Attachment 1 - 40 Ton Chiller Specification.pdf

ARNOLD ENGINEERING DEVELOPMENT

BUILDING 430

CHILLER REPLACEMENT PROJECT

10905 NEW HAMPSHIRE AVE.

SILVER SPRING, MD 20903-1050

Arnold Engineering Development Complex Air Force

AEDC

White Oak, Silver Spring MD

Air-Cooled Scroll Water Chillers

PART 1 - GENERAL

1.01 SUMMARY

A. Section includes design, performance criteria, refrigerants, controls, and installation requirements for air-cooled rotary scroll packaged chillers.

1.02 REFERENCES

A. AHRI 550/590 - Standard for Water Chilling Packages using the Vapor Compression Cycle

B. AHRI 370 - Sound Rating of Large Outdoor Refrigerating and Air-Conditioning Equipment

C. ASHRAE 15 - Safety Code for Mechanical Refrigeration

D. ASHRAE 90.1 - Energy Efficient Design of New Buildings

E. UL 60335-2-40 - Standard for HVAC equipment for safety requirements

F. ASTM B117 - Standard Method of Salt Spray (Fog) Testing

G. ASTM A123 - Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

H. ASTM A525 - Zinc (Hot-Dip Galvanized) Coatings on Sheet Steel Products

I. ASTM D1654 - Evaluation of Painted or Coated Specimens, Subjected to Corrosive

Environments

J. ANSI/AFBMA 9-1978 - Load Ratings and Fatigue Life for Ball Bearings.

K. ISO 9001

L. California Administrative Code - Title 24

M. UL Listed ETL-2019

N. UL/CUL

1.03 SUBMITTALS

A. Submit dimensional plan and elevation view drawings, weights, and loadings, required clearances, location and size of all field connections, electrical requirements and wiring diagrams.

B. Submit product data indicating rated capacities, accessories, and any special data.

C. Submit manufacturer's installation instructions.

1.04 REGULATORY REQUIREMENTS

A. Comply with codes and standards specified.

B. Chiller must be built in an ISO 9001 classified facility.

1.05 VERIFICATION OF CAPACITY AND EFFICIENCY

A. All proposals for chiller performance must include an AHRI approved selection method.

Verification of date and version of computer program selection or catalog is available through AHRI.

1.06 DELIVERY, HANDLING AND STORAGE

A. Comply with manufacturer's installation instructions for rigging, unloading, and transporting chillers.

B. Chiller shall be capable of withstanding -40⁰F (-40⁰C) to 158⁰F (70⁰C) storage temperatures for an indefinite period of time.

1.07 WARRANTY

A. Year 2 parts warranty whole unit

B. 1st year labor warranty

C. $5000 max $ crane allowance 1st year

D. 2nd year labor warranty whole unit

E. 1st year refrigerant warranty

F. 2nd year refrigerant warranty

G. 12/34 delayed startup warranty

PART 2 - PRODUCTS

2.01 CHILLER DESCRIPTION

A. The contractor shall furnish and install a 40 Ton capacity “TRANE” air-cooled water chiller with a minimum of two scroll compressors (Base Model Part Number -

CGAM040F2**3EXD2A1A3A1AX*A1A2B4XXXXXXA1A3A1D1XXLX).

B. The chillers shall be installed in accordance with this specification and perform at the specified conditions as scheduled.

2.02 CHILLER OPERATION

A. Chiller shall be able to start and operate in ambient conditions from 0⁰F (-18⁰C) to 125⁰F

(52⁰F). Wide ambient operation is accomplished with factory installed and tested protection. If field installed wide ambient solution is used, this shall be purchased and installed at contractor expense.

B. Chiller shall be capable of low temperature process operation with a leaving solution temperature less than 40⁰F (4⁰C).

C. Chiller shall be capable of starting up with 95⁰F (35⁰C) entering fluid temperature to the evaporator. Maximum water temperature that can be circulated with the Chiller not operating is 125⁰F (52⁰C)

D. Chiller shall provide evaporator freeze protection and low limit control to avoid low evaporator refrigerant temperature trip-outs during critical periods of chiller operation.

Whenever this control is in effect, the controller shall indicate that the chiller is in adaptive mode. If the condition exists for more than 30 seconds, a limit warning alarm relay shall energize.

E. The Chiller shall be capable of starting in 85 seconds after power restoration and be able to attain 80% load in less than 150 seconds after power restoration.

F. Chiller shall be able to operate within 4 feet of a solid wall and/or 8 feet between two chillers side by side.

G. Chiller shall be able to operate with a 2-minute loop time for comfort cooling applications.

Chiller manufacturer shall provide a buffer tank and contractor shall install at no additional cost to owner if additional loop time is required.

2.03 COMPRESSORS

A. Construct chiller using fully hermetic scroll type compressors with R454B or R-32 optimized and dedicated scroll profile. Refrigerant shall have a GWP of less than 600.

B. Provide direct drive motor cooled by suction gas with only three major moving parts and a completely enclosed compression chamber that leads to increased efficiency.

C. Each compressor shall have overload protection internal to the compressor.

D. Each compressor shall include centrifugal oil pump, oil level sight glass and oil charging valve.

E. Each compressor will have crankcase heaters installed and properly sized to minimize the amount of liquid refrigerant present in the oil sump during off cycles.

2.04 EVAPORATOR

A. The evaporator shall be a high efficiency, brazed plate-to-plate type heat exchanger consisting of parallel plates. Braze plates shall be stainless steel with copper braze material.

B. The water side working pressure shall be rated at 150 psig (10.3 bar) and tested at 1.5 times maximum allowable water side working pressure.

C. The refrigerant side working pressure shall be rated at 460 psig (29.6 bars) and tested at

1.1 maximum allowable refrigerant side working pressure.

D. Insulate the evaporator with a minimum of 0.75-inch (K=0.28) UV rated insulation. If the insulation is field installed, the additional money to cover material and installation costs in the field should be included in the bid.

E. Evaporator heaters shall be factory installed and shall protect chiller down to -20⁰F (-

29⁰C). Contractor shall wire separate power to energize heat tape and protect evaporator while chiller is disconnected from the main power.

F. Provide water drain connection, vent, and fittings. Factory installed leaving water temperature control and low temperature cutout sensors.

G. Water connections shall be grooved pipe.

H. Proof of flow shall be provided by the equipment manufacturer, mechanically installed, and electrically wired, at the factory of origin.

I. Factory installed cleanable strainer.

2.05 FANS

A. Low sound fans shall by dynamically balanced and direct driven.

B. All condenser fan TEAO motors have permanently lubricated ball bearings and external overload protection.

2.06 CONDENSER

A. The condenser coils shall consist of copper tubes mechanically bonded into plate-type aluminum fins. A subcooling coil shall be an integral part of the main condenser coil.

B. The condenser coils shall have an integral sub-cooling circuit and shall be designed for at least 650 psig (44.8 bar) working pressure. Leak tested at 650 psig (44.8 bar).

2.07 ENCLOSURES/CHILLER CONSTRUCTION

A. Units shall be constructed of a galvanized steel frame with galvanized steel panels and access doors.

B. Chiller panels, base rails and control panels shall be finished with a baked-on powder paint. Control panel doors shall have door stays.

C. Mount starters and Terminal Blocks in a UL 60335-2-40 rated weatherproof panel provided with full opening access doors. If a circuit breaker is chosen, it should be a lockable, through-the-door type with an operating handle and clearly visible from outside of chiller indicating if power is on or off.

D. The coating or paint system shall withstand 500 hours in a salt-spray fog test in accordance with ASTM B117.

2.08 CHILLER MOUNTED STARTER

A. The starter shall be across-the-line configuration, factory-mounted and fully pre-wired to the compressor motor(s) and control panel.

B. Unit shall have a single point power connection.

C. A control power transformer shall be factory-installed and factory-wired to provide unit control power.

D. Control panel shall be dead front construction for enhanced service technician safety.

E. Unit wiring shall run in liquid-tight conduit.

F. A molded case high fault interrupting capacity circuit breaker shall be factory pre-wired with terminal block power connections and equipped with a lockable external operator handle, making it available to disconnect the chiller from main power. Energy Meter capable of measuring line current by phase, average current, voltage by phase, average voltage, frequency, unit power consumption, reactive and apparent power, and power factor.

G. High short circuit current rating (SCCR) with selection of high fault protection device.

2.09 REFRIGERANT CIRCUIT

A. All chillers shall have 2 refrigeration circuits, each with two or three (manifolded) compressors on each circuit.

B. Provide for refrigerant circuit:

1. Liquid line shutoff valve

2. Discharge service valve

3. Filter

4. Liquid line sight glass.

5. Electronic expansion valve sized for maximum operating pressure

6. Charging valve

C. Full operating charge of R454B or R-32 and oil.

2.10 CONTROLS

A. Factory-mounted to the control panel door, the operator interface with an ‘LCD touch-screen display

B. Display shall consist of a menu driven interface with easy touch screen navigation to organized sub-system reports for compressor, evaporator, and motor information as well as associated diagnostics.

C. The chiller control panel shall provide password protection of all set-points

D. Chilled water temperature control shall be microprocessor-based, proportional and integral controller to show water and refrigerant temperature, refrigerant pressure, and diagnostics.

This microprocessor-based controller is to be supplied with each chiller by the chiller manufacturer.

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

1. Run time.

2. Number of starts.

3. Current chiller operating mode.

4. Chilled water set point and set point source.

5. Electrical current limit set point and set point source.

6. Entering and leaving evaporator water temperatures.

7. Saturated evaporator and condenser refrigerant temperatures.

8. Evaporator and condenser refrigerant pressure.

9. Differential oil pressure.

10. Phase reversal/unbalance/single phasing and over/under voltage protection.

11. Low chilled water temperature protection.

12. High and low refrigerant pressure protection.

13. Load limit thermostat to limit compressor loading on high return water temperature.

14. Condenser fan sequencing to automatically cycle fans in response to load, expansion valve pressure, condenser pressure, and differential pressure to optimize chiller efficiency.

15. Display diagnostics.

16. Compressors: Status (on/off), %RLA, anti-short cycle timer, and automatic compressor lead-lag.

F. On chiller, mount weatherproof control panel, containing starters, power and control wiring, factory wired with terminal block power connection. Provide primary and secondary fused control power transformer.

G. The chiller controller shall utilize a microprocessor that will automatically take action to prevent chiller shutdown due to abnormal operating conditions associated with:

evaporator refrigerant temperature, high condensing pressure and motor current overload.

H. Provide the following safety controls with indicating lights or diagnostic readouts.

1. Low chilled water temperature protection.

2. High refrigerant pressure.

3. Loss of chilled water flow.

4. Contact for remote emergency shutdown.

5. Motor current overload.

6. Phase reversal/unbalance/single phasing.

7. Over/under voltage.

8. Failure of water temperature sensor used by controller.

9. Compressor status (on or off).

I. Provide the following operating controls:

1. A variable method to control capacity in order to maintain leaving chilled water temperature based on PI algorithms. Five-minute solid state anti-recycle timer to prevent compressor from short cycling. Compressor minimum stop-to-start time limit shall be 2 minutes. If a greater than 5-minute start-to-start, or greater than 2 minute stop-to-start timer is included, hot gas bypass shall be provided to insure accurate chilled water temperature control in light load applications.

2. Chilled water pump output relay that closes when the chiller is given a signal to start.

3. Load limit thermostat to limit compressor loading on high return water temperature to prevent nuisance trip outs.

4. High ambient unloader pressure controller that unloads compressors to keep head pressure under control and help prevent high pressure nuisance trip outs on days when outside ambient is above design.

5. Compressor current sensing unloader chiller that unloads compressors to help prevent current overload nuisance trip outs.

6. Low ambient lockout control with adjustable setpoint.

7. Condenser fan sequencing which adjusts the speed of all fans automatically in response to ambient, condensing pressure and expansion valve pressure differential thereby optimizing chiller efficiency.

J. Provide user interface on the front of the panel. If display is on the inside of the panel, then a control display access door shall be provided to allow access to the display without removal of panels. Provide user interface with a minimum of the following features:

1. Leaving chilled water setpoint adjustment from LCD input

2. Entering and leaving chilled water temperature output

3. Pressure output of condenser

4. Pressure output of evaporator

5. Ambient temperature output

6. Voltage output

7. Current limit setpoint adjustment from LCD input.

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

L. Digital Communications to BAS system shall consist of a BACnet IP interface

M. The chiller control panel shall provide an alarm relay output that shall energize whenever a fault requiring manual reset is detected by the panel.

N. The chiller control panel shall provide an output for chiller Percent Capacity via a 2-10VDC or 4-20mA signal to a building automation system.

O. The controller shall be capable of controlling chiller in variable applications. At flow rate changes of 10% or less per minute, controller shall maintain leaving temperature control of

+/-2degF). At flow rate changes of up to 30% or less per minutes, chiller shall stay online.

2.11 SOUND

A. Acoustics: Manufacturer must provide both sound power and sound pressure data in decibels. Sound pressure data per AHRI 370 must be provided at full load.

B. If manufacturer cannot meet the noise levels, sound attenuation devices and/or barrier walls must be installed to meet this performance level.

2.12 ACCESSORIES

A. Chiller shall have full architectural louvers panels.

B. Chiller shall ship with elastomeric isolators

PART 3 - EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer's requirements.

1. Level the chiller using the base rail as a reference. The chiller must be level within

1/2" in over the entire length and width. Use shims as necessary to level the chiller.

3.02 SERVICE AND START-UP

A. Startup - Provide all labor and materials to perform startup. Startup shall be performed by a factory-trained technician from the original equipment manufacturer (OEM). Technician shall confirm that equipment has been correctly installed and passes specification checklist prior to equipment becoming operational and covered under OEM warranty. This shall be done in strict accordance with manufacturer's specifications and requirements.

Third-party service agencies are not permitted.

B. A start-up log shall be furnished by the factory approved start-up technician to document the chiller's start-up date and shall be signed by the owner or his authorized representative prior to commissioning the chillers.

C. Chiller manufacturers shall maintain service capabilities no more than 25 miles from the jobsite.

D. Provide local service agent with direct access to factory support on equipment.

E. The service provider shall employ a minimum of one full time, competent HVAC and automation system servicepersons on staff, whose office in which they operate from is within 25 miles of the job site and who have been within their employment for a minimum of 5 years.

F. Optional Service agreement for the Chiller. The agreement may be expanded to include to perform preventative maintenance and troubleshooting services on chillers from other manufacturers which are located at the facility.

G. During the first 12 months of operation, a factory-trained technician from the original equipment manufacturer (OEM) shall perform quarterly on-site operating inspections to confirm the chiller's operational performance. The manufacturer shall provide the owner with a report describing the condition of the equipment, current operating log, any issues found needing to be addressed, and recommended corrective actions.

H. General: Install and commission, as shown on the schedules and plans, factory assembled, charged, and tested air cooled scroll compressor chiller(s) as specified herein.

Chiller shall be designed, selected, and constructed using a refrigerant with Flammability rating of “1”, as defined by ANSI/ASHRAE STANDARD - 34 Number Designation and

Safety Classification of Refrigerants. Chiller shall include, but is not limited to a complete system with not less than two refrigerant circuits above 35 tons (123 kW), scroll compressors, direct expansion type evaporator, air-cooled condenser, refrigerant, lubrication system, interconnecting wiring, safety and operating controls including capacity controller, control center, motor starting components, and special features as specified herein or required for safe, automatic operation.

3.03 EXISTING CHILLER REMOVAL

A. Contractor shall take ownership of the existing chiller. Disconnect the existing chiller from power and control, and from piping and mounting. Remove the existing chiller from its installed location and make the location ready for the new chiller described herein. This may require relocating, removing, and replacing the existing concrete columns to ensure the platform is appropriate for the chiller weight and footprint dimensions. The bidder is encouraged to visit the site to include in their pricing the removal of existing chiller and placement of new chiller in their overall scope of work. Make legal and lawful disposal of the chiller, which may involve recycling of the unit beginning with refrigerant recovery and dismantling of the assembly for recycling or other appropriate disposition.