APPENDIX G - Lowell Justice Center - Multistack Centrifugal Chiller O M Manual.pdf

MASSACHUSETTS TRIAL COURT | REGION 3 CHILLER

SERVICE AGREEMENT

Region 3 Chiller Service Agreement RFP | Page 17 of 30

COMMONWEALTH OF MASSACHUSETTS

MASSACHUSETTS TRIAL COURT

REQUEST FOR PROPOSALS

Region 3 Chiller and Associated HVAC Equipment Preventive Maintenance and Repair Service Agreement

APPENDIX G

Lowell Justice Center - Multistack Centrifugal Chiller O&M Manual

This appendix is incorporated by reference into the Region 3 Chiller Service Agreement Request for Proposals.

Facilities Management & Capital Planning

Dimeo Construction Company 75 Chapman Street Providence, Rhode Island 02905 Phone: (401) 781-9800

Project: 800-15 - Lowell Justice Center 370 Jackson Street

Lowell, Massachusetts 01854

1.6-A Centrifugal Water Chillers O&M Manual Rev. 1 SPEC SECTION: 236416 - Centrifugal Water Chillers SUBMITTAL MANAGER: Charles Benjamin (Dimeo Construction

Company)

STATUS: Open DATE CREATED: 01/30/2020

ISSUE DATE: 01/30/2020 REVISION: 1

RESPONSIBLE

CONTRACTOR:

Patrick J. Kennedy & Sons, Inc. RECEIVED FROM: Bob Collins

RECEIVED DATE: SUBMIT BY: 01/28/2020

FINAL DUE DATE: 02/6/2020 LOCATION:

SUB JOB: COST CODE:

LEAD TIME: TYPE: Closeout

APPROVERS: Leah Fishback (ARUP), Finegold Alexander (Finegold Alexander Architects)

BALL IN COURT:

Charles Benjamin (Dimeo Construction Company)

DISTRIBUTION:

DESCRIPTION:

ATTACHMENTS:

236416-003 1.6-A Centrifugal Water Chillers O&M Manual DCC_SUB.pdf

SUBMITTAL WORKFLOW

NAME SUBMITTER/

APPROVER SENT DATE DUE DATE RETURNED

DATE RESPONSE ATTACHMENTS COMMENTS

Leah Fishback Approver 1/30/2020 2/6/2020 2/7/2020

Reviewed, Make Corrections Noted

Arup response 236416-003-1 1.6-A Cntrf Water Chillers O&M.pdf

Attached please find Arup response

Finegold Alexander Approver 2/7/2020 2/6/2020 2/10/2020 Reviewed, For Record Only

236416-003-1 1.6-A Cntrf Water Chillers O&M.pdf

The attached submittal has been reviewed for record.

See engineer's stamp for comments.

-Leah Wolkovich- Quartey

BY DATE COPIES TO

Dimeo Construction Company Page 1 of 1 Printed On: 02/11/2020 10:53 AM

Submittal #236416-003.1 236416 - Centrifugal Water

Chillers https://app.procore.com/199218/project/submittal_logs/document_downloader?attachment_id=2223461898&item_id=20448706&item_type=SubmittalLog&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2234016192&item_id=33445243&item_type=SubmittalLogApprover&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2234016192&item_id=33445243&item_type=SubmittalLogApprover&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2234016192&item_id=33445243&item_type=SubmittalLogApprover&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2234016192&item_id=33445243&item_type=SubmittalLogApprover&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2235753894&item_id=33445244&item_type=SubmittalLogApprover&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2235753894&item_id=33445244&item_type=SubmittalLogApprover&project_id=199218 https://app.procore.com/199218/project/submittal_logs/20448706/submittal_log_approvers/document_downloader?attachment_id=2235753894&item_id=33445244&item_type=SubmittalLogApprover&project_id=199218

Submittal Transmittal

LOWELL JUDICIAL CENTER

Attention:

Project #: 242633-00

Leah Fishback

60 State Street Boston, MA 02109 t +617 864 2987

Returned: 2/7/2020

Arup

Review is only for general conformance with the design concept of the project and general compliance with the information given in the contract documents. Contractor is responsible for quantities and dimensions which shall be confirmed and correlated at the job site; checking for deviations between the field, submittal and the contract documents alerting Arup of same; fabrication processes and techniques; the means and methods of construction; coordination of its work with that of all other trades; and performing all work in a safe and satisfactory manner. This review does not modify Contractor?s duty to comply with the contract documents and any action shown is subject to requirements of plans and specifications. This review does not increase Arup's standard of care or scope of services and Contractor shall immediately notify Arup of any intent to make a claim based on this submittal.

60 State Street Boston, MA 02109

Submittal Package No. Description Stamps

236416-003-1 1.6-A Centrifugal Water Chillers O&M Manual DCC

See comments on attachment.

Hilary Williams

[X] MAKE CORRECTIONS NOTED,

RESUBMITTAL NOT REQUIRED

Storage Marker:

Received: 1/31/2020

236416-003-1

Dimeo Construction Company 75 Chapman Street Providence, Rhode Island 02905 Phone: (401) 781-9800

Project: 800-15 - Lowell Justice Center 370 Jackson Street

Lowell, Massachusetts 01854

1.6-A Centrifugal Water Chillers O&M Manual Rev. 1 SPEC SECTION: 236416 - Centrifugal Water Chillers SUBMITTAL MANAGER: Charles Benjamin (Dimeo Construction

Company)

STATUS: Open DATE CREATED: 01/30/2020

ISSUE DATE: 01/30/2020 REVISION: 1

RESPONSIBLE

CONTRACTOR:

Patrick J. Kennedy & Sons, Inc. RECEIVED FROM: Bob Collins

RECEIVED DATE: SUBMIT BY: 01/28/2020

FINAL DUE DATE: 02/6/2020 LOCATION:

SUB JOB: COST CODE:

LEAD TIME: TYPE: Closeout

APPROVERS: Leah Fishback (ARUP), Finegold Alexander (Finegold Alexander Architects)

BALL IN COURT:

Leah Fishback (ARUP)

DISTRIBUTION:

DESCRIPTION:

ATTACHMENTS:

236416-003 1.6-A Centrifugal Water Chillers O&M Manual DCC_SUB.pdf

SUBMITTAL WORKFLOW

NAME SUBMITTER/

APPROVER SENT DATE DUE DATE RETURNED

DATE RESPONSE ATTACHMENTS COMMENTS

Leah Fishback Approver 1/30/2020 2/6/2020 Pending

Finegold Alexander Approver 2/6/2020 Pending

BY DATE COPIES TO

Dimeo Construction Company Page 1 of 1 Printed On: 01/30/2020 06:20 PM

Submittal #236416-003.1 236416 - Centrifugal Water

Chillers https://app.procore.com/199218/project/submittal_logs/document_downloader?attachment_id=2223461898&item_id=20448706&item_type=SubmittalLog&project_id=199218

Job: Lowell Justice Center

Contractors Stamp

Architects Stamp

Engineers Stamp

Contractor Comments:

Architect Comments:

Engineer Comments:

Submittal No:

Submittal Title:

Sent Date:

Due Date:

Submittal Cover Page

Lowell, Ma DCC Job #800-15

236416-003

1.6-A Centrifugal Water Chillers O&M Manual

01/14/2020

01/28/2020

DCC Project No. 074‐10

Prepared by: Date:

Submittal No.

Reviewed for General Acceptance only. This review does not relieve the subcontractor of the responsibility for making the work conform to the requirements of the contract. The subcontractor is responsible for all dimensions, correct fabrication and accurate fit with the work of other trades.

Yale‐ School of Management

DIMEO CONSTRUCTION COMPANY

Project Name DCC Project No.

cbenjamin 9:05 am, Jan 14, 2020

236416-003

Lowell Justice Center 800-15

ARUP (AS DEFINED IN CONTRACT) SUBMITTAL REVIEW

NO EXCEPTION TAKEN

MAKE CORRECTIONS NOTED, RESUBMITTAL NOT REQUIRED

REVISE AND RESUBMIT, NOT ACCEPTED FOR REASONS GIVEN

SUBMITTAL NOT REVIEWED, REASONS MAY BE GIVEN AS NOTED

FOR INFORMATIONAL PURPOSES ONLY

NOT REQUESTED

REVIEWED FOR LOADS ONLY

ON STRUCTURES

BUILDING SYSTEMS

HVAC

ELECTRICAL

PLUMBING

FIRE PROTECTION

REJECTED

Review is only for general conformance with the design concept of the project and general compliance with the information given in the contract documents. Contractor is responsible for quantities and dimensions which shall be confirmed and correlated at the job site; checking for deviations between the field, submittal and the contract documents alerting Arup of same; fabrication processes and techniques; the means and methods of construction; coordination of its work with that of all other trades; and performing all work in a safe and satisfactory manner. This review does not modify Contractor’s duty to comply with the contract documents and any action shown is subject to requirements of plans and specifications. This review does not increase Arup’s standard of care or scope of services and Contractor shall immediately notify Arup of any intent to make a claim based on this submittal.

BY ____________________ DATE_________________

Based on the understanding that this will be included in the final O&M manual with all other items requested in 230500.

H Williams 2/7/20

SUBMITTAL REVIEW

Architect’s review is for general conformance with the design concept and contract documents. Markings or comments shall not be construed as relieving the contractor from compliance with the project plans and specifications, nor departures therefrom. The contractor remains responsible for details and accuracy, for confirming and correlating all quantities and dimensions, for selecting fabrication processes, for techniques of assembly, and for performing his work in a safe manner.

ARCHITECT'S REVIEW RESPONSE REQUIRED

BY: DATE:Leah Wolkovich-Quartey 02/10/2020

Note Markings

No Exceptions Taken

Rejected

Not Reviewed

Resubmit For Record

Revise & Resubmit✘

✘ Resubmit Not Required

MS0122F through MS1402F MS5082 through MS5202

Gen 2 Water-Cooled MagLev™ Centrifugal Chillers

Installation, Operation, Maintenance

Gen 2 Water-Cooled MagLev™ Chillers Installation, Operation, Maintenance

General Information Safety Information Chiller Model Number Nomenclature Chiller Nameplates Installation.........................................................................5 - 43

Condenser Water/Cooling Tower Control Considerations Shipping Information Receiving Rigging, Lifting General Data Electrical Ratings Dimensions and Clearance Requirements......................................... 7- 35 Mounting Requirements Vibration Isolation Piping Installation Considerations Evaporator Piping Condenser Piping Flow Protection Water Quality, Treatment Specifications Refrigerant Pressure Relief Piping Electrical Information Field Connections Grounding VFD Harmonics

Harmonic, EMI, and RFI Filtration FlexSys Default Field Connection and I/O Summary.........................39-43

Operation........................................................................... 44-49 Component Overview Compressor Evaporator Condenser Refrigerant Metering Chiller Controls Chiller Operation

FlexSys Sequence of Operation and Control Strategy Control Loop Architecture Electronic Expansion Valve (EXV) Logic

Chiller Control Screens Home Screen Main Navigation Menu Trend Graphs Input/Output Overview Event Log

Maintenance...................................................................... 50-51 Appendix A: Assembly of Knocked Down Chiller Appendix B: Generator Operators Sequence

Table of Contents

This manual provides information on the proper installation, operation and maintenance requirements for a Multistack chiller. Follow these instructions to help ensure that the chiller performs properly. Failure to follow these instructions can significantly affect the chiller’s performance and reliability and may adversely affect the equipment warranty.

Multistack has a policy of continual improvement and reserves the right to change product design, literature and specifications without notice.

Installation, Operation, Maintenance

DANGER: To avoid risk of electric shock, personal injury or death, disconnect all electrical power before performing maintenance or service. The unit may have more than one electrical power supply. Assume all electrical wires are live, energized wires. Use lockout/tag outs.

DANGER: Never remove a lockout from equipment unless you placed it there. Each person shall place his/her own lock/tag when required to isolate an energy source. Do not start any adjustment, service or repair without verifying that the tag/lock out switch or control cannot be by-passed or over-ridden.

Verify that the locked-out switch or control cannot be overridden. Test the equipment to be certain that the locked-out switch is de-energized and not simply malfunctioning. Press all start buttons to confirm that the equipment WILL NOT start.

DANGER: During installation, testing, servicing and troubleshooting this product, it may be necessary to work with live electrical components. Only qualified licensed electricians or other properly trained persons may perform these tasks. Failure to follow all electrical safety precautions can result in death or serious injury. All HVAC equipment must be installed per the National Electric Code (NEC) and/or all applicable state/local codes.

DANGER: Incorrect handling of HVAC equipment can result in explosions, electrical shock or fire, causing property damage, injury and/or fatality.

DANGER: HVAC liquids and chemicals can be dangerous if used incorrectly or if spills or accidents occur. Handle detergents and solvents with care to avoid spills and burns.

DANGER: Refrigerant cylinders can explode causing serious injury and/or death if not handled and stored properly.

WARNING: Danger of electrical shock. Many types of HVAC equipment have switches and regulators with electrical current on even when other parts of the equipment appear to be turned off. Main circuit breakers must be turned off before servicing equipment to avoid injury, fatality.

WARNING: Be sure to use lifting slings with lifting capacity to safely handle unit weight. Consult the unit’s as-built submittal drawings for unit weight data.

CAUTION: Working with HVAC (heating, ventilating and air conditioning) equipment can be hazardous due to electricity, moving parts, chemicals, combustion and other hazards. Use safe work habits including proper tools and personal protective equipment. Understand and heed all safety information, installation guidelines and operation and maintenance procedures.

NOTE: Use proper personal protective equipment when working with HVAC equipment. For example, shoes and boots that protect ankles and feet, safety glasses for eye protection, gloves to protect hands and flash gear are common protective items for HVAC technicians. Injuries and accidents can be prevented or minimized by using appropriate protective equipment.

NOTE: Understand and pay attention to all safety information including all equipment manufacturer safety instructions, labels and signs. Always follow original equipment manufacturer’s instructions, and local building codes and ordinances.

Safety Information This manual includes warnings, cautions and notes.

DANGER conveys serious hazards for injury or death.

WARNING indicates risk of injury or death.

CAUTION warns of possible injury or damage.

NOTE calls out work practices that can result in optimal operations.

Installation, Operation, Maintenance

Chiller Model Number Nomenclature

C Condenser Tube Type2

8 Evaporator (entering)3

8 Condenser (entering)4

F Controller Option5

A Amperage Code (see amperage codes)

1 A - B4 copper, B- B4 Cu-Ni, C - B5 copper, D - C5 Cu-Ni, V - other 2 A - C4 copper, B- C4 Cu-Ni, C - C5 copper, D - C5 Cu-Ni, V - other 3 1- std left/mwb right, 2 - std right/mwb left, 3 - mwb left/std right, 4 - mwb right/std left, 5 - both MWB left, 6 - both MWB right, 7 - both std left, 8 both std right 4 1- std left/mwb right, 2 - std right/mwb left, 3 - mwb left/std right, 4 - mwb right/std left, 5 - both MWB left, 6 - both MWB right, 7 - both std left, 8 both std right 5 F - FlexSys base, G - FlexSys with options, V - Other

General Information

A 208/3/60 B 24/1/60 C 575/3/60 D 200/3/50 E 380 - 415/3/50 F 380/3/60 G 120/1/60 H 460/3/60 I J K

L 230/3/60 M 208/1/60 N 575/1/60 O 200/1/50 P 380-415/1/50 Q 380/1/60 R 460/1/60 S 220/230/1/60 T U

V OTHER

A 70 B 80 C 90 D 100 E 110 F 125 G 150 H 175 I 200 J 225 K 250 L 300

M 350 N 400 O 450 P 500 Q 600 R 700 S 800 T 350/500 U 400/500 V 450/500 W 450/600 X 500/600

Amperage Codes/MOP Voltage Codes

Installation, Operation, Maintenance

Chiller Electrical Ratings Refer to the unit nameplate and/or model number description on Page 4 for amperage and voltage information. Always confirm that wiring and fuses are rated and sized per the jobsite-specific chiller selection.

General Data Refer to unit dimensional drawings, Pgs. 7 - 35, for empty, shipping and operating weights.

1 Nominal chiller capacity in tons at AHRI 550/590 conditions.

2 Estimated refrigerant charge of R-134a at nominal capacity. Adjust by 0.33 lb./ton for alternate capacities.

Installation, Operation, Maintenance

Safety Information This manual includes warnings, cautions and notes.

DANGER conveys serious hazards for injury or death.

WARNING indicates risk of injury or death.

CAUTION warns of possible injury or damage.

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ig n.

Sp ec ia l o pt io ns m ay re qu ire p ar ts to sh ip lo os e.

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S0

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S1

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S1

2F C hi lle rs Si de -b y- Si de S he lls

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S1

2F C hi lle rs Si de -b y- Si de S he lls

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S5

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

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2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S5

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

S5

2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

U ni t D im en si on s an d

Cl ea ra nc es M

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2F C hi lle rs

Fo r r ef er en ce on ly.

D im en sio ns an d we ig ht s a re su bj ec t t o c ha ng e u po n fin al d es ia l o pt io ns m ay re qu ire p ar ts to sh ip lo

Installation, Operation, Maintenance

NOTE calls out work practices that can result in optimal operations.

Warnings, cautions and notes include:

DANGER: To avoid the risk of electrical shock, personal injury or death, disconnect all electrical power to the unit before performing any maintenance or service.

The unit may have more than one electrical power supply. Assume all electrical wires are live, energized wires. Use lockout/tag outs.

DANGER: Use extreme caution when working around electrical components, wiring and connections to avoid injury or death by electric shock.

DANGER: Never remove a lockout from equipment unless you placed it there. Each person shall place his/her own lock/tag when required to isolate an energy source. Do not start any adjustment, service or repair without verifying that the tag/lock out switch or control cannot be by-passed or over-ridden. Verify that the locked-out switch or control cannot be overridden. Test the equipment to be certain that the locked-out switch is de-energized and not simply malfunctioning.

Press all start buttons to confirm that the equipment WILL NOT start. Confirm that the system being serviced or repaired is the system that has been locked out.

Before restarting equipment, verify all tools and other items have been removed, all machine guards are in place, all electric systems are reconnected, and personnel are clear of equipment.

DANGER: Only properly trained persons and qualified licensed electricians may perform installation, testing, servicing and troubleshooting of this product. Failure to follow all electrical safety precautions can result in death or serious injury. All HVAC equipment must be installed per the National Electric Code (NEC) and/or all applicable state/local codes.DANGER: Incorrect handling of HVAC equipment can result in explosions, electrical shock or fire, causing property damage, injury and/or fatality.

DANGER: HVAC liquids and chemicals can be dangerous if used incorrectly or if spills or accidents occur. Handle detergents and solvents with care to avoid spills and burns.

DANGER: Refrigerant cylinders can explode causing serious injury and/or death if not handled and stored properly.

WARNING: Only qualified, licensed electricians with proper personal protection equipment should wire Multistack chillers. Injury or death my result if not properly wired due to electric shock hazard.

WARNING: Danger of electrical shock. Many types of HVAC equipment have switches and regulators with electrical current on even when other parts of the equipment appear to be turned off. Main circuit breakers must be turned off before servicing equipment to avoid injury, fatality.

WARNING: Be sure to use lifting slings with lifting capacity to safely handle unit weight. Consult the unit’s as-built submittal drawings for unit weight data.

WARNING: If welding on chiller water connections, use proper electrical grounding to avoid damaging the compressors or chiller controls. Never weld directly on the heat exchanger shells. Only an authorized ASME-certified repair agency may weld directly on ASME-certified shells. After welding, an “R” stamp is required.

CAUTION: Thermal dispersion flow sensors are factory calibrated. Special tools are needed to adjust calibration in the field.

CAUTION: Working with HVAC (heating, ventilating and air conditioning) equipment can be hazardous due to electricity, moving parts, chemicals, combustion and other hazards. Use safe work habits including proper tools and personal protective equipment. Understand and heed all safety information, installation guidelines and operation and maintenance procedures.

CAUTION: Pressurized application of cleaning substances or refrigerants must be done with the correct procedures to ensure the safety of technicians and others, and avoid property damage.

NOTE: Use correct tools for HVAC equipment installation, maintenance and adjustment. Use the right type and size tools to make tight connections without stripping threads or breaking screws and bolts. Use accurate refrigerant and electrical meters to properly maintain and diagnose HVAC equipment.

NOTE: Use proper personal protective equipment when working with HVAC equipment. For example, shoes and boots that protect ankles and feet, safety glasses for eye protection, gloves to protect hands and flash gear are common protective items for HVAC technicians. Injuries and accidents can be prevented or minimized by using appropriate protective equipment.

NOTE: Understand and pay attention to all safety information including all equipment manufacturer safety instructions, labels and signs. Always follow original equipment manufacturer’s instructions, and local building codes and ordinances.

NOTE: Do not begin work until barricades, warning signs or other protective devices have been installed to isolate the work area from local traffic.

Chiller Nameplates

Multistack MagLev centrifugal chillers have multiple nameplates: Evaporator, Condenser, each Compressor and Unit.

Unit Nameplate - located on right side of the FlexSys™ control panel, provides model and serial numbers, rated capacity, electrical rating information, compressor type and electrical ratings, and total factory refrigerant charge.

Installation, Operation, Maintenance

Evaporator Nameplate - welded to evaporator on side opposite of the main control panel. Includes heat exchanger model and serial numbers, test pressures, weights, and certification stamps.

Condenser Nameplate - welded on condenser on side opposite of the main control panel Includes heat exchanger model and serial numbers, test pressures, weights, and certification stamps.

Compressor Nameplate -located on the right side of the compressor service cover.

Installation Notes:

compressors are liquid refrigerant cooled and require a minimum pressure ratio of 1.5 to properly cool the compressor’s power electronics. Running machines below minimum pressure ratio is not sustainable and can cause alarms, faults or damage to the equipment.

3. Maximum number of starts per hour is based on compressor not being in a critical fault condition. Each MagLev compressor protects against critical faults by a lockout if same critical fault occurs three times in 30 minutes. Current Fault and Discharge Pressure faults create automatic compressor lockout faults per UL guidelines.

Condenser Water/Cooling Tower Control Considerations Properly controlling the condenser water loop is critical in maximizing the efficiency of the MagLev™ centrifugal chiller. Testing shows that a 1-degree F change in entering condenser water temperature will cause a two percent change in chiller efficiency. Multistack recommends running the coldest entering condenser water temperature possible for maximum chiller efficiency at all times. Multistack also recommends that condenser water flow only be regulated in an equal marginal performance control strategy.

*Running cold entering condenser water on the condenser can help chiller efficiency, but may create a choke condition on the compressors that could limit chiller capacity. Contact Multistack for application- specific details.

When running the chiller with cold ambient air/cold entering condenser water temperatures, a chiller- controlled three-way valve is required. The FlexSys controller logic can run the chiller at the lowest permissible entering condenser water temperature throughout the chiller’s operating range. This logic is also used to help the chiller start in an inverted condition, i.e. when chilled water temperature is greater than condenser water temperature, resulting in no pressure differential on the chiller when it starts.

It is generally more efficient to run the cooling tower fan(s) harder to decrease the entering condenser water temperature—the energy consumed by the cooling tower is a fraction of that used by the chiller.

Installation Overview The following section of the IOM will provide detailed information on the proper receiving, handling, rigging, and site installation requirements for a MagLev centrifugal chiller. All requirements must be met to ensure that the MagLev centrifugal chiller performs properly. Failure to follow these instructions can significantly affect the chiller’s performance and reliability. Failure to follow the policies and procedures outlined may adversely affect the equipment warranty.

Shipping Information All MagLev™ centrifugal chillers are factory run tested prior to shipment to confirm proper operation. Shipping is set up by the Multistack expediter and shipping department based on the information in this form.

If the chiller is shipped complete, it ships charged with refrigerant; if it is shipped disassembled, the refrigerant ships loose.

Receiving Upon receipt of the MagLev centrifugal chiller, inspect the chiller for damage. If there is any damage, contact Multistack Service Department immediately at (608)-366-2400. Freight damage must be reported to Multistack within 48 hours of chiller receipt.

Rigging, Lifting WARNING: Use lifting slings with lifting capacity to safely handle unit weight. Consult the chiller submittal drawings for unit weight data.

MagLev centrifugal chillers are available with an optional manufacturing frame to assist in moving the chiller. If the manufacturing frame is not used, care must be exercised when moving the chiller. Only properly trained and skilled rigging personnel should attempt to move this equipment. Contact Multistack for additional manufacturing frame information.

On each heat exchanger, rigging eyes are provided at the top of the tube sheets plates. Lifting hooks can be attached on the outer-most eye of the evaporator tube sheet and the outer-most eye of the condenser. After attaching the lifting hooks they must be connected to a lifting bar to prevent damage to the chiller.

Installation, Operation, Maintenance

The lifting bar should be equal in length to the distance between the tube sheet plates. The lifting capacity must be 1.5 times the shipping weight of the unit plus the lifting bar, hooks, cables, and clevises.

Dimensions and Clearance Requirements Pages 7 - 35 provide unit dimensions and clearances. Minimum clearance is 30 inches on all sides and 36 inches overhead clearance. Recommended clearance is 42 inches all sides and overhead. Additional clearance is recommended at one end for future tube cleaning or replacement.

Electrical Clearances – NEC, local, or regional building codes may require more clearance than listed above or shown. Consult local governing agencies to determine if more clearance is required.

Mounting Requirements The chiller must be mounted on a level concrete or steel base with adequate service clearance as listed above. Whether the mounting base is concrete or steel, ensure that it has an adequate rating to support the full operating weight of the complete chiller. Multistack provides bolt holes on the heat exchanger mounting feet. If bolting the chiller to the concrete pad, Multistack recommends using these holes. When the chiller ships with the optional steel lifting frame from the factory, the chiller is bolted to the steel frame.

Vibration Isolation MagLev centrifugal chillers produce virtually no vibration, however to reduce any noise or vibration that might be transmitted to the building Multistack recommends the use of neoprene style vibration pads under the heat exchanger mounting feet. The pads can be obtained through United Refrigeration using part number SUPERWPAD. The pads come in 18-inch squares, ¾-inch thick. These pads can be easily cut to match the chiller feet.

Spring isolators can be used if required. Verify local building codes to ensure that additional vibration isolation is not required per seismic regulations. Spring isolators should be rated for 1.5 times chiller operating weight. Account for expansion, contraction, and movement of water piping with vibration isolators.

Piping Installation Considerations

WARNING- If welding on the points of connection of the chiller, the chiller must be properly grounded to avoid damaging the compressors and chiller controls. Never attempt to directly weld to the heat exchanger shells or the ASME certification is void. Only an authorized ASME certified repair agency may weld on these shells.

Evaporator Piping The standard water side connections on the evaporator are mechanical groove type connectors on dished style heads. Marine water box heads and weld neck flange connections are optional. The entering chilled water connection is on the bottom; the leaving chilled water connection is on the top. Refer to the specific application drawing to ensure all connection types and sizes are correct. Water box connections are defined in submittal process. Once approved, any changes to the water box connection, including “swapping of heads” becomes the responsibility of the customer.

The evaporator on each MagLev chiller has a 3/4-inch NPT plug on the bottom of the chiller head. This plug is to be replaced with a field-provided drain valve.

The evaporator is not self-draining. If a chiller is to be winterized to prevent water freezing internally, the chiller must have the water blown out of the tubes.

The installing contractor must provide adequate evaporator valves to ensure that it can be isolated and drained for service and maintenance.

The chilled water inlet and outlet connections on the evaporator must match the fitting/flange size on the evaporator and may not be reduced. Piping to and from the heat exchanger connections must be done such that the weight and strain of piping and accessories is off the heat exchanger. Use of flexible

Installation, Operation, Maintenance connectors is recommended to reduce sound transmission and allow pipe expansion/contraction.

A 20-mesh type strainer must be installed on the evaporator inlet. This strainer must be cleaned periodically to ensure proper fluid flow rate and prevent heat exchanger fouling.

All chilled water piping up to the evaporator connection must be properly insulated. Once the chiller is in place, install the insulated covers over the lifting eyelets.

Condenser Piping The condenser water inlet and outlet connections must match the fitting/flange size on the condenser and may not be reduced. Standard water side condenser connections are mechanical groove-type connectors on dished-style heads. Marine water box heads and weld neck flange connections are optional. The entering condenser water connection is on the bottom; the leaving condenser water connection is on top. Refer to the specific application drawings to ensure all connection types and sizes are correct.

The condenser on each MagLev chiller has a 3/4-inch NPT plug on the bottom of the chiller head. This plug is to be replaced with a field-provided drain valve, provided in the field. The condenser is not self-draining. If a chiller is to be winterized to prevent water freezing internally, the chiller must have the water blown out of the tubes.

Condenser piping connections must be done such that the weight and strain of piping and accessories is off the heat exchanger. Use of flexible connectors is recommended to reduce sound transmission and allow pipe expansion/contraction.

A 20-mesh type strainer must be installed on the inlet of the condenser. This strainer must be cleaned periodically to ensure proper fluid flow rate and prevent heat exchanger fouling. The installing contractor must provide adequate valves to ensure that the heat exchangers can be isolated and drained for service and maintenance.

Note: Water side connections must not be reduced from the heat exchanger connection points. Doing so will create a higher localized velocity that can damage the tube sheets. If the water connections must be reduced, it should be five to 10 pipe diameters from the heat exchanger to allow turbulence to stabilize before entering the chiller.

Flow Protection All MagLev centrifugal chillers come with factory mounted and wired thermal dispersion switches with LED flow indication for flow protection. This feature allows MagLev centrifugal chillers the ability to provide low ΔP alarms, low ΔP faults, high ΔP alarms, and high ΔP faults. This ensures that the heat exchangers are protected against low flow or too much flow.

Water Quality, Treatment Specifications Water quality and its effect on heat exchangers in refrigeration components is a complicated issue. Multistack recommends that technicians work with a water treatment professional familiar with the Langelier and Ryznar indexes. These indexes account for the variables that affect water quality and are used to help determine if water will tend to be scale forming, neutral, or corrosive. The following values are acceptable for Multistack shell and tube heat exchangers:

Specifications for water with 25 percent glycol

Conductivity: 1000 - 15,000 ppm

If the condenser water loop is open, contaminants including debris, trash, mud, algae, sand, and scale can accumulate in the condenser causing restrictions, erosion or corrosion. Multistack cannot be responsible for heat exchangers damaged due to untreated/poorly treated water. Multistack does not recommend the use of acid to remove scale from heat exchangers. If acid is used to de-scale a heat exchanger, the heat exchanger must be properly flushed then tested

Installation, Operation, Maintenance

Small Hub (Optional) Point Tag Description Customer Connection

DI-9: Evap Pump #1 Fault inidcates fault with evap pump VFD C DI-10: Cond Pump #1 VFD Fault inidcates fault with cond pump VFD C DI-11: Tower Fan VFD #1 Fault inidcates fault with tower pump VFD C

DI-12: Not Used C DO-17: Isolation Valve Relay opens/closes chiller isolation valves C

DO-18: Evap Pump #1 Enable start/stop of evap pump C DO-19: Cond Pump #1 Enable start/stop of condpump C

DO-20: Tower #1 Enable start/stop of tower pump C AI-19: Evap DP Transmitter feedback for evap pump control C

AI-20: Not Used C AI-21: Chilled Water Flow Meter optional feedback for chilled water pump control C

AI-22: Cond DP Transmitter feedback for cond pump control C AI-23: Evap Pump #1 VFD Feedback indicates where VFD is currently operating C AI-24: Cond Pump #1 VFD Feedback indicates where VFD is currently operating C AI-25: Tower Fan #1 VFD Feedback indicates where VFD is currently operating C

AI-26: Not Used C T-9: System Chilled Water In used for cross talk only C

T-10: System Chilled Water Out used for cross talk only C T-11: System Condenser Water In used for cross talk only C

T-12: System Condenser Water Out used for cross talk only C AO-5: Chilled Water Bypass requires chilled water flow meter to operate C AO-6: Evap Pump # 1 Signal control signal to VFD C AO-7: Cond Pump #1 Signal control signal to VFD C AO-8: Tower Fan #1 Signal control signal to VFD C

* DP transmitter, enable, and speed output required for all VFD pumps

** Enable & Speed Signal required for VFD tower control (option 13)

Must add OAT/RH Sensore for Option 14

Installation, Operation, Maintenance

Installation, Operation, Maintenance

Gen 2: 5 Compressors

Point Tag Description Factory Connected

Customer Connection Required Optional

DI-1 System Start / Stop Chiller Enable/Disable C R DI-2: E-Stop Chiller Shuts down if opened C R

DI-3: Evap Flow Switch Proof of Flow on Evap F R DI-4: Cond Flow Switch Proof of Flow on Cond F R

DI-5: LP Switch System Low Pressure Safety all comps shut down if opened F R

DI-6: HP Switch System High Pressure Safety all comps shut down if opened F R

DI-7: Not Used DI-8: Not Used

DO-1: Cooling Fan Enable Panel Cooling fan cycles off CPU temp F

DO-2: Chiller Run Contact makes once chiller has 2 kW present & comps running C O

DO-3: Chiller Fault Contact makes when any fault condition is present C O DO-4: Any Comp Locked Out Contact make if any comp is locked out & can't run C O DO-5: Compressor 1 Enable Makes C1 Interlock Contact F R

DO-6: C-1 Economizer Enable Enable/Disable of C1 Economizer Solenoid based off comp motor power F

DO-7: Compressor 2 Enable Makes C2 Interlock Contact F R

DO-8: C-2 Economizer Enable Enable/Disable of C2 Economizer Solenoid based off comp motor power F

DO-9: Compressor 3 Enable Makes C3 Interlock Contact F R

DO-10: C-3 Economizer Enable Enable/Disable of C3 Economizer Solenoid based off comp motor power F

DO-11: Compressor 4 Enable Makes C4 Interlock Contact F R

DO-12: C-4 Economizer Enable Enable/Disable of C4 Economizer Solenoid based off comp motor power F

DO-13: Compressor 5 Enable Makes C5 Interlock Contact F R

DO-14: C-5 Economizer Enable Enable/Disable of C5 Economizer Solenoid based off comp motor power F

DO-15: Not Used DO-16: Not Used

AI-1: OSA Temperature Used for optimized tower control C O AI-2: OSA Humidity Used for optimized tower control C O AI-3: Level Sensor Feedback for Main EXV/S F R

AI-4: Economizer Pressure 1 Feedback for Economizer EXV 1 F AI-5: Economizer Pressure 2 Feedback for Economizer EXV 2 F

AI-6: Not Used AI-7: Not Used AI-8: Not Used

Legend

F Factory Connection

C Customer Connection

R Required for Chiller to Run

O Optional at Customers Descretion

Installation, Operation, Maintenance

Gen 2: 5 Compressors

Point Tag Description Factory Connected

Customer Connection Required Optional

AI-9: Load Limit Input 4 mA= no load limit 20 mA= max load limit C O AI-10: CHW Reset Input 4 mA= 0 degree reset 20 mA= 10 degree reset C O T-1: Chilled Water Out provides temp in F or C F R T-2: Chilled Water In provides temp in F or C F

T-3: Condenser Water In provides temp in F or C F T-4: Condenser Water Out provides temp in F or C F

T-5: Liquid Line 1 Temp used to check subcooling F T-6: Economizer Temp 1 used for SH for economizer F T-7: Economizer Temp 2 used for SH for economizer F

T-8: Not Used AO-1: Chiller kW provides chiller total kW C O

AO-2: Chiller Amps provides chiller total amps C O AO-3: 3-Way Valve output signal for cond bypass for inverted starts C O

AO-4: Tower Output Signal output signal for tower setpoint C O

Legend

F Factory Connection

C Customer Connection

R Required for Chiller to Run

O Optional at Customers Descretion

Installation, Operation, Maintenance for proper pH levels before returning to normal operation. Heat exchangers damaged due to improper acid cleaning

ASHRAE 15 Standard uses a complicated formula that accounts for total equivalent length of the pipe including fittings, valve capacity, internal pipe diameter, Moody friction factor, outlet pressure and back pressure on the relief valve. These formulas can be found in the ASHRAE 15 Standard.

In addition to relief valve piping, ASHRAE 15 requires a refrigerant monitoring system with powered ventilation to protect the mechanical room from refrigerant leaks. The intent is to ensure that the machinery room is not a confined space. MagLev centrifugal chillers have a dedicated relay contact to be interlocked with the refrigerant monitoring system supplied by others. This relay contact is used to immediately shut down the chiller if the refrigerant monitoring system senses a refrigerant leak. The default position (either normally open or normally closed) contact is determined in the I/O set up menu of the FlexSys controller. Consult local building codes and ensure that your installation meets ASHRAE 15 requirements.

Electrical Information WARNING: Only qualified, licensed electricians should wire MagLev centrifugal chillers. Severe injury or death can result if the chiller is not properly wired due to electrical shock hazard. Only qualified technicians using proper personal protection equipment may perform this work.

Field wiring must comply with all federal, state and local regulations. Breakers, fuses, wire, and wire size must be sized and installed per the National Electric Code (NEC). Applied voltage to all MagLev centrifugal chillers must be within ± 10 percent of unit nameplate voltage. Any voltage imbalance between phases must not exceed two percent. According to NEMA Standard MG-1-1998, a two percent voltage imbalance will cause a current imbalance of six to 10 times the voltage imbalance. It is very important to minimize unbalance between electrical phases.

Field Connections DANGER: Use extreme caution when working around electrical components, wiring and connections to avoid injury or death by electric shock.

All MagLev centrifugal chillers come standard with a single point of connection up to 800 amps. Above 800 amps the chillers have dual points of electrical connection. This feature simplifies the electrical installation. The main electrical conduit feeding the main chiller breaker is to enter from the top, or right side of the panel when looking at the panel. Please note that there is a dedicated chiller ground in this panel. This ground must connect to a true earth ground.

See “Grounding” for more…