236416 FL - Centrifugal Water Chillers- Addendum 3.pdf

Armed Forces Retirement Home Sheridan Building Design Documents | Specifications

Bid Addendum 2/12/25

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SECTION 236416 - CENTRIFUGAL WATER CHILLERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Packaged, water-cooled, electric-motor-driven centrifugal chillers.

B. Related Requirements:

1. Section 284400 "Refrigerant Detection and Alarm" for refrigerant monitors, alarms, supplemental breathing apparatus, and ventilation equipment interlocks.

1.3 DEFINITIONS

A. COP: Coefficient of performance. The ratio of the rate of heat removal to the rate of energy input, using consistent units for any given set of rating conditions.

B. DDC: Direct digital control.

C. EER: Energy-efficiency ratio. The ratio of the cooling capacity given in terms of Btu/h to the total power input given in terms of watts at any given set of rating conditions.

D. IPLV: Integrated part-load value. A single-number part-load efficiency figure of merit for a single chiller calculated according to the method defined by AHRI 550/590 and referenced to AHRI standard rating conditions.

E. kVAR: Kilovolt-ampere reactive.

F. kW/Ton: The ratio of total power input of the chiller in kilowatts to the net refrigerating capacity in tons at any given set of rating conditions.

G. NPLV: Nonstandard part-load value. A single-number part-load efficiency figure of merit for a single chiller calculated according to the method defined by AHRI 550/590 and intended for operating conditions other than the AHRI standard rating conditions.

H. SCCR: Short-circuit current rating.

1.4 ACTION SUBMITTALS

A. Product Data: For each type of product.

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1. Include refrigerant, rated capacities, operating characteristics, furnished specialties, and accessories.

2. Performance at AHRI standard conditions and at conditions indicated.

3. Performance at AHRI standard unloading conditions.

4. Minimum evaporator flow rate.

5. Minimum condenser flow rate.

6. Refrigerant capacity of chiller.

7. Oil capacity of chiller.

8. Fluid capacity of evaporator, condenser.

9. Characteristics of safety relief valves.

10. Minimum entering condenser-fluid temperature.

11. Performance at varying capacities with constant design condenser-fluid temperature.

Repeat performance at varying capacities for different condenser-fluid temperatures from design to minimum in 5 deg F increments.

12. Force and moment capacity of each piping connection.

B. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work.

1. Detail equipment assemblies and indicate dimensions, weights, load distribution, required clearances, method of field assembly, components, and location and size of each field connection.

2. Wiring Diagrams: For power, signal, and control wiring.

1.5 INFORMATIONAL SUBMITTALS

A. Coordination Drawings:

1. Drawings, drawn to scale, on which the following items are shown and coordinated with each other, using input from installers of the items involved:

a. Structural supports.

b. Piping roughing-in requirements.

c. Wiring roughing-in requirements, including spaces reserved for electrical equipment.

d. Access requirements, including working clearances for mechanical controls and electrical equipment, and tube pull and service clearances.

2. Coordination drawings showing plan, section, and elevation views, drawn to scale.

3. Each view to show screened background with the following:

a. Column grids, beams, columns, and concrete housekeeping pads.

b. Room layout with walls, floors, and roofs, including each room name and number.

c. Equipment and products of other trades that are located in the vicinity of chillers and part of final installation, such as lighting, fire-suppression, and plumbing systems.

B. Certificates: For certification required in "Quality Assurance" Article.

C. Source quality-control reports.

D. Field Quality-Control Reports: Startup service reports.

E. Sample Warranty: For special warranty.

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1.6 CLOSEOUT SUBMITTALS

A. Operation and Maintenance Data: For each chiller to include in emergency, operation, and maintenance manuals.

B. Instructional Videos: Including those that are pre-recorded and those that are recorded during training.

1.7 MAINTENANCE MATERIAL SUBMITTALS

A. Tool kit to include the following:

1. A tool kit specially designed by chiller manufacturer for use in servicing chiller(s) furnished.

2. Special tools required to service chiller components not readily available to Owner service personnel in performing routine maintenance.

3. Lockable case with hinged cover, marked with large and permanent text to indicate the special purpose of tool kit, such as "Chiller Tool Kit." Text size shall be at least 1 inch high.

4. A list of each tool furnished. Permanently attach the list to underside of case cover. Text size shall be at least 1/2 inch high.

B. Touch-up Paint: 32-oz. container of paint used for finish coat. Label outside of container with detailed description of paint to allow for procurement of a matching paint in the future.

1.8 QUALITY ASSURANCE

A. AHRI Certification: Certify chiller according to AHRI 550 certification program.

B. Green Seal Compliance: Signed by manufacturer, certifying compliance with GS-31.

1.9 DELIVERY, STORAGE, AND HANDLING

A. Ship chillers from the factory fully charged with refrigerant.

B. Ship each chiller with a full charge of refrigerant. Charge each chiller with nitrogen if refrigerant is shipped in containers separate from chiller.

C. Ship each oil-lubricated chiller with a full charge of oil.

1. Ship oil factory installed in chiller.

1.10 WARRANTY

A. 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.

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PART 2 - PRODUCTS

2.1 PERFORMANCE REQUIREMENTS

A. Seismic Performance: Centrifugal chillers shall withstand the effects of earthquake motions determined according to ASCE/SEI 7.

1. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event."

2. Component Importance Factor: 1.5.

B. Condenser-Fluid Temperature Performance:

1. Startup Condenser-Fluid Temperature: Chiller shall be capable of starting with an entering condenser-fluid temperature of 60 deg F and providing stable operation until the system temperature is elevated to the minimum operating entering condenser-fluid temperature.

2. Minimum Operating Condenser-Fluid Temperature: Chiller shall be capable of continuous operation over the entire capacity range indicated with an entering condenser-fluid temperature of 65 deg F.

3. Make factory modifications to standard chiller design if necessary, to comply with performance indicated.

C. Site Altitude: Chiller shall be suitable for altitude at which installed without affecting performance indicated. Make adjustments to affected chiller components to account for site altitude.

D. Performance Tolerance: Comply with standard capacity tolerances and IPLV/NPLV performance tolerances per AHRI 550/590:

E. ASHRAE Compliance:

1. ASHRAE 15 for safety code for mechanical refrigeration.

2. ASHRAE 147 for refrigerant leaks, recovery, and handling and storage requirements.

F. ASHRAE/IES Compliance: Applicable requirements in ASHRAE/IES 90.1.

G. ASME Compliance: Fabricate and label chillers to comply with ASME Boiler and Pressure Vessel Code: Section VIII, Division 1, as applicable to chiller design. For chillers charged with R-134a refrigerant, include an ASME U-stamp and nameplate certifying compliance.

H. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

I. Comply with requirements of Underwriters Laboratories and include label by a qualified testing agency showing compliance.

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2.2 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, available manufacturers offering products that may be incorporated into the Work include, but are not limited to the following:

1. Carrier Global Corporation.

2. Daikin Applied. (Basis of Design)

3. Trane.

4. YORK: brand of Johnson Controls International plc, Building Solutions North America.

2.3 MANUFACTURED UNIT

A. Description: Factory-assembled and tested chiller complete with compressor, compressor motor, compressor motor controller, lubrication system evaporator, condenser, controls, interconnecting unit piping and wiring, and indicated accessories.

B. Fabricate chiller mounting base with reinforcement strong enough to resist chiller movement during a seismic event when chiller is anchored to field support structure.

2.4 COMPRESSOR-DRIVE ASSEMBLY

A. Description: Single-stage or multistage, variable- or dynamic-displacement, centrifugal-type compressor driven by an electric motor.

B. Oil-Free Technology:

1. Where indicated, compressors shall have oil-free technology.

2. Where indicated, compressors shall have oil-free technology using a permanent magnet synchronous motor, magnetic bearings, integral variable-frequency controller, and digital electronic controls.

a. Magnetic Bearings or Roller Element Bearings:

1) Levitated shaft position shall be actively controlled and monitored by an X-, Y-, and Z-axis digital position sensor.

2) Compressor assembly shall be capable of coming to a controlled, safe stop without damage during a power failure by diverting stored power to the magnetic bearing control system.

b. Integrate monitoring and controls associated with magnetic bearings into chiller controls, including following:

1) Operating Information: Positions, currents, temperatures, rotor elongation, and speed.

2) Warning Messages: Vibration.

3) Safety Shutdown: Internal fault, high bearing temperature or current, startup failure, speed signal fault, overspeed fault, communication error, rotor elongation, oscillator fault, rotor contraction, unauthorized rotation, and high and low voltage.

4) Cycling Shutdown: Position, low-frequency displacement, vibration, speed signal fault, startup failure, serial communications fault.

C. Compressor:

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1. Casing: Cast iron, precision ground.

2. Impeller: High-strength cast-aluminum or cast-aluminum alloy on carbon- or alloy-steel shaft.

D. Drive: Direct-drive, hermetic design, using an electric motor as the driver.

1. Drive Coupling: For chillers with open drives, provide flexible disc with all-metal construction and no wearing parts to ensure long life without the need for lubrication.

2. Seals: Seal drive assembly to prevent refrigerant leakage.

E. Compressor Motor:

1. Continuous-duty, squirrel-cage, induction-type, two-pole motor with energy efficiency required to suit chiller energy efficiency indicated.

2. Factory mounted, aligned, and balanced as part of compressor assembly before shipping.

3. Motor shall be of sufficient capacity to drive compressor throughout entire operating range without overload and with sufficient capacity to start and accelerate compressor without damage.

4. For chillers with open drives, provide motor with open-drip-proof, Type I enclosure.

5. Provide motor with thermistor or RTD in single motor winding to monitor temperature and report information to chiller control panel.

6. Provide motor with thermistor or RTD to monitor bearing temperature and report information to chiller control panel.

7. Provide open-drive motor with internal electric heater, internally powered from chiller power supply.

F. Vibration Balance: Balance chiller compressor and drive assembly to provide a precision balance that is free of noticeable vibration over the entire operating range.

1. Overspeed Test: At least 20 percent above design operating speed.

2. Vibration Limits: Velocities not to exceed 0.15 inches/s and 0.8 mils peak to peak on all axes.

G. Service: Easily accessible for inspection and service.

1. Compressor's internal components shall be accessible without having to remove compressor-drive assembly from chiller.

2. Provide lifting lugs or eyebolts attached to casing.

H. Economizers: For multistage chillers, provide interstage economizers.

I. Capacity Control: Modulating, variable-inlet, guide-vane assembly combined with hot-gas bypass, if necessary, to achieve performance indicated.

1. Maintain stable operation that is free of surge, cavitation, and vibration throughout range of operation. Configure to achieve most energy-efficient operation possible.

2. Operating Range: From 100 to 15 percent of design capacity.

3. Condenser-Fluid Unloading Requirements over Operating Range: Constant-design of entering condenser-fluid temperature each 10 percent in capacity reductions.

4. Chillers with variable-frequency controllers shall modulate compressor speed with variable-inlet, guide-vane control to achieve optimum energy efficiency.

5. Avoid use of hot-gas bypass if other options are available to achieve performance indicated. Apply hot-gas bypass according to ASHRAE/IES 90.1 and governing codes.

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J. Oil Lubrication System: Consisting of pump, filtration, heater, cooler, factory-wired power connection, and controls.

1. Bearings, gears, and other rotating surfaces shall be lubricated at all operating, startup, coast down, and standby conditions, including power failure.

2. Manufacturer's standard method to remove refrigerant from oil.

3. Oil filter shall be the easily replaceable cartridge type, minimum 0.3-micron efficiency, with means of positive isolation while servicing.

4. Refrigerant-cooled oil cooler.

5. Factory-installed and pressure-tested piping with isolation valves and accessories.

6. Oil compatible with refrigerant and chiller components.

7. Positive visual indication of oil level.

2.5 REFRIGERATION

A. Refrigerant:

1. Type: R-123; ASHRAE 34, Class B1 or R-134a; ASHRAE 34, Class A1.

2. Compatibility: Chiller parts exposed to refrigerants shall be fully compatible with refrigerants, and pressure components shall be rated for refrigerant pressures.

B. Refrigerant Flow Control: Manufacturer's standard refrigerant flow-control device satisfying performance requirements indicated.

C. Pressure Relief Device:

1. Comply with requirements in ASHRAE 15, ASHRAE 147, and applicable portions of ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.

2. Select and configure pressure relief devices to protect against corrosion and inadvertent release of refrigerant.

3. Where dual pressure relief devices are installed in series, provide a sensor with indicator between devices to indicate refrigerant release past first device.

4. For Chillers Using R-123: Manufacturer's standard offering complying with ASHRAE 15 and ASHRAE 147 Rupture disc constructed of frangible carbon or spring-loaded, pressure relief valve; single- or multiple-reseating type.

5. For Chillers Using R-134a: ASME-rated, spring-loaded, pressure relief valve; single- or multiple-reseating type. Pressure relief valve(s) shall be provided for each heat exchanger. Condenser shall have dual valves with one being redundant and configured to allow either valve to be replaced without loss of refrigerant.

D. Refrigeration Transfer: Provide service valves and other factory-installed accessories required to facilitate transfer of refrigerant from chiller to a remote refrigerant storage and recycling system. Comply with requirements in ASHRAE 15 and ASHRAE 147.

E. Refrigerant Isolation for Chillers Using R-134a:

1. Suction side of compressor from evaporator shall have an isolation valve to allow for isolation and storage of full refrigerant charge in the chiller evaporator shell.

F. Purge System:

1. For chillers operating at sub-atmospheric pressures (using R-123 refrigerant), factory install an automatic purge system for collection and return of refrigerant and lubricating oil

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Bid Addendum 2/18/25 and for removal of non-condensables, including, but not limited to, water, water vapor, and non-condensable gases.

2. System shall be of thermal purge design, refrigerant, or air cooled, and equipped with a carbon filter that includes an automatic regeneration cycle.

3. Factory wire to chiller's main power supply and system complete with controls, piping, and refrigerant valves to isolate the purge system from the chiller.

4. Construct components of noncorrodible materials.

5. Controls shall interface with chiller control panel to indicate modes of operation, set points, data reports, diagnostics, and alarms.

6. Efficiency of not more than 0.02 lb of refrigerant per pound of air when rated according to

AHRI 580.

7. Operation independent of chiller according to ASHRAE 147.

G. Positive-Pressure System:

1. For chillers operating at sub-atmospheric pressures (using R-123 refrigerant), factory install an automatic positive-pressure system.

2. During nonoperational periods, positive-pressure system shall automatically maintain a positive pressure for atmosphere in the refrigerant-pressure vessel of not less than 0.5 psig adjustable up to a pressure that remains within the vessel design pressure limits.

3. System shall be factory wired and include controller, electric heat, pressure transmitter, or switch.

2.6 EVAPORATOR

A. Description: Shell-and-tube design, with water in tubes and refrigerant surrounding tubes within shell. Shell is separate from condenser.

B. Shell Material: Carbon-steel rolled plates with continuously welded seams or seamless pipe.

C. Designed to prevent liquid refrigerant carryover from entering compressor.

D. Evaporator shall have sight glass or other form of positive visual verification of liquid-refrigerant level.

E. Tubes:

1. Individually replaceable from either end and without damage to tube sheets and other tubes.

2. Mechanically expanded into end sheets and physically attached to intermediate tube sheets.

3. Material: Copper.

4. Nominal OD: Manufacturer's choice.

5. Minimum Wall Thickness: Manufacturer's choice.

6. External Finish: Manufacturer's standard.

7. Internal Finish: Enhanced.

F. End Tube Sheets: Continuously welded to each end of shell; drilled and reamed to accommodate tubes, with positive seal between fluid in tubes and refrigerant in shell.

G. Intermediate Tube Sheets: Installed in shell and spaced along length of tube at intervals required to eliminate vibration and to avoid contact of tubes resulting in abrasion and wear, but not more than 4 feet apart.

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H. Flow Sensor: Thermal dispersion type, factory calibrated for project-specific application.

2.7 CONDENSER

A. Description: Shell-and-tube design, with water in tubes and refrigerant surrounding tubes within shell. Shell is separate from evaporator.

B. Shell Material: Carbon-steel rolled plates with continuously welded seams or seamless pipe.

C. Designed to prevent direct impingement of high-velocity hot gas from compressor discharge on tubes.

D. Condenser shall have sight glass or other form of positive visual verification of refrigerant charge and condition.

E. Tubes:

1. Individually replaceable from either end and without damage to tube sheets and other tubes.

2. Mechanically expanded into end sheets and physically attached to intermediate tube sheets.

3. Material: Copper.

4. Nominal OD: Manufacturer's choice.

5. Minimum Wall Thickness: Manufacturer's choice.

6. External Finish: Manufacturer's standard.

7. Internal Finish: Enhanced.

F. End Tube Sheets: Continuously welded to each end of shell; drilled and reamed to accommodate tubes, with positive seal between fluid in tubes and refrigerant in shell.

G. Intermediate Tube Sheets: Installed in shell and spaced along length of tube at intervals required to eliminate vibration and to avoid contact of tubes resulting in abrasion and wear, but not more than 4 feet apart.

H. Flow Sensor: Thermal dispersion type, factory calibrated for project-specific application.

2.8 INSULATION

A. Closed-cell, flexible elastomeric thermal insulation complying with ASTM C534, Type I for tubular materials and Type II for sheet materials.

1. Thickness: 3/4 inch.

B. Adhesive: As recommended by insulation manufacturer.

C. Factory-applied insulation over all cold surfaces of chiller capable of forming condensation.

Components shall include, but not be limited to, evaporator shell and end tube sheets, evaporator water boxes including nozzles, refrigerant suction pipe from evaporator to compressor, cold surfaces of compressor, refrigerant-cooled motor, and auxiliary piping.

1. Apply adhesive to 100 percent of insulation contact surface.

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2. Before insulating steel surfaces, prepare surfaces for paint, and prime and paint as indicated for other painted components. Do not insulate unpainted steel surfaces.

3. Seal seams and joints to provide a vapor barrier.

4. After adhesive has fully cured, paint exposed surfaces of insulation to match other painted parts.

5. Manufacturer has option to factory or field insulate chiller components installed in multiple pieces to reduce potential for damage during installation.

6. Manufacturer has option to factory or field insulate water boxes and nozzles to reduce potential for damage during installation.

D. Field-Applied Insulation:

1. Components that are not factory insulated shall be field insulated to comply with requirements indicated.

2. Manufacturer shall be responsible for chiller insulation whether factory or field installed, to ensure manufacturer is the single point of responsibility for chillers.

3. Manufacturer factory-authorized service representative shall instruct and supervise installation of field-applied insulation.

4. After field-applied insulation is complete, paint insulation to match factory-applied finish.

2.9 ELECTRICAL

A. Factory installed and wired, and functionally tested at factory before shipment.

B. Single-point, field-power connection to nonfused disconnect switch. Minimum short circuit current rating (SCCR) according to UL 508 shall be as required by electrical power distribution system, but not less than 42,000 A.

1. Branch power circuit to each motor, electric heater, dedicated electrical load, and control, with circuit breaker or disconnect switch having SCCR to match main disconnecting means.

a. NEMA KS 1, heavy-duty fusible switch with rejection-type fuse clips rated for fuses. Select and size fuses to provide Type 2 protection according to IEC 60947- 4-1.

b. NEMA AB 1, motor-circuit protector (circuit breaker) with field-adjustable, short-circuit-trip set point.

2. NEMA ICS 2-rated motor controller for auxiliary motors, hand-off-auto switch, and overcurrent protection for each motor. Provide variable-frequency controller for each variable-speed motor furnished.

3. Control-circuit transformer with primary and secondary side fuses.

C. Terminal blocks with numbered wiring to match wiring diagram. Spare wiring terminal block for connection to external controls or equipment.

D. Factory-installed wiring located outside of enclosures shall be installed in metal raceway, and terminal connections shall be made with not more than a 24-inch length of liquid-tight flexible metallic conduit.

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E. Factory install and wire capacitor bank for the purpose of power factor correction to 0.95 at full load.

1. If capacitors are mounted in a dedicated enclosure, use same NEMA enclosure type as that for motor controller. Provide enclosure with service entrance knockouts and bushings for conduit.

2. Capacitors shall be of non-PCB dielectric fluid, metallized electrode design, with low loss with low-temperature rise. The kVAR ratings shall be indicated and shall not exceed the maximum limitations set by NFPA 70. Provide individual cells as required.

3. Provide each cell with current-limiting replaceable fuses and carbon-film discharge resistors to reduce residual voltage to less than 50 V within one minute after de-energizing.

4. Provide a ground terminal and a terminal block or individual connectors for phase connection.

2.10 MOTOR CONTROLLER

A. Enclosure: Factory installed, unit mounted, NEMA 250, Type 1, with hinged full-front access door with lock and key or padlock and key.

B. Control Circuit: Obtained from integral control power transformer with a control power transformer source of enough capacity to operate connected control devices.

C. Overload Relay shall be sized according to UL 1995 or shall be an integral component of chiller control microprocessor.

D. Across-the-Line Controller: NEMA ICS 2, Class A, full voltage, non-reversing; include isolation switch and current-limiting fuses.

E. Star-Delta, Reduced-Voltage Controller: NEMA ICS 2, closed transition.

F. Autotransformer Reduced-Voltage Controller: NEMA ICS 2, closed transition; include isolation switch and current-limiting fuses.

G. Solid-State, Reduced-Voltage Controller: NEMA ICS 2.

1. Include surge suppressor in solid-state power circuits to provide three-phase protection against damage from supply voltage surges 10 percent or more above nominal line voltage.

2. Visual indication of motor and control status, including the following conditions:

a. Controller on.

b. Overload trip.

c. Loss of phase.

d. Starter fault.

H. Accessories: Devices shall be factory installed in controller enclosure unless otherwise indicated.

1. Externally Operated, Door-Interlocked Disconnect: Short circuit current rating (SCCR) according to UL 508 shall be as required by electrical power distribution system, but not less than 42,000 A.

2. Push-Button Stations, Pilot Lights, and Selector Switches: NEMA ICS 2, heavy-duty type.

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3. Stop and Lockout Push-Button Station: Momentary-break, push-button station with a factory-applied hasp arranged so padlock can be used to lock push button in depressed position with control circuit open.

4. Control Relays: Time-delay relays.

5. Elapsed-Time Meters: Numerical readout in hours on face of enclosure.

6. Number-of-Starts Counter: Numerical readout on face of enclosure.

7. Meters: Panel type, 2-1/2 inches with 90-degree scale and 1 percent accuracy. Where indicated, provide transfer device with an off position. Meters shall indicate the following:

a. Ammeter: Output current for each phase, with current sensors rated to suit application.

b. Voltmeter: Output voltage for each phase.

c. Frequency Meter: Output frequency.

d. Real-time clock with current time and date.

e. Total run time.

8. Multifunction Digital-Metering Monitor: Microprocessor-based unit suitable for three- or four-wire systems and with the following features:

a. Selectable, digital display of the following:

1) Phase Currents, Each Phase: Plus or minus 1 percent.

2) Phase-to-Phase Voltages, Three Phase: Plus or minus 1 percent.

3) Phase-to-Neutral Voltages, Three Phase: Plus or minus 1 percent.

4) Three-Phase Real Power: Plus or minus 2 percent.

5) Three-Phase Reactive Power: Plus or minus 2 percent.

6) Power Factor: Plus or minus 2 percent.

7) Frequency: Plus or minus 0.5 percent.

8) Integrated Demand with Demand Interval Selectable from Five to 60

Minutes: Plus or minus 2 percent.

9) Accumulated energy, in megawatt hours (joules), plus or minus 2 percent;

stored values unaffected by power outages for up to 72 hours.

b. Mounting: Display and control unit flush or semi-recessed in instrument compartment door.

9. Phase-Failure, Phase-Reversal, Undervoltage Relays: Solid-state sensing circuit with adjustable undervoltage setting and isolated output contacts for hardwired connection.

10. Power Protection: Chiller shall shut down within six cycles of power interruption.

2.11 VARIABLE-FREQUENCY CONTROLLER

A. Motor controller shall be factory mounted and wired on the chiller to provide a single-point, field-power termination to the chiller and its auxiliaries.

B. Description: NEMA ICS 2; listed and labeled according to UL 508 as a complete unit and arranged to provide variable speed by adjusting output voltage and frequency.

C. Enclosure: Unit mounted, NEMA 250, Type 1, with hinged full-front access door with lock and key.

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D. Integral Disconnecting Means: Door-interlocked, NEMA AB 1, instantaneous-trip circuit breaker with lockable handle. Minimum short circuit current rating (SCCR) according to UL 508 shall be as required by electrical power distribution system, but not less than 42,000 A.

E. Technology: Pulse width modulated (PWM) output with insulated gate bipolar transistors;

suitable for variable torque loads.

F. Controller shall consist of a rectifier converter section, a digital/analog driver regulator section, and an inverter output section.

1. Rectifier section shall be a full-wave diode bridge that changes fixed-voltage, fixed-frequency, ac line power to a fixed dc voltage. Silicon controller rectifiers, current source inverters, and paralleling of devices are unacceptable. Rectifier shall be insensitive to phase rotation of the ac line.

2. Regulator shall provide full digital control of frequency and voltage.

3. Inverter section shall change fixed dc voltage to variable-frequency, variable ac voltage for application to a squirrel-cage motor. Inverter shall produce a sine-coded, PWM output waveform and shall conduct no RFI back to the input power supply.

G. Output Rating: Three phase, with voltage proportional to frequency throughout voltage range.

H. Operating Requirements:

1. Input AC Voltage Tolerance: 460-V ac, plus 10 percent or 506 V maximum.

2. Input frequency tolerance of 60 Hz, plus or minus 2 Hz.

3. Capable of driving full load, without derating, under the following conditions:

a. Ambient Temperature: Zero to 40 deg C.

b. Relative Humidity: Up to 90 percent (noncondensing).

c. Altitude: Up to 3300 feet.

4. Minimum Efficiency: 96 percent at 60 Hz, full load.

5. Minimum Displacement Primary-Side Power Factor: 95 percent without harmonic filter;

98 percent with harmonic filter.

6. Overload Capability: 1.05 times the full-load current for seven seconds.

7. Starting Torque: As required by compressor-drive assembly.

8. Speed Regulation: Plus or minus 1 percent.

9. Isolated control interface to allow controller to follow control signal over a 10:1 speed range.

10. To avoid equipment resonant vibrations, provide critical speed lockout circuitry to allow bands of operating frequency at which controller shall not operate continuously.

11. Capable of being restarted into a motor coasting in either the forward or reverse direction without tripping.

I. Internal Adjustability Capabilities: Integral to controller or through chiller control panel.

1. Minimum Output Frequency: 6 Hz.

2. Maximum Output Frequency: 60 Hz.

3. Acceleration: Two seconds to a minimum of 60 seconds.

4. Deceleration: Two seconds to a minimum of 60 seconds.

5. Current Limit: 30 percent to a minimum of 100 percent of maximum rating.

J. Self-Protection and Reliability Features: Subjecting the controller to any of the following conditions shall not result in component failure or the need for replacement:

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1. Overtemperature.

2. Short circuit at controller output.

3. Ground fault at controller output. Variable-frequency controller shall be able to start a grounded motor.

4. Open circuit at controller output.

5. Input undervoltage.

6. Input overvoltage.

7. Loss of input phase.

8. Reverse phase.

9. AC line switching transients.

10. Instantaneous overload, line to line or line to ground.

11. Sustained overload exceeding 100 percent of controller-rated current.

12. Starting a rotating motor.

K. Motor Protection: Controller shall protect motor against overvoltage and undervoltage, phase loss, reverse phase, overcurrent, overtemperature, and ground fault.

L. Automatic Reset and Restart:

1. Capable of three restarts after controller fault or on return of power after an interruption and before shutting down for manual reset or fault correction.

2. Controller shall be capable of automatic restart on phase-loss and overvoltage and undervoltage trips.

M. Visual Indication: On face of controller enclosure or chiller control enclosure. indicating the following conditions:

1. Power on.

2. Run.

3. Overvoltage.

4. Line fault.

5. Overcurrent.

6. External fault.

7. Motor speed (percent).

8. Fault or alarm status (code).

9. DC-link voltage.

10. Motor output voltage.

11. Input kilovolt amperes.

12. Total power factor.

13. Input kilowatts.

14. Input kilowatt-hours.

15. Three-phase input voltage.

16. Three-phase output voltage.

17. Three-phase input current.

18. Three-phase output current.

19. Three-phase input voltage THD.

20. Three-phase input current THD.

21. Output frequency (Hertz).

22. Elapsed operating time (hours).

23. Diagnostic and service parameters.

N. Operator Interface: At controller or chiller control panel; with start-stop and auto-manual selector with manual-speed-control potentiometer.

O. Control Signal Interface:

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1. Electric Input Signal Interface: A minimum of two analog inputs (0 to 10 V or 0/4-20 mA) and six programmable digital inputs.

2. Manufacturer has option to incorporate control signal interface into chiller control panel.

P. Active Harmonic Distortion Filter:

1. Factory mounted and wired to limit total voltage and current distortion to 5 percent.

2. Factory mounted and wired to limit total demand distortion (TDD) to 5 percent of unit input.

Q. Cooling: Water cooled.

R. Accessories: Devices shall be factory installed in controller enclosure unless otherwise indicated.

1. Control Relays: Auxiliary and adjustable time-delay relays.

S. Chiller Capacity Control Interface: Equip chiller with adaptive control logic to automatically adjust the compressor motor speed and the compressor pre-rotation inlet vane position independently to achieve maximum part-load efficiency in response to sensor inputs that are integral to the chiller controls.

2.12 CONTROLS

A. Control: Standalone and microprocessor based, with all memory stored in nonvolatile memory, so that reprogramming is not required on loss of electrical power.

B. Enclosure: Unit mounted, NEMA 250, Type 1, hinged or lockable, factory wired with a single-point, with field-power connection and a separate control circuit.

C. Factory-installed wiring outside of enclosures shall be in a NFPA 70-approved raceway. Make terminal connections with liquid-tight or flexible metallic conduit.

D. Operator Interface: Multiple-character digital or graphic display with dynamic update of information and with keypad or touch-sensitive display located on front of control enclosure. In either imperial or metric units selectable through the interface, display the following information:

1. Date and time.

2. Operating or alarm status.

3. Fault history with not less than last 10 faults displayed.

4. Set points of controllable parameters.

5. Trend data.

6. Operating hours.

7. Number of chiller starts.

8. Outdoor-air temperature or space temperature if required for chilled-water reset.

9. Entering- and leaving-fluid temperatures of evaporator and condenser.

10. Difference in fluid temperatures of evaporator and condenser.

11. Fluid flow of evaporator and condenser.

12. Fluid-pressure drop of evaporator and condenser.

13. Refrigerant pressures in evaporator and condenser.

14. Refrigerant saturation temperature in evaporator and condenser shell.

15. Compressor refrigerant suction and discharge temperature.

16. Compressor bearing temperature.

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17. Motor bearing temperature.

18. Motor winding temperature.

19. Oil temperature.

20. Oil discharge pressure.

21. Phase current.

22. Percentage of motor-rated load amperage.

23. Phase voltage.

24. Demand power (kilowatts).

25. Energy use (kilowatt-hours).

26. Power factor.

27. For chillers equipped with variable-frequency controllers and harmonic filters, include the following:

a. Output voltage and frequency.

b. Voltage THD for each phase.

c. Supply current TDD for each phase.

d. Inlet vane position.

e. Controller internal ambient temperature.

f. Heatsink temperature.

28. Purge suction temperature if purge system is provided.

29. Purge elapsed time if purge system is provided.

30. The display items listed above will differ from manufacturer to manufacturer.

E. Control Functions:

1. Manual or automatic startup and shutdown time schedule.

2. Entering and leaving chilled-water temperatures, control set points, and motor load limits.

Evaporator-fluid temperature shall be reset based on return-water temperature.

3. Current limit and demand limit.

4. Condenser-fluid temperature.

5. External chiller emergency stop.

6. Variable evaporator flow.

7. Thermal storage.

F. Manually Reset Safety Controls: The following conditions shall shut down chiller and require manual reset:

1. Low evaporator pressure; high condenser pressure.

2. Low evaporator-fluid temperature.

3. Low oil differential pressure.

4. High or low oil pressure.

5. High oil temperature.

6. High compressor-discharge temperature.

7. Loss of condenser-fluid flow.

8. Loss of evaporator-fluid flow.

9. Motor overcurrent.

10. Motor overvoltage.

11. Motor undervoltage.

12. Motor phase reversal.

13. Motor phase failure.

14. Sensor- or detection-circuit fault.

15. Processor communication loss.

16. Motor controller fault.

17. Extended compressor surge.

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18. Excessive air-leakage detection for chillers using R-123 refrigerant.

G. Trending: Capability to trend analog data of up to five parameters simultaneously over an adjustable period and frequency of polling.

H. Security Access: Provide electronic security access to controls through identification and password, with at least three levels of access: view only; view and operate; and view, operate, and service.

I. Control Authority: At least four conditions: Off, local manual control at chiller, local automatic control at chiller, and automatic control through a remote source.

J. Communication Port: RS-232 port, USB 2.0 port or higher, or equivalent connection capable of connecting a printer.

K. BAS System Interface: Factory install hardware and software to enable system to monitor, control, and display chiller status and alarms.

1. Hardwired I/O Points:

a. Monitoring: On-off status, common trouble alarm, and electrical power consumption (kilowatt-hours).

b. Control: On-off operation, chilled-water, and discharge temperature set-point adjustment.

2. Communication Interface: ASHRAE 135 (BACnet) open-protocol communication interface shall enable control system operator to remotely control and monitor the chiller from an operator workstation.

a. Control features and monitoring points displayed locally at chiller control panel shall be available through the control system, including, as a minimum, the following:

1) Start-stop command from remote source.

2) Unit control source, local, analog, digital or modem.

3) Chiller control panel start-stop.

4) Accumulated operating hours.

5) Accumulated starts.

6) Compressor motor status.

7) Unit operation code.

8) Unit safety fault code.

9) Unit cycling fault code.

10) Chilled-water pump status.

11) Chilled-water flow proof.

12) Chilled-water entering temperature.

13) Chilled-water leaving temperature.

14) Chilled-water leaving temperature set-point adjustment from remote source.

15) Condenser(s) water entering temperature.

16) Condenser(s) water leaving temperature.

17) Evaporator refrigerant pressure.

18) Condenser(s) refrigerant pressure.

19) Evaporator refrigerant saturation temperature.

20) Condenser(s) refrigerant saturation temperature.

21) Refrigerant discharge temperature.

22) Refrigerant level.

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23) Refrigerant liquid level set point.

24) Oil pressure differential.

25) Oil sump pressure.

26) Oil pump pressure.

27) Oil sump temperature.

28) High-speed thrust bearing proximity position.

29) High-speed thrust bearing proximity reference.

30) Motor current percent of full-load amps.

31) Motor current phase A.

32) Motor current phase B.

33) Motor current phase C.

34) Motor current set-point adjustment from remote source.

35) Motor bearing shaft end vibration.

36) Motor bearing opposite shaft end vibration.

37) Motor bearing shaft end temperature.

38) Motor bearing opposite shaft end temperature.

39) Motor average winding temperature.

40) Variable-frequency controller selection, auto or fixed.

41) Variable-frequency controller output voltage.

42) Variable-frequency controller input power, rate.

43) Variable-frequency controller input power, consumption.

44) Variable-frequency controller DC bus voltage.

45) Variable-frequency controller inverter link current.

46) Variable-frequency controller output frequency.

47) Variable-frequency controller internal ambient temperature.

48) Variable-frequency controller converter heatsink temperature.

49) Variable-frequency controller harmonic filter installed, true or false.

50) Harmonic Filter THD at maximum voltage, percent.

51) Harmonic filter total demand distortion at maximum current, percent.

52) Harmonic filter total supply kVA.

53) Anti-recycle time remaining.

54) Liquid line solenoid.

55) Pre-rotation vanes position.

56) Adaptive capacity control valve surge map installed, true or false.

57) Adaptive capacity control new surge point, true or false.

58) Adaptive capacity control surge type, pressure differential or current.

59) Adaptive capacity control surge count.

60) Adaptive capacity control PRV position.

61) Adaptive capacity control output frequency.

L. Quick-Start Feature:

1. Automatically restore chiller operation up to 100 percent capacity within five minutes after a 15-second power interruption.

2. Quick-start feature shall ensure guide vanes remain open following a power interruption event and quick ramp-up speed logic is employed to facilitate shortest time to deliver chilled water at set-point temperature.

3. Chiller manufacturer shall provide integral UPS unit(s) with chiller controls if required to keep chiller integral controls operational to comply with requirement.

4. Chiller manufacturer shall demonstrate chiller start time with the quick-start feature enabled while simulating power fault, power service return, restart time, and capacity control, to produce desired chilled-water temperature at load indicated.

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2.13 ACCESSORIES

A. Flow Switches:

1. Chiller manufacturer shall furnish a switch for each evaporator and condenser and verify field-mounting location before installation.

2. Paddle Flow Switches:

a. Vane operated to actuate a double-pole, double-throw switch, with one pole field wired to the chiller control panel and the other pole field wired to the DDC system for HVAC.

b. Contacts: Platinum alloy, silver alloy, or gold-plated switch contacts with a rating of 10 A at 120-V ac.

c. Pressure rating equal to pressure rating of heat exchanger.

d. Construct body and wetted parts of Type 316 stainless steel.

e. House switch in a NEMA 250, Type 4 enclosure constructed of die-cast aluminum.

f. Vane length to suit installation.

3. Pressure-Differential Switches:

a. Construction: Wetted parts of body and trim constructed of Type 316 stainless steel.

b. Performance: Switch shall withstand, without damage, the full-pressure rating of the heat exchanger applied to either port and exhibit zero set-point shift due to variation in working pressure.

c. Set Point: Screw type, field adjustable.

d. Electrical Connections: Internally mounted screw-type terminal blocks.

e. Switch Enclosure: NEMA 250, Type 4.

f. Switch Action: Double-pole, double-throw switch, with one pole field wired to the chiller control panel and the other pole field wired to the DDC system for HVAC.

B. Vibration Isolation:

1. Chiller manufacturer shall furnish vibration isolation for each chiller.

2. Neoprene Pad:

a. Two layers of 0.375-inch-thick, ribbed- or waffle-pattern neoprene pads separated by a 16-gage, stainless-steel plate.

b. Fabricate pads from 40- to 50-durometer neoprene.

c. Provide stainless-steel square bearing plate to load the pad uniformly between 20 and 40 psig with a 0.12- to 0.16-inch deflection.

3. Spring Isolator:

a. Stable in operation and designed for not less than 30 percent reserve deflection beyond actual operating conditions.

b. Isolators shall be designed so that the Kx/Ky ratio shall be 1.0 or more for stability.

c. Provide PVC or neoprene-coated springs and hot-dip, galvanized-steel components. Aluminum components shall be etched and painted. Nuts, bolts, and washers shall be zinc electroplated.

d. Isolators shall be adjustable and with an open spring, having one or more coil springs attached to a top compression plate and a baseplate.

e. An elastomeric pad with a minimum thickness of 0.25 inch shall be bonded to the baseplate.

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f. Spring assembly shall be removable and fit within a welded-steel enclosure consisting of a top plate and rigid lower housing, which serves as a blocking device during installation.

g. Isolated restraining bolts shall not be engaged during normal operation and shall connect the top plate and lower housing to prevent the isolated equipment from rising when drained of fluid.

h. Isolators shall be selected for a nominal 1-inch deflection.

i. Integrate seismic restraints in applications that require seismic requirements.

2.14 SOURCE QUALITY CONTROL

A. Perform functional run tests of chillers before shipping.

B. Factory test and inspect evaporator and condenser according to ASME Boiler and Pressure Vessel Code: Section VIII, Division 1.

C. Factory test and inspect evaporator and condenser according to ASME Boiler and Pressure Vessel Code: Section VIII, Division 1. Pressure test fluid side of heat exchangers, including water boxes, to 1.5 times the rated pressure. Pressure proof test refrigerant side of heat exchangers to a minimum of 45 psig. Vacuum and pressure test for leaks.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine chillers before installation. Reject chillers that are damaged.

B. Examine roughing-in for equipment support, anchor-bolt sizes and locations, piping, control and electrical connections to verify actual locations, sizes, and other conditions affecting chiller performance, maintenance, and operations before equipment installation.

1. Chiller locations indicated on Drawings are approximate. Determine exact locations before roughing-in for piping and control and electrical connections.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 CHILLER INSTALLATION

A. Coordinate sizes and locations of concrete bases with actual equipment provided. Cast anchor-bolt inserts into bases.

B. Coordinate sizes, locations, and anchoring attachments of structural-steel support structures.

C. Install chillers on support structure indicated.

D. Equipment Mounting:

1. Install chillers on cast-in-place concrete equipment bases. Comply with requirements for equipment bases and foundations specified in Section 033000 "Cast-in-Place Concrete."

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2. Comply with requirements for vibration isolation and seismic-control devices specified in Section 230548 "Vibration and Seismic Controls for HVAC."

3. Comply with requirements for vibration isolation devices specified in Section 230548.13 "Vibration Controls for HVAC."

E. Maintain manufacturer's recommended clearances for service and maintenance.

F. Maintain clearances required by governing code.

G. Chiller manufacturer's factory-trained service personnel shall charge chiller with refrigerant and fill with oil if not factory installed.

H. Install separate devices furnished by manufacturer and not factory installed.

1. Chillers shipped in multiple major assemblies shall be field assembled by chiller manufacturer's factory-trained service personnel.

I. Comply with requirements for piping specified in Section 232113 "Hydronic Piping," Section 232116 Hydronic Piping Specialties," and Section 232300 "Refrigerant Piping."

Drawings indicate general arrangement of piping, fittings, and specialties.

J. Where installing piping adjacent to chillers, allow space for service and maintenance.

K. Evaporator-Fluid Connections:

1. Connect to evaporator inlet with shutoff valve, strainer, flexible connector, thermometer, and plugged tee with pressure gage.

2. Connect to evaporator outlet with shutoff valve, balancing valve, flexible connector, thermometer, plugged tee with shutoff valve and pressure gage, flow meter, and drain…