser waterflow at job conditions (glycol applications shall be tested at adjusted conditions). Operating controls shall be adjusted and checked. The refrigerant charge shall be adjusted for optimum operation and recorded on the unit nameplate. Manufacturer shall supply a certificate of completion of a successful run-test.

Penalty for failing to meet the test shall be determined by the Owner/Engineer on the basis of life cycle cost.

MANUFACTURED UNITS


Factory assembled and tested water chiller complete with UL label, compressor, evaporator, condenser, controls, starter or variable speed drive, interconnecting unit piping and wiring, indicating accessories, and mounting frame.

The Contractor shall furnish and install centrifugal water chillers as shown and scheduled in the Drawings and Specifications. The units shall produce the specified tonnage per the scheduled data in accordance with AHRI 550/590. The unit shall bear the AHRI certification label as applicable.

Efficiency and Performance Tolerances: The following allowable tolerances shall be followed:

The tolerance on allowable capacity shall be [as defined by AHRI Standard] [0 percent] [________].The IPLV/NPLV and full load tolerances shall be [as defined by AHRI Standard] [0 percent] [________], and the tolerances at full load and all part load test points shall be [as defined by AHRI Standard] [0 percent]



[________]. The tolerances for kW/ton at all points shall be [as defined by AHRI Standard] [0 percent] [________].

The evaporator and condenser shall be built in accordance with ANSI/ASHRAE 15 Safety Standards for Refrigeration Systems.

WATER COOLED CENTRIFUGAL CHILLERS

Acceptable Manufacturers: Subject to compliance with requirements of the Contract Documents, acceptable manufacturers shall be as follows or Owner approved equal:

Trane, Model CVHF

Compressor and Motor:

Compressor shall be centrifugal.

The chiller shall be able to unload to 15 percent of design tonnage with constant 55-degree F entering water temperature.

The impellers shall be fully shrouded and made of a high strength aluminum alloy. Impellers shall be dynamically balanced and over-speed tested at 1.25 times impeller shaft speed.

Evaporator:

The evaporator tubes shall be internally enhanced. The minimum tube wall thickness shall be 0.028 inch.

The evaporator water piping connections shall not be grooved.

The evaporator water boxes shall be standard non-marine type with connections in accordance with schedule.

Supply and return head water boxes shall be designed for a working pressure of 150 psig and shall be factory hydrostatic pressure tested at 150 percent of the design pressure. Provide drain and vent connections in water boxes.

Adjustable or float type refrigerant metering devices and thermal expansion valves shall be inspected and adjusted by the manufacturer at the end of each year for the first 5 years of operation to ensure equivalent reliability and maintenance to a fixed orifice system. A written report shall be forwarded to the Owner each year to confirm completion.

The evaporator shall have a refrigerant relief device sized to meet the requirements of ASHRAE safety code for mechanical refrigeration.

Condenser:

The condenser tubes shall be internally enhanced. The minimum tube wall



thickness shall be 0.028 inch.

The condenser water piping connections shall not be grooved.

The condenser water boxes shall be standard non-marine type with connections in accordance with schedule.

Supply and return head water boxes shall be designed for a working pressure of 150 psig and shall be factory hydrostatic pressure tested at 150 percent of the design pressure. Provide drain and vent connections in water boxes.

Purge System:

The purge efficiency shall meet ASHRAE Standard 147-2002, Paragraph 4.7.

The purge shall be capable of operating when the chiller is idle in accordance with ASHRAE Standard 147-2002, Paragraph 4.7.2 (a).

Control:

The chiller shall be controlled by a stand-alone microprocessor based control center. The chiller control panel shall provide control of chiller operation and monitoring of chiller sensors, actuator, relays, and switches.

The enclosure shall be unit mounted NEMA 250, Type 1.

A color, liquid crystal display (LCD) shall be unit mounted. The display shall be fully adjustable in height and viewing angle. Animated graphical representations of chiller subsystem operation shall be used to enhance the user interface.

Display shall consist of a menu driven interface with easy touch screen navigation to organized subsystem reports for compressor, evaporator, condenser, purge, and motor information, as well as associated diagnostics. The controller shall display all active diagnostics and a minimum of (20) historical diagnostics.

The controller shall have the ability to display all primary sub-system operational parameters on dedicated trending graphs. The operator must be able to create up to (6) additional custom trend graphs, choosing up to (10) unique parameters for each graph to trend log data parameters simultaneously over an adjustable period and frequency polling.

The chiller control panel shall provide control of chiller operation and monitoring of chiller modules, sensors, actuators, relays, and switches. The chiller control panel shall include controls to safely and efficiently operate the chiller.

The chiller control panel shall provide the following safeties:

Low Chilled Water Temperature



Low Evaporator Refrigerant Temperature or PressureHigh Condenser Refrigerant PressureEvaporator and Condenser Water Flow StatusLow Oil PressureLow Oil TemperatureHigh Oil TemperatureHigh Motor Winding TemperaturesHigh Motor CurrentStarter/AFD Function FaultsSensor FaultsUnit Controls OperationChiller control panel or starter shall incorporate advanced motor protection to safeguard the motor throughout the starting and running cycles from the adverse effects of:

Current Phase LossCurrent Phase UnbalanceCurrent Phase ReversalUnder/Over VoltageMotor Current OverloadDistribution Fault Protection with Auto Restart; consisting of 3 phase current sensing devices that monitor status of currentStarter Contactor Fault ProtectionStarter Transition Failure

The front of the chiller control panel shall display the following in clear language, without the use of codes, look-up tables, or gauges:

Run TimeNumber of StartsCurrent Chiller Erating ModeChilled Water Setpoint and Setpoint SourceElectrical Current Limit Setpoint and Setpoint SourceEntering and Leaving Evaporator Water TemperaturesEntering and Leaving Condenser Water TemperaturesSaturated Evaporator and Condenser Refrigerant TemperaturesOil Tank TemperatureOil Tank PressureOil Pump Discharge PressureDifferential Oil PressureCompressor Motor Current per phaseCompressor Motor Percent RLACompressor Motor Voltage per phasekw Energy Consumption and Power FactorCompressor Motor Winding Temperatures per phasePurge Operating ModePurge Operating StatusTime Until Next Purge RunDaily Pump-Out - 24 HoursAverage Daily Pump-Out - 7 DaysPurge Refrigerant Compressor Suction TemperaturePurge Liquid Temperature (Chiller Condenser Saturated Refrigerant



Temperature)Daily Pump-Out Limit/Alarm

The chiller control panel shall provide leaving chilled water temperature reset based upon return water temperature.

The chiller control panel shall be capable of providing short cycling protection.

The chiller controller shall communicate directly to a BACnet compatible control panel.

Starters - Variable Speed Drive (VSD), Remote Mounted:

The centrifugal water chiller shall be furnished with a air cooled variable speed drive (VSD) as shown on the Drawings. The VSD shall be remote (free standing) mounted and shipped completely factory assembled, wired, and tested.

The VSD will be specifically designed to interface with the centrifugal water chiller controls and allow for the operating ranges and specific characteristics of the chiller. The VSD control logic shall optimize chiller efficiency by coordinating compressor motor speed and compressor inlet guide vane position to maintain the chilled water setpoint while avoiding surge. If a surge is detected, VSD surge avoidance logic will make adjustments to move away from and avoid surge at similar conditions in the future.

The VSD efficiency shall be 97 percent or better at full speed and full load. Fundamental displacement power factor shall be a minimum of 0.97.

The VSD shall be solid state, microprocessor based pulse-width modulated (PWM) design. The VSD shall be voltage and current regulated. Output power devices shall be IGBT transistors.

Power semi-conductor and capacitor cooling shall be from a liquid or air cooled heat sink.

The VSDs shall each be furnished in a NEMA 1 metal enclosure having, as minimum, a short circuit withstand rating of 65,000 amps in accordance with UL 508. It will include 3 phase input lugs, plus a grounding lug for electrical connections, output motor connection via factory installed bus bars, and all components properly segregated and completely enclosed in a single metal enclosure.

Enclosure shall include a padlockable, door mounted circuit breaker with a minimum AIC rating of 65,000 amps.

The entire chiller package shall be UL/CUL listed.

The VSD shall be tested to ANSI/UL Standard 508 and shall be listed by a Nationally Recognized Testing Laboratory (NRTL) as designated by OSHA.



Compliance to recommendations for harmonic mitigation.

The VSD design shall include a DC link reactor on positive and negative rails to minimize power line harmonics and protect the VSD from power line transients.

Input shall be nominal [460] [480] [575] [600] volts, 3 phase, 60 Hertz, AC power, plus or minus 10 percent of nominal voltage.

Line frequency shall be 38 to 60 Hertz.

The VSD shall include the following features:

Control Circuit Voltages; physically and electrically isolated from power circuit voltage150 Percent Instantaneous Torque; available for improved surge controlSoft Start, Adjustable Linear Acceleration, Coast-to-StopAdjustable Current Limiting and UL Approved Electronic Motor Overload ProtectionInsensitivity to Incoming Power Phase SequenceVSD and Motor Protection; from the following faults:

Output Line-to-Line Short Circuit ProtectionLine-to-Ground Short Circuit ProtectionPhase Loss at AFD InputPhase Reversal / ImbalanceOver-VoltageUnder-VoltageOver Temperature

The following VSD status indicators shall be available to facilitate start-up and maintenance:

Output Speed in Hertz and rpmInput Line VoltageInput Line kWOutput / Load AmpsAverage Current in Percent RLALoad Power FactorFaultVSD Transistor Temperature

Service Conditions:

Operating Ambient Temperature 14 Degrees F to 104 Degrees F (Minus 10 Degrees C to 40 Degrees C)Room Ambient up to 95 Percent Relative HumidityElevation to 3,300 Feet (1,000 Meters); for every 3,300 feet above 3,300 feet, the rated output current shall be decreased by 4 percent up to 9,900 feet.

Warranties: The variable speed drive shall be warranted by the manufacturer



for whichever comes first; a period of 12 months from the date of installation or 18 months after shipment.

Factory Insulation: Factory applied, anti-sweat insulation shall be attached to the cooler shell and ends, flow chamber, tube sheets, suction connection, and (as necessary) to the auxiliary tubing. The insulation shall be a flexible, closed-cell plastic type, 3/4 inch thick, applied with vapor-proof cement. The insulation will normally prevent sweating in environments with relative humidity up to 75 percent and dry bulb temperatures ranging from 50 to 90 Degrees F.

Isolation Mounting: Included with the unit are (4) vibration isolation mounts, consisting of 1-inch thick neoprene isolation pads, for field mounting. The pads are to be mounted under the steel mounting pads on the tube sheets.

Start-Up and Operator Training: The services of a factory trained, field service representative shall be provided to supervise the final leak testing, charging, and initial start-up, and conduct concurrent operator instruction.

WATER COOLED CENTRIFUGAL CHILLERS

Acceptable Manufacturers: Subject to compliance with requirements of the Contract Documents, acceptable manufacturers shall be as follows or Owner approved equal:

York, Model YK

Compressor and Motor:

The compressor will be a single-stage centrifugal type powered by an open-drive electric motor. The housing will be fully accessible with vertical circular joints, with the complete operating assembly removable from the compressor and scroll housing. Compressor castings will be designed for 235 psig working pressure and hydrostatically pressure tested at 355 psig for R-134A units. The rotor assembly will consist of a heat-treated alloy steel drive shaft and impeller shaft with a cast aluminum, fully shrouded impeller. The impeller will be designed for balanced thrust, dynamically balanced and over-speed tested for smooth, vibration-free operation. Insert-type journal and thrust bearings will be fabricated of aluminum alloy, precision bored and axially grooved.

Internal single helical gears with crowned teeth will be designed so that more than (1) tooth is in contact at all times to provide even load distribution and quiet operation. Each gear shall be individually mounted in its own journal and thrust bearings to isolate it from impeller and motor forces. Shaft seal shall be provided in double bellows, double-seal, cartridge type. A gravity-fed oil reservoir shall be built into the top of the compressor to provide lubrication during coast-down in the event of a power failure.

Capacity control shall be achieved by use of pre-rotation vanes to provide fully modulating control from maximum to minimum load. The unit shall be capable of operating at 15 percent capacity with 55-degree F entering cooling tower



water during part-load operation in accordance with ARI Standard 550/590. Pre-rotation vanes along with a VFD will be automatically controlled by an external electric actuator to maintain constant leaving chilled water temperature.

Lubrication System:

Lubrication oil shall be force-fed to all compressor bearings, gears, and rotating surfaces by an external variable speed oil pump. The oil pump shall vary oil flow to the compressor based on operating and standby conditions, ensuring adequate lubrication at all times. The oil pump shall operate prior to start-up, during compressor operation and during coast-down. Compressor shall have an auxiliary reservoir to provide lubrication during coast-down in the event of a power failure.

An oil reservoir, separate from the compressor, shall contain the submersible 2 horsepower oil pump and a 1,000 watt oil heater, thermostatically controlled to remove refrigerant from the oil. The oil reservoir shall be designed and stamped in accordance with ASME or applicable pressure vessel code.

Oil shall be filtered by an externally mounted, micron replaceable cartridge oil filter equipped with service valves. Oil cooling shall be done via a refrigerant cooled oil cooler, with all piping factory installed. Oil side of the oil cooler shall be provided with service valves. An automatic oil return system to recover any oil that may have migrated to the evaporator shall be provided. Oil piping shall be completely factory installed and tested.

Motor Driveline:

The compressor motor shall be an open drip-proof, squirrel cage, induction type operating at 3,570 RPM.

The open motor shall be provided with a D-flange, bolted to a cast iron adapter mounted on the compressor to allow the motor to be rigidly coupled to the compressor to provide factory alignment of motor and compressor shafts.

Motor drive shaft shall be directly connected to the compressor shaft with a flexible disc coupling. Coupling shall have all metal construction with no wearing parts to ensure long life, and no lubrication requirements to provide low maintenance.

Evaporator:

Evaporator shall be of the shell-and-tube, falling film type designed for 180 psig working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plate with fusion welded seams; have carbon steel tube sheets, drilled and reamed to accommodate the tubes; and intermediate tube supports spaced no more than 4 feet apart. Tubes shall be high-efficiency, internally and externally enhanced type having plain copper lands at all intermediate tube supports to provide maximum tube wall thickness at the support area. Each tube shall be roller expanded into the tube



sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 feet per second. Two (2) liquid level sight glasses shall be located on the side of the shell to aid in determining proper refrigerant charge. Aluminum mesh eliminators shall be located above the tube bundle to prevent liquid refrigerant carryover to the compressor. Minimum tube wall thickness to be 0.028 inch.

The evaporator shall have a refrigerant relief device sized to meet requirements of ASHRAE 15 safety code for mechanical refrigerant.

Water boxes shall be removable to permit tube cleaning and replacement. Stub-out water connections shall not be grooved. Vent and drain connections with plugs shall be provided on each water box.

Condenser:

Condenser will be of the shell-and-tube type, designed for 235 psig working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plate with fusion welded seams; have carbon steel tube sheets, drilled and reamed to accommodate the tubes; and intermediate tube supports spaced no more than 4 feet apart. Tubes shall be high-efficiency, internally and externally enhanced type having plain copper lands at all intermediate tube supports to provide maximum tube wall thickness at the support area. Each tube will be roller expanded into the tube sheets providing a leak-proof seal, and be individually replaceable. Water velocity through the tubes will not exceed 12 feet per second. Tube wall to minimum thickness of 0.028 inch.

Water boxes and cover plates shall be removable to permit tube cleaning and replacement. Stub-out water connections shall not be grooved. Vent and drain connections with plugs shall be provided on each water box.

Refrigerant Isolation for Chillers Using R-134a: Factory install isolation valves in the compressor discharge line to the condenser and the refrigerant liquid line leaving the condenser to allow for isolation and storage of full refrigerant charge in the chiller condenser shell.

Refrigerant Flow Control: Refrigerant flow to the evaporator shall be controlled by a variable orifice for improving unloading capabilities.

Control:

The chiller shall be controlled by a stand-alone microprocessor based control center. The chiller control panel shall provide control of chiller operation and monitoring of chiller sensors, actuators, relays, and switches. The VSD has a building in factory provided disconnect.

The control panel shall include a color liquid crystal display (LCD) surrounded by Asoft@ keys, which are redefined based on the screen displayed at that time. This shall be mounted in the middle of a keypad interface and installed in a locked enclosure. The screen shall detail all operations and parameters, using a graphical representation of the chiller and its major components. The



panel shall display countdown timer messages so the operator knows when functions are starting and stopping. Every programmable point shall have a pop-up screen with the allowable ranges, so that the chiller cannot be programmed to operate outside of its design limits. The chiller control panel shall also provide:

System operating information, including:

Return and Leaving Chilled Water TemperatureReturn and Leaving Condenser Water TemperatureEvaporator and Condenser Saturation TemperatureDifferential Oil PressurePercent Motor CurrentEvaporator and Condenser Saturation TemperatureCompressor Discharge TemperatureOil Reservoir TemperatureCompressor Oil TemperatureOperating HoursNumber of Compressor Starts

Digital programming of setpoints through the universal keypad, including:

Leaving Chilled Water TemperaturePercent Current LimitPull-Down Demand Limiting6-Week Schedule for Starting and Stopping Chiller, Pumps, and TowerRemote Reset Temperature Range

Status messages, indicating:

System Ready to StartSystem RunningSystem Coast-DownSystem Safety Shutdown - Manual RestartSystem Cycling Shutdown - Auto RestartSystem PrelubeStart Inhibit

Safety shutdowns enunciated through the display and the status bar, and consist of system status, system details, day, time, cause of shutdown, and type of restart required. Safety shutdowns with a fixed speed drive shall include:

Evaporator - Low PressureEvaporator - Transducer or Leaving Liquid ProbeEvaporator - Transducer or Temperature SensorCondenser - High Pressure Contacts OpenCondenser - High PressureCondenser - Pressure Transducer out of RangeAuxiliary Safety - Contacts ClosedDischarge - High Temperature



Discharge - Low TemperatureOil - High TemperatureOil - Low Differential PressureOil - High Differential PressureOil - Sum Pressure Transducer Out of RangeOil - Differential Pressure CalibrationOil - Variable Speed Pump JV Pressure Setpoint Not AchievedControl Panel - Power FailureMotor or Starter - Current ImbalanceThrust Bearing - Proximity Probe ClearanceThrust Bearing - Proximity Probe Out-of-RangeThrust Bearing - High Oil TemperatureThrust Bearing - Oil Temperature SensorWatchdog - Software Reboot

Safety shutdowns with a VSD shall include:

VSD Shutdown - Requesting Fault DataVSD - Stop Contacts OpenVSD - 105 Percent Motor Current OverloadVSD - High Phase A, B, C Inverter Heat-Sink TemperatureVSD - High Converter Heat-Sink Temperature

Cycling shutdowns with a VSD shall include:

VSD Shutdown - JV Requesting Fault DataVSD - Stop Contacts OpenVSD - Initialization FailedVSD - High Phase A, B, C Instantaneous CurrentVSD - Phase A, B, C Gate DriverVSD - Single Phase Input PowerVSD - High DC Bus VoltageVSD - Pre-Charge DC Bus Voltage ImbalanceVSD - High Internal Ambient TemperatureVSD - Invalid Current Scale SelectionVSD - Low Phase A, B, C Inverter Heat-Sink TemperatureVSD - Low Converter Heat-Sink TemperatureVSD - Pre-Charge - Low DC Bus VoltageVSD - Logic Board ProcessorVSD - Run SignalVSD - Serial Communications

Trending data with the ability to customize points of once every second to once every hour. The panel shall trend up to (6) different parameters from a list of over (140), without the need of an external monitoring system.

The operating program stored in non-volatile memory (EPROM) to eliminate reprogramming the chiller due to AC power failure or battery discharge. Programmed setpoints shall be retained in lithium battery-backed RTC memory for a minimum of 11 years with power removed from the system.



A fused connection through a transformer in the compressor motor starter to provide individual over-current protected power for all controls.

A numbered terminal strip for all required field interlock wiring.

An RS-232 port to output all system operating data, shut-down/cycling message, and a record of the last (10) cycling or safety shut-downs to a field-supplied printer. Data logs to a printer at a set programmable interval. This data can be preprogrammed to print from 1 minute to 1 day.

The capability to interface with a building automation system to provide:

Remote Chiller Start and StopRemote Leaving Chiller Liquid Temperature AdjustRemote Current Limit Setpoint AdjustRemote Ready to Start ContactsSafety Shutdown ContactsCycling Shutdown ContactsRun Contacts

Compressor Motor Starter:

A variable speed drive shall be factory installed on the chiller. It will vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The adaptive capacity control logic shall automatically adjust motor speed and compressor pre-rotation vane position independently for maximum part-load efficiency by analyzing information fed to it by sensors located throughout the chiller.

Drive shall be PWM type utilizing IGBT with a power factor of 0.95 or better at all loads and speeds.

The variable speed drive shall be unit mounted in a NEMA 1 enclosure with all power and control wiring between the drive and chiller factory installed, including power to the chiller oil pump. Field power wiring shall be a single point connection and electrical lugs for incoming power wiring will be provided. The entire chiller package will be UL listed.

The following features will be provided:

Door Interlocked Circuit Breaker Capable of Being PadlockedUL Listed Ground Fault ProtectionOver Voltage and Under Voltage Protection3-Phase Sensing Motor Over Current ProtectionSingle Phase ProtectionInsensitive to Phase RotationOver Temperature ProtectionDigital Read-Out at the Chiller Unit Control Panel of Output Frequency, Output Voltage, 3 Phase Output Current, Input Kilowatts and Kilowatt-hours, Self-Diagnostic Service Parameters



Factory Insulation: Factory applied, anti-sweat insulation shall be attached to the cooler shell to include flow chamber, tube sheets, suction connection, and (as necessary) to the auxiliary tubing. The insulation will be a flexible, closed-cell plastic type, 3/4 inch thick, applied with vapor-proof cement. The insulation will normally prevent sweating in environments with relative humidity up to 75 percent and dry bulb temperatures ranging from 50 to 90 Degrees F.

Isolation Mounting: Included with the unit are (4) vibration isolation mounts, consisting of 1-inch thick neoprene isolation pads, for field mounting. The pads are to be mounted under the steel mounting pads on the tube sheets.

Start-Up and Operator Training: The services of a factory trained, field service representative shall be provided to supervise the final leak testing, charging, and the initial start-up, and conduct concurrent operator instruction.

ARCHITECTURE/COMMUNICATION

General Requirements: The Project shall be comprised of a high speed Ethernet network utilizing BACnet/IP, Lonworks or Modbus communications between system controllers and workstations. Communications between system controllers and sub-networks of custom application controllers and/or application specific controllers shall utilize BACnet/MSTP (RS485) communications.

Each system controller shall perform communications to a network of custom application and application specific controllers using BACnet/MSTP, Lonworks or Modbus (RS485) as prescribed by the BACnet standard.

Each system controller shall function as a BACnet, Lonworks or Modbus router to each unit controller providing a unique BACnet, Lonworks or Modbus device ID for all controllers within the system.

For the minimum points to be mapped to the BMS by BACnet, , Lonworks or Modbus refer to the BMS points list. As part of the Shop Drawing submittal for this equipment, indicate confirmation of the minimum points by BACnet, Lonworks or Modbus and provide a list of additional points that are available.

POWER CAPACITOR

General Requirements: This Contractor shall provide capacitors to provide a minimum power factor of 90 percent at 40 percent of full load. Mount capacitors and provide any wiring required, whether they are integral with the equipment control cabinet or installed adjacent to it. Equipment shall be as manufactured by Westinghouse, Sprague or Cornell-Dubelier. Individual capacitors shall be dry electrolytic type and enclosed in integrated dust-tight enclosure. Provide illuminated fuse holder caps which shall illuminate when fuse is blown or removed.

CHILLER PLANT MANAGER CONTROL

General: Contractor shall provide a chiller plant manager control system to perform chiller control. Chiller control system shall have the capability to monitor



and control its centrifugal chillers and associated equipment.

System Hardware: Chiller plant manager system shall consist of the following hardware:

Factory-Installed Microprocessor-Based Controller

System Functions: Chiller plant manager shall perform the following chiller control functions using prepackaged, factory installed pretested control and monitoring programs.

Chiller Start/Stop; based on time of day schedule or optimal start/stop conditionsChilled Water Pump Start/Stop; based on time of day schedule or optimal start/stop conditionsCondenser Water Pump Start/Stop; based on time of day schedule or optimal start/stop conditionsChiller Sequence ControlChiller Lead/Lag ControlChilled Water Setpoint ControlChilled Water Temperature Reset ControlChilled Water Temperature Reset Control OverrideChiller Soft-Loading ControlCondenser Water Temperature Limit ControlChiller Current Limit Control

System Diagnostic and Alarm Indication:

Chiller diagnostic and alarm status shall be displayed and alarm status shall be annunciated at the Building Management System.

Chiller system diagnostic and alarm status shall include:

System Entering and Leaving Water Temperature SensorsUnit Communications FailurePower LossSystem Control Module

Description of Operation: Chiller Plant Manager system shall automatically coordinate the operation of chillers, cooling towers, chilled water pumps, and condenser water pumps.

Chiller Start/Stop Control: The Building Management System time of day software or optimal start/stop software shall perform start/stop control for the chillers. Upon starting the chillers, the chiller plant manager system shall automatically determine the appropriate chiller control required, i.e. chiller soft-loading control, normal sequencing control, etc. Start/stop control of the chillers shall be subject to operator entered:

Minimum "on" time for the plant.Minimum "off" time for the plant.



Chilled water setpoint when the plant turns "on".Chilled water setpoint when the plant turns "off".Ambient lockout temperature.Ambient lockout temperature deadband.

Chilled Water Pump Control: Chiller control system shall provide factory-installed contacts for controlling individual chilled water pump for chiller. Chiller plant manager control system shall be equipped with minimum "on" and minimum "off" timers for pump control.

Condenser Water Pump Control: Chiller control system shall provide factory installed contacts for controlling condenser water pumps. Upon a call for mechanical cooling, the chiller plant manager control system shall start the condenser water pump(s).

Speed control signal for cooling tower fan speed shall be fed from chiller control panel to cooling tower fan VFD.

Chiller Sequence Control: Chiller plant manager system shall sequence chillers system load levels. Chiller plant manager control system shall monitor the system load and sequence "on" the next scheduled chiller when the system load rises above the maximum load level for the (1) chiller that is operating. Likewise, the chiller plant manager control system shall monitor the system load and sequence "off" the next scheduled chiller when the system load falls below (2) chillers operating minimum load level for the chillers that are operating.

Chiller Lead/Lag Control: Chiller plant manager system shall perform automatic lead/lag chiller rotation based on programmed rotation designation for each chiller, and rotation time interval. Chiller sequencing shall take place in the rotation designated by the operating program until the rotation time interval has elapsed.

Chilled Water Setpoint Control: Chiller plant manager control system shall establish the chilled water setpoint for the stand alone microprocessor controller for each individual chiller. The stand alone chiller control panel in turn shall use the setpoint for chilled water temperature control.

Chilled Water Temperature Reset Control: Chiller plant manager control system shall perform chilled water temperature reset based on either system load as determined by return water temperature or outdoor ambient temperature. The rate of chilled water temperature reset shall be adjustable. The temperature sensors shall be provided with the chiller plant manager control system. These sensors shall have matched calibration characteristics with the supply chilled water temperature sensor.

Chilled Water Temperature Reset Control Override: Chiller plant manager system shall have the capability to provide chilled water reset temperature control override based on critical zone temperature or humidity.

Soft-Loading Control: Chiller control system shall automatically perform



soft-loading of chillers upon start-up. The chiller control system shall automatically return to normal chiller control upon expiration of the soft-loading time period.

Current Limit Control: Chiller plant manager shall establish the current limit setpoint for the stand alone microprocessor controller for each individual chiller. The operator shall be allowed to reset the current limit setpoint.

Sequence of Operation:

Plant manager shall sequence each chiller to meet the building cooling load by monitoring building return water temperature, chilled water supply temperature, building GPM flows, and/or chiller amp draws.

Chiller plant manager shall sequence the cooling tower pump(s), cooling tower fan(s), modulate tower fan, and/or pump speeds to optimize chiller/tower efficiency and performance.

Plant manager shall modulate a bypass valve or throttling valve in condenser water loop to meet minimum condenser water temperature limits of the chillers.

PERFORMANCE SPECIFICATIONS FOR HIGH EFFICIENCY REFRIGERATED PURGE SYSTEM

General: High efficiency chiller purge system shall be installed on centrifugal chiller equipment to improve the separation of air from the chiller refrigerant charge. This shall reduce the amount of refrigerant lost to the atmosphere due to normal purge operation.

Requirements:

Scope: High efficiency chiller purge system shall include complete installation, testing, and start-up for the chillers indicated. There shall be a separate purge system for each chiller.

Operation: High efficiency purge system shall have automatic controls to allow unattended operation. The controls shall provide options for:

Continuous OperationOperation Only When Chiller Compressor is RunningPurge Lockout

Excessive Purge Alarm: Purge system shall automatically lockout and alarm if excessive purging is detected. An operator override of the lockout shall be provided.

Design: High efficiency purge system shall have a low temperature refrigeration system that generates temperatures lower than 10 degrees F at the separation coil. The purge refrigeration system shall have an integral air cooled condensing system and shall not require cooling water. The high



efficiency purge system shall be able to operate while the chiller compressor is off.

High efficiency purge system shall have a gravity based system for returning liquified refrigerant to the chiller. Return systems requiring float valves are unacceptable.

Purge system shall have a serviceable refrigerant dryer to separate water and acid from the returning valve.

Air shall be extracted from the separation tank using an exhaust compressor and a solenoid isolation valve.

Efficiency: High efficiency purge system shall release to the atmosphere no more than 0.8 pounds of refrigerant per pound of air when operating at standard room conditions and at 100 degree F chiller condensing temperature.

Safety Controls and Diagnostics:

High efficiency purge shall turn off in the event that excessive purging has been detected. Upon lockout, an alarm light and a remote alarm relay shall activate. An operator override of this function shall be provided.

High efficiency purge system shall have a purge duration timer which gives an accurate indication of the amount of air being purged from the chiller. High efficiency purge system shall have a refrigerant moisture indicator.

REFRIGERANT MONITOR

Description:

Monitor shall be compound-specific with a measurement and display range of 0 to 1,000 ppm. The monitor shall be calibrated for the refrigerant (R-123) and specified with a display accuracy of plus or minus 1 ppm.

(3) factory-set alarm levels shall be provided, each with a front panel light and a latching binary contact closure for the control of remote devices. Electrically interconnect the alarm contact into the BMS system to alarm the District Communications Center.

An analog output corresponding to the unit display shall be provided for connection to the energy management control system or other recording equipment.

A means to automatically re-zero the instrument shall be included.

Regular maintenance of the unit shall be limited to recalibration once per year and monthly confirmation of clean air source for recalibration.

Ambient temperature operating range shall be 40 to 110 degrees F.



SIGNAGE

General: Provide engraved plastic laminated signs at each refrigeration system. Signs shall have a minimum 1/2-inch high lettering. As a minimum, the information included shall be as follows:

Name, Address, and Phone Number of InstallerRefrigerant Number and Amount of RefrigerantLubricant Identity and AmountField Test Pressure Applied

PART - EXECUTION

INSTALLATION

Mounting: Contractor shall verify curb dimension and location requirements with applicable Contractor.

Power: Contractor shall wire to starters and contactors in control panel from disconnect switches. Electrical Contractor shall wire to main circuit breaker in starter panel.

Control: Contractor shall furnish, connect, and install a Dwyer Capsu-Photohelic differential pressure switch and shall interlock chilled water pumps with chiller such that when chiller is energized, chilled water pumps shall start, and flow shall be proven before chiller can start. The reverse shall be true on chiller shut-down.

Power and control wiring shall be this Contractor's responsibility.

Control wiring for cooling tower VFD speed control or multi-stage tower fan control shall be by this Contractor.

Insulation: Insulate chilled water headers and sections of chiller not factory insulated after installation with 2-inch thick, 5-pound per board foot density Johns-Manville Spintex rigid board insulation with A.F. cover installed on copper clad "Graham Pins". Provide round cutouts at each stud nut and a 2-inch thick press fitted round plug of insulation over each nut. Insulate flange edges and unit collar for complete coverage and finish entire section with 6 ounce canvas neatly pasted on and painted to match unit.

Piping: Contractor shall furnish and install chilled water piping as shown on Drawings and herein specified.

Unit Connection: Connect piping to chiller with Mason Industries, Type MFTNC, twin sphere, neoprene connectors.

Connect all water piping so centrifugal unit and water circuits are serviceable.

Provide and install valves in water piping upstream and downstream of the evaporator and condenser water boxes to provide means of isolating shells for maintenance and to balance and trim system.



Install a pressure differential pressure switch in both the chilled water and condenser water piping adjacent to inlet and outlet connections of both the evaporator and condenser.

Provide and install drain valves to each water box.

Install vent cocks to each water box.

Install strainers ahead of all pumps and automatic modulating valves.

Furnish and install all necessary auxiliary water piping for oil cooler and purge condenser.

Furnish and install pressure relief piping from pressure relief rupture disc to atmosphere.

Arrange piping for easy dismantling to permit tube cleaning.

MANUFACTURER'S FIELD SERVICES


All start-up, maintenance, and monitoring functions shall be performed by a manufacturer's commercial agent to confirm, in writing, that equipment has been correctly installed and passes specification checklist prior to equipment becoming operational and covered under OEM warranty.

Applied chiller manufacturers shall maintain service capabilities no more than 50 miles from the job site.

The manufacturer shall furnish complete submittal wiring diagrams of the chiller(s) starter(s) and associated components like cooling towers, pumps, interlocks, etc. as applicable for field maintenance and service.

Comprehensive start-up, training, physical inspection, and remote monitoring are required to maintain specified performance and efficiency of the chiller system and to confirm like new condition prior to the equipment finishing its warranty.

EXECUTIVE COORDINATION: Pre-start instructions and coordination shall be provided by senior lead technician or supervisor to:

Review installation checklist with installing contractor.Review start-up procedures and required support.Review training requirements, timing, and logistics with the installing contractor.

START-UP: Provide all labor and materials to perform the start-up. This shall be done in strict accordance with manufacturer's specifications and requirements.



Provide a complete log of all operating parameters.Ensure actual performance matches with submittals and computerized selection programs for other than submittal conditions.Submit a hard copy of the service report and logs.

TRAINING: A minimum of 40 hours of chiller control system training, in conjunction with the BMS Contractor, shall be provided during the warranty period.

Additional training shall be on an as-needed basis to ensure proper operation of the system by the Owner's personnel. This additional training shall be performed at no additional cost to the Owner.

INSPECTIONS: For the duration of the warranty during operation, there shall be inspections in 3-month intervals, to perform the following:

Check the general operation of the unit.Provide a complete log as in Item b. above.Check operation of the control circuit.Check operation of the lubrication system.Check operation of the motor and starter.Analyze the record data; compare the data to the original design conditions.Review operating procedures with operating personnel.Do (1) oil analysis and submit the written report. Change the oil and filter as required in the published manufacturer's literature.Complete all recommended maintenance and tests as documented in the manufacturer's published literature.Provide a written report of completed work, operating log, and indicate any uncorrected deficiencies.At the final inspection (performed within 30 days of warranty expiration), ensure that the chillers are functioning correctly and that all warranty items are resolved to the Owner's satisfaction.

CENTRAL MONITORING: Provide remote monitoring through the building BMS system as follows:

Critical Alarm MonitoringAutomated Alarm Routing and Notification of Local Trane Field Office Service PersonnelRoutine Verification of Communications LinkArchived Documentation of Critical Events HistoryAutomated Alarm Activity Reports - On Basis As Required

SYSTEM FILL AND START-UP

System Test: Furnish sufficient refrigerant and dry nitrogen for pressure testing under manufacturer's supervision.

Unit Start-Up: Unit start-up shall be performed under supervision of a qualified



field engineer provided by chiller manufacturer.

Alignment: Adjust chiller in alignment on concrete foundations, sole plates, and subbases level, grouted, and bolt-in place.

Power and Control Wiring: Main power wiring to the chiller will be provided under Division 26. Customized wiring diagrams specifically for this Project shall be submitted with the Shop Drawings. Control wiring installation shall be the responsibility of the chiller and chiller plant control system supplier and installing Contractor.

Signage Installation: Signs shall be installed outside refrigeration system machinery room immediately adjacent to each door and at refrigeration equipment.

Leak Test, Charging and Start-Up: Manufacturer shall furnish a factory trained representative without charge for not less than 3 working days to supervise leak testing, evacuation and dehydration, charging the unit, start-up, and instruction of Owner's personnel on operation and maintenance. After date of Substantial Completion, manufacturer shall provide one year service, including parts and labor, shut down at end of first cooling season and start-up at beginning of second year. A 1-year refrigerant warranty shall also be provided.

Warranty: Manufacturer shall provide 5-year motor, compressor, and drive train parts warranty.

EMERGENCY OPERATION PLAN

General Requirements: Contractor shall coordinate, train, and assist the Owner in developing an emergency shutdown plan for the refrigeration system. Emergency plan shall include precautions and procedures to be followed during emergency events.

Instructions for Shutting System Down in Case of an Emergency; including instructions limiting entry to authorized personnel with appropriate respiratory equipment when alarm is activatedName, Address, and Day and Night Telephone Numbers for Obtaining ServiceNames, Addresses, and Telephone Numbers of Corporate, Local, State, and Federal Agencies; to be contacted as required in the event of a reportable incidentEmergency Plan; posted outside refrigeration system machinery room immediately adjacent to each door

Respiratory Equipment: Contractor shall advise Owner of requirements for respiratory equipment required for this installation and assist in procuring such equipment.

WATER COOLED CENTRIFUGAL CHILLER SCHEDULE

Refer to Drawings for schedules.



END OF SECTION
