Attachment 2 Design Analysis.pdf

DESIGN ANALYSIS

Final Submittal

Upgrade Chiller- Phase 3 Athens, GA

U.S. Department Of Agriculture Agricultural Research Service (ARS) Richard B. Russell Agricultural Research Center (RRC) 950 College Station Road Athens, Georgia 30605

Prepared For:

U.S. Department Of Agriculture Agricultural Research Service (ARS) Southeast Area 141 Experiment Station Road Stoneville, MS 38776

Design Contract No. 12405B21D0003 Design Task Order No. 12405B24F0343

Prepared By:

The Johnson-McAdams Firm, P.A.

Greenwood, Mississippi

April 25, 2025

Phase 3 Chiller Upgrade USNPRC USDA-ARS Athens, GA

Table of Contents

1.0 Project Background

2.0 A/E Scope of Design Services

2.1 Design challenges:

3.0 General Facility Information

3.1 Facility Description

3.2 Facility Location

4.0 Site Inspection

5.0 Mechanical Systems

5.1 HVAC Design Standards

5.2 HVAC Design Conditions

5.3 Chiller System General Description

6.0 Electrical Power Systems

6.1 Electrical Design Standards

6.2 Electrical System Overview

7.0 Architectural

7.1 Architectural Design Standards

7.2 Architectural Overview

8.0 Appendix A – Mechanical Equipment Cut Sheets

USDA-ARS Athens, GA

1.0 Project Background

The United States Department of Agriculture (USDA), Agriculture Research Service (ARS), Southeast Area requires Architectural-Engineering (A-E) services to prepare a design to complete the upgrade of the chilled water system to accommodate the facility’s full chiller load.

This project will include the replacement of one chiller at the Russell Research Center (RRC) with a larger capacity unit (approximately 800-1000 tons) and chilled water pump to match the units installed in Phase 2, make necessary modifications to the electrical distribution panels, wiring, controls, associated piping and pumps to accommodate the new higher capacity system.

This is the final phase of the long-term plan to have chillers and associated equipment upsized so that one chiller can carry the full facility load and the second chiller system will provide redundancy in the event of a chiller outage.

Phase 1 consisted of replacing the existing cooling towers. Phase 2 consisted of replacing the existing 400-ton chiller, CH-2, with a 900-ton chiller and replacing the existing chilled water pump, CHWP-2. Phase 3 (this project) will address chiller CH-1 and chilled water pump, CHWP-1.

2.0 A/E Scope of Design Services

The A/E will be required to design the most cost-effective option to complete Phase 3 of the chiller plant upgrade. The A/E will develop Plans, Specifications Estimated Construction Cost (ECC) and Design Analysis to accomplish the following:

1. Demolition of existing 400-ton chiller and its associated chilled water pump.

2. Design and installation of new 900-ton Trane chiller to match the unit installed in Phase 2.

3. Design, sizing, and installation of new chilled water pump, piping and hydronic components to match the unit installed in Phase 2.

4. Design, sizing and installation of electrical system to supply new chiller and pump.

5. Integration of new chiller and pump into existing ALC DDC Control system.

6. Replacement of existing non-functional sliding door with a coiling overhead door with motorized operator. The existing opening will be modified (partially closed off) based on the layout of the boiler control room which blocks the opening.

(This scope item was changed during the design. The opening will become a cased opening with no new door.)

2.1 Design challenges:

1. Downtime for tie-ins during installation must be minimized. Piping spools should be prefabricated to the fullest extent possible to reduce downtime for tie-ins.

2. Installation to be coordinated with the site operation schedule.

3. The building will remain occupied throughout construction.

The A/E will conduct four (4) site visits:

1. Investigation and information collection – COMPLETED

2. 50% construction progress/support

3. Commissioning

4. Final construction inspection

3.0 General Facility Information

3.1 Facility Description

The facility is a multi-story building located on the campus of the U.S. National Poultry Research Center in Athens, GA.

3.2 Facility Location

The facility is located at:

Richard B. Russell Agricultural Research Center (RRC) 950 College Station Road Athens, Georgia 30605

4.0 Site Inspection

The Johnson-McAdams Firm (JMC) design team conducted a site visit on Tuesday 17 September 2024 to verify the existing conditions of the chiller system.

Attendees: Jeffrey Martin – USDA ARS – Facilities Manager

Walt Dennis – USDA ARS – Mechanical Facilities Tom Lovelace, PE – JMC Mechanical Engineer & Project Manager Walker Sayle, PE – JMC Electrical Engineer

The following are observations from the site visit:

1. The existing chiller system was carefully documented and found to closely match the as-built drawings provided to the A/E.

2. The existing nameplate data of chiller CH-2 (which was installed in Phase 2 of this project) was photographed and it will be used as the basis of design for the new chiller, CH-1.

3. Similarly, the existing nameplate data of chilled water pump CH-2 (which was installed in Phase 2 of this project) was photographed and it will be used as the basis of design for the new chilled water pump CHWP-1.

4. The existing valving that was installed in Phase 2 of the project may allow the new chiller to be installed without an outage.

5. The existing piping was inspected and dimensions of the pipe lengths and the equipment sizes were verified.

USDA-ARS Athens, GA

5.0 Mechanical Systems

5.1 HVAC Design Standards

1. USDA ARS Facilities Design Standard 242.1

2. National Fire Protection Association: National Fire Codes

3. ASHRAE Handbook of Fundamentals

4. ASHRAE Handbook of HVAC Applications

5. ASHRAE Handbook of HVAC Systems and Equipment

6. ASHRAE Standard 90.1: Energy Standard for Buildings Except Low-Rise

Residential Buildings

7. All applicable State and Local codes.

5.2 HVAC Design Conditions

Location: Athens, GA (ASHRAE 2021 Handbook of Fundamentals) Summer Dry Bulb .................. 93.2°F (1.0% occurrence) Summer Wet Bulb ................. 74.2°F (mean coincident wet bulb) Winter ................................... 26.3°F (99.0% occurrence) Latitude ................................. 33.948 N Longitude .............................. 83.328 W Elevation ............................... 785 FT

5.3 Chiller System General Description

1. The existing chilled water system consists of two (2) cooling towers located outside adjacent to the Mechanical Room. Two (2) cooling tower (condenser water) pumps are located inside the mechanical room. They provide heat rejection water to the chillers. The existing cooling towers and pumps are sized so that the entire heat rejection load can be accomplished with one (1) cooling tower and one (1) cooling tower pump.

2. Currently, the building is equipped with two water cooled centrifugal water chillers. CH-2 was upgraded from 400-tons to 900-tons as part of previous project phases. The chilled water pump, CHWP-2 was also upsized to accommodate the additional chilled water flow. The intent of this phase of the project is to upgrade the remaining chiller and chilled water pump (CH-2 and CHWP-2) so that the entire chiller system will be redundant. The chilled water piping and the condenser water piping will be increased in size to accommodate the additional water flow rates.

USDA-ARS Athens, GA

6.0 Electrical Power Systems

6.1 Electrical Design Standards

1. USDA ARS Facilities Design Standard 242.1

2. NFPA 70 National Electrical Code 2023 Edition

3. NFPA 101 Life Safety Code 2024 Edition

4. ASHRAE 90.1 Energy Standards for Buildings Except Low Rise Residential

Buildings, 2019

6.2 Electrical System Overview

1. The project will be powered from the existing main electrical switchgear. The switchgear is a 3200-amp, 3-phase 4-wire, 480/277-volt, 85-kA SSCR. The switchgear has two normal power utility connections and an emergency connection.

2. During the construction of Phase 2, there were existing conditions that prevented the electrical contractor from proceeding with original plan. As a result, a work proposal was generated to provide alternatives to powering the chillers. The work proposal can be found in Appendix B. The proposal mentioned that the existing switchgear breaker designated as “spare” to power the chiller in Phase 2 was not compatible with the design intent. The breaker was manufactured to accept a bus way connection instead of cable connections. As a result, the Phase 3 chiller will be fed from this spare breaker and will utilize a busway connection and then transition to cabling out in the main mechanical space. This will mirror the existing conditions of the busway that is powering the recently replaced chiller. Utilizing a connection that is native to the existing breaker will reduce outages and coordination issues with modifying or replacing the breaker. The proposal describes that to reconfigure the existing breaker to accommodate cabling would require two separate shutdowns and significant lead time considerations.

3. The existing spare breaker is a 1600-amp frame with a 1200-amp trip. The breaker is a Square D masterpact NW 16 H2. The proposed chiller has a maximum overcurrent protection (MOCP) rating of 1200-amps. The existing breaker size and configuration will be sufficient for the new chiller.

USDA-ARS Athens, GA

7.0 Architectural

7.1 Architectural Design Standards

1. USDA ARS Facilities Design Standard 242.1

2. IBC 2021 International Building Code, 2021 Edition

3. IEBC 2021 International Existing Building Code, 2021 Edition

4. NFPA 101 Life Safety Code, 2024

7.2 Architectural Overview

The existing opening between the boiler room and the chiller room was temporarily enlarged during Phase 2 to allow access for the new chiller to be brought into the chiller room. Some of the existing CMU blocks were removed and a temporary support was installed. The existing opening is partially blocked by the boiler control room which was most likely installed after the original construction of the building. The opening will be finished out and will become a cased opening.

8.0 Appendix A – Mechanical Equipment Cut Sheets

Unit Features

Chiller Model Refrigeration Capacity Total Power Fullload Eff Refrigerant Line Volt Line Frequency Starter Type

CVHF 900.0 tons 522.6 kW 0.5807 kW/ton R-514A 460. V 60. Hz VFD

Unit Overview Application type Standard cooling

Insulation Unit insulation package

Rupture Guard RuptureGuard-relief valve-field install

Tracer Controls BACnet Spring Isolators Spring isolators

Compressor 870 Impeller 309

Orifice 1335 NPLV.IP 0.3700 kW/ton

Rated NPLV.IP 0.3700 kW/ton

Selection Tolerances Selection Tolerance AHRI Tolerance w/ Test

Shell Information Evaporator Condenser

Fluid Temperature Entering 50.00 F 85.00 F Leaving 40.00 F 95.00 F

Fluid Properties Fluid Type water water

Fluid Concentration 0.00 % 0.00 %

Fouling Factor 0.000100 hr-sq ft-deg F/ Btu

0.000250 hr-sq ft-deg F/ Btu

Flow Rate Design Flow 2149 gpm 2540 gpm

Min Flow 873.0 gpm 1418 gpm Max Flow 4802 gpm 5197 gpm

Fluid Pressure Drop PD at Design Flow 15.5 ft H2O 10.3 ft H2O

PD at Min Flow 2.71 ft H2O 3.63 ft H2O PD at Max Flow 66.9 ft H2O 36.8 ft H2O

Evaporator Condenser

Construction Features Shell Size 142L 142L

Bundle Size 1750 1420 Tube Type TECU IECU

Tube Thickness 0.025" 0.025"

Connection Type Victaulic connection evap.

Victaulic connection cond.

Water box type non-marine non-marine Water box pressure 150 psig 150 psig

Wbox Arrangement Evap in RH end - evap out RH end

Cond in RH end - cond out RH end

Flow Proving Thermal dispersion flow switch (IFM)

Thermal dispersion flow switch (IFM)

Number of Passes Two pass evap water box

Two pass cond water box

Fluid Volume 35.59 cu ft 46.58 cu ft

Unit Electrical

Low Voltage AFD type UM refrig-cooled AFD w/ harmonic filter

Low Voltage AFD connection type Circuit breaker AFD frame size 900 max RLA

Low Voltage AFD enclosure type Standard enclosure - NEMA 1 Motor 598

Total Power 522.6 kW

Min Circuit Ampacity 863.00 A Max Overcurrent Protection 1200.00 A

Nameplate RLA 741.80 A Primary RLA 691.30 A

Motor Locked Rotor Amps 4743.00 A

Physical Information Operating Weight 39641.0 lb

Cond Shell Construction

Standard condenser construction

Agency Listing U.L. / CUL listed

Shipping Weight - No Charge 33582.0 lb

Regional Code Requirement No Requirement

Chiller Heat Rejected to ambient 8.921 MBh

Refrigerant charge 1600.0 lb AFD Heat Rejected to ambient 18.43 MBh

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1 Sales Office:

Information for AHRI and ASHRAE Projects

AHRI 550/590 2015

classification Certified

ASHRAE 90.1-2007 Complies ASHRAE 90.1-2007 Add. M Complies

ASHRAE 90.1-2010 Complies ASHRAE 90.1-2013 Complies ASHRAE 90.1-2016 Complies ASHRAE 90.1-2019 Complies ASHRAE 90.1-2022 Complies

Certified in accordance with the AHRI Water-Cooled Water- Chilling and Heat Pump Water-Heating Packages Certification Program, which is based on AHRI Standard 550/590 (I-P) and AHRI Standard 551/591 (SI). Certified units may be found in the AHRI Directory at www.ahridirectory.org.

Warranty Labor 1st year 1st year labor warranty whole unit

Information for LEED Projects Refrigeration capacity 900.0 tons

Refrigerant charge 1600.0 lb Total power 522.6 kW

NPLV.IP 0.3700 kW/ton Rated NPLV.IP 0.3700 kW/ton

Compliant with the requirements of the LEED Energy and Atmosphere Enhanced Refrigerant Management Credit (EAc4) due to the R-514A refrigerant GWP being less than 2.

Note: Trane recognizes and respects the U.S. Green Building Council® mandate that a default 2% Refrigerant Leakage Rate (Lr) be used by all manufacturers of centrifugal chillers when calculating the Enhanced Refrigerant Management Credit because there is no industry standard. Trane has exhaustively documented a leak rate of less than 0.5% for CenTraVac™ chillers (models CVHE, CVHF, CVHG, CVHS, CVHM, CDHF, CDHG, CVHH and CDHH) and utilizes an average design refrigerant charge of less than 2 lb./ton.

The U.S. Green Building Council’s LEED® green building program is the preeminent program for the design, construction, maintenance and operations of high-performance green buildings. It provides independent, third-party verification that a building project meets the highest green building and performance measures.

Trane Select Assist Version Number: 55287

Data Generation Date: 9/19/2024

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Compressor-Motor Direct drive multiple-stage compressor, multi-stage capacity control guide vanes. Shrouded aluminum alloy impellers dynamically balanced. Motor-compressor assembly balanced to .15 in./sec (.0038m/sec) maximum vibration measured on motor and bearing housings. Refrigerant cooled, hermetically sealed, two-pole, squirrel cage induction motor. Two pressure lubricated bearings support the rotating assembly. A direct drive submerged oil pump motor, 3/4 hp (.560 kW) 115V/50/60/1 provides filtered and temperature controlled oil to compressor bearings.

Evaporator-Condenser Shells are carbon steel plate. Evaporator includes rupture disk per BSR/ASHRAE 15 Safety Code.

Carbon steel tube sheets are drilled, reamed and grooved to accommodate tubes. Tubes are individually replaceable externally finned seamless copper. Tubes are mechanically expanded into tube sheets. Eliminators are installed over entire length of the evaporator tube bundle. A multiple orifice control system maintains proper refrigerant flow. Condenser baffle prevents direct impingement of compressor discharge gas upon the tubes. Refrigerant side of the assembled unit is tested at both pressure(30.00 psi leak test) and vacuum. Water side is hydrostatically tested at one and one-half times design working pressure, but not less than 225.00 psi.

Trane reserves the right to implement chiller technology enhancements that will reduce the chiller's refrigerant charge, with no impact on chiller performance. Changes may be reflected in the chiller's nameplate refrigerant charge and the quantity of refrigerant charge shipped to the jobsite, depending upon the final date of equipment manufacture.

Water Boxes Drains and vents - Water boxes typically have 3/4-inch NPTI vents and drain connections provided.

Evaporators have 2 vents and 2 drains, condensers have 1 vent and 1 drain. If grooved connections are offered, the design is based on Style 77.

Non-marine water boxes have water connections that extend out from the end.

Evaporator Water box Hinge The water box is provided with a hinge on one or both ends of the evaporator to facilitate access to and maintenance of the evaporator tubes as needed without the need for separate rigging. See the dedicated drawing of the hinge(s) being supplied.

CondenserWater box Hinge The water box is provided with a hinge on one or both ends of the condenser to facilitate access to and maintenance of the condenser tubes as needed without the need for separate rigging. See the dedicated drawing of the hinge(s) being supplied.

Economizer A flash economizer with no moving parts provides power saving capability.

Purge System The EarthWise(TM) purge includes a 1/4 hp 115V/60/1, 100V/50/1 air cooled condensing unit, purge tank, drier elements, and a 1/20 hp (.037 kW) 115V/60/1, 110V/50/1 pump-out compressor. The purge is designed with an activated carbon filtration system that includes an autoregeneration feature which results in automatic high-efficiency removal of noncondensibles from the chiller without manual carbon maintenance. The purge meets Green Seal GS-31 with a leak rate less than 1.0% of the charge per year and also meets ASHRAE 147 with a leak rate of less than one unit mass of refrigerant per unit of air.

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

AdaptiView Control Panel:

The Tracer(tm) AdaptiView is a microprocessor-based chiller control system that provides complete stand alone system control and monitoring for the water cooled CenTraVac (TM). It is a factory mounted package including a full complement of controls to safely and efficiently operate the CenTraVac chiller, including oil management, purge operation, interface to the starter, and comprehensive motor protection including three phase solid state motor overload. Inlet and outlet water (fluid) temperature sensors are located in the evaporator and condenser waterbox connections as standard.

The display is a touch sensitive 12 1/8" diagonal color liquid crystal display (LCD) that uses color graphics and animation to ensure ease of use. The touch sensitive interface allows the operator to view the chiller graphically and receive a status indication via subsystem animations. The operator can navigate easily between the primary chiller subsystems including: compressor, evaporator, condenser, and motor. For each subsystem, you can view status and detailed operating parameters.

In addition, alarms, reports, trending, and settings can all be accessed quickly from the main screen.

The display is mounted on a flexible "arm" that allows extensive height and viewing angle variations.

The panel supports an extensive list of languages including the default English. The data can be set to be viewed in inch pounds IP or metric units SI. For remote starters - Class 1 control panel voltage (30-115 V) are clearly labeled in the control panel. Class 2 input voltage (30V max) is also labeled in the control panel.

Operating Data including:

*operating hours *number of starts *chilled water setpoint *evaporator and condenser water flow status *evaporator entering and leaving water temperatures *evaporator saturated refrigerant temperatures *evaporator approach temperature *evaporator refrigerant pressure *condenser entering and leaving water temperatures *condenser saturated refrigerant temperatures *condenser approach temperature *condenser refrigerant pressure *oil differential pressure *oil tank temperature *purge mode *purge average daily pump-out time *% RLA per phase for motor *RLA per phase *volts per phase *power factor *kw *kwh *frequency

The AdaptiView also contains the following dedicated reports:

Evaporator, Condenser, Compressor, Motor, Purge, and ASHRAE. Each report is comprised of a detailed listing of operational data relative to that chiller subsystem.

Control functions including:

*leaving chilled water temperature *percent demand limit *chiller water reset (based on return water temperature *front panel control type *setpoint source *differential to start *differential to stop

Status data including:

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

*waiting to start *running *run limit *run inhibit (adaptive) *auto *free cooling (option) *preparing to shutdown *shutting down (post lube) *stopped

Safeties including:

Automatic safety shutdown for:

*Low chilled water temperature, *low evaporator refrigerant temperature *high condenser refrigerant pressure *evaporator and condenser flow status *low oil pressure *oil pressure overdue *high or low oil temperature *high bearing oil temperature (requires enhanced protection option) *high motor current *high motor temperature *starter function faults *critical temperature and pressure sensor faults

The devices are of a latching trip out type requiring manual reset. Non-latching safety trip outs for operating conditions external to the chiller automatically permits unit to resume normal operation when condition is corrected.

Advanced motor protection monitors 3-phase current to provide latching trip out protection from adverse effects of phase loss, phase unbalance, phase reversal, loss of phase reversal protection, and electrical distribution faults (momentary power loss) by instantaneous trip out of motor.

Surge protection - Detects surge and limits chiller loading through inlet vane modulation. Head relief through lowering cooling tower water temperature can be requested. If not corrected within 7 minutes, chiller is shut down.

Enhanced Adaptive Control(TM) - Built in intelligence to keep the chiller on line (safely making maximum tons) while simultaneously preventing chiller damage/failure. During any chiller limiting mode of operation, the control panel enunciates the condition via a relay output.

Trending:

The controller provides 10 standard graphs for trending multiple parameters, The operator can add an additional 6 custom graphs if desired. On any one custom graph, the operator can choose to trend up to 10 unique parameters from a more comprehensive list. Two Y axes are available for any graph to facilitate readability.

Diagnostics:

AdaptiView includes comprehensive diagnostic monitoring. All active diagnostics are available, and up to 20 historic diagnostics are communicated to the operator via the 12 1/8" LCD display with graphic navigation system. Each diagnostic is time and date stamped.

Security:

The AdaptiView can be set to prevent unauthorized access to the chiller settings. The operator can choose to secure the operating settings with a password. Data and reports can still be accessed once the settings are locked out.

The memory for the AdaptiView is non-volatile type, so if power is lost, operating settings are retained.

A life time battery is standard, which is used only to support the clock function for the chiller.

Chilled and Condenser water pump relays:

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Chilled water and condenser water pump relays are provided and it is recommended that they be used for pump control.

BACnet(MSTP) Direct Points List:

The following points are available directly from the chiller. Recognize that some of these points require chiller options or configurations.

Inputs Including Chiller Auto/Stop Chiller Mode (e.g. cool) External Base Loading Enable/Disable (requires Extended Operation option) External Base Loading Setpoint (requires Extended Operation option) Chilled Water Setpoint Current Limit Setpoint Heating Setpoint (requires Extended Operation option) Wall Mounted Refrigerant Specific Monitor (requires Extended Operation option) Clear Diagnostics

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Outputs Including Evaporator Pump relay Condenser Pump relay Chilled Water Flow Status Condenser Water Flow Status Evaporator Water Flow Rate (requires Flow Compensation option) Condenser Water Flow Rate (requires Flow Compensation option) Chiller capacity (requires Flow Compensation option) Leaving Chilled Water Temperature Entering Chilled Water Temperature Entering Condenser Water Temperature Leaving Condenser Water Temperature Second Condenser Entering Water Temperature (requires HR or Aux condenser bundle) Second Condenser Leaving Water Temperature (requires HR or Aux condenser bundle) Active Chilled/Hot Water Setpoint Active Current Limit Setpoint Active Base Loading Setpoint (requires Extended Operation option) Head Relief Request relay Compressor Running relay Chiller On/Off Limit Warning relay Maximum Capacity relay Alarms Description1

Manual Reset Alarm relay Auto Reset Alarm relay Purge Alarm relay

Alarm Reset Condenser Refrigerant Pressure Condenser Refrigerant Temperature Evaporator Refrigerant Pressure Evaporator Refrigerant Temperature Compressor Discharge Refrigerant Temperature (requires Enhanced Protection option) Differential refrigerant pressure (not for head pressure control) Operating Status (Alarm, Run Enabled, Local Control, Limited) Chiller Modes (i.e. Off, Starting, Running, Shutting Down) Base Loading Active (requires Extended Operation option) Hot Gas Bypass Active (requires Hot Gas Bypass option) Operating Mode (e.g. Cool) Current Per Line Voltage Per Phase Unit Power Consumption (kW) Motor winding temperature Motor power factor (uncorrected) Oil Temperature Oil Pressure Differential

High Side Oil Pressure Low Side Oil Pressure

Compressor Starts Compressor Run Time Inlet guide vane position Inboard bearing oil temperature (requires Enhanced Protection option) Outboard bearing oil temperature (requires Enhanced Protection option) Purge Status2 Purge pumpout Average (24 hour) Purge pump-out Purge regeneration Purge carbon tank temperature Purge liquid temperature Purge suction temperature Purge time to next purge run Purge pump-out chiller on-7 days

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Purge pump-out chiller off-7 days Purge pump-out life Purge regeneration life Refrigerant Monitor AFD output frequency AFD transistor temperature

Hardwire BAS Interface provides:

Chilled Water Setpoint input - Provides for setpoint adjustment of control point from multiple sources Current Limit Setpoint input - provides for setpoint adjustment of control point from multiple sources Percent RLA Output - provides % RLA output Condenser Pressure Output - A hardwire output signal of condenser pressure, or differential pressure between the evaporator and condenser is provided.

Operating Status:

The following hardwire binary outputs are available:

Compressor running relay Alarm relay - manual reset Alarm relay - auto reset Limit warning relay Purge alarm relay Head relief request relay Maximum capacity relay

Evaporator Proof of Flow - Thermal Dispersion A factory provided, field installed thermal dispersion type proof of flow switch (IFM) is provided. The thermal dispersion controller is mounted in the chiller control panel, the piping probe and wiring is shipped lose for field installation in the ship with components box. Follow the installation instructions in the chiller installation manual. Reference specific IFM Installation manual (PART-SVN223*-EN) notes shipped with your flow switch /contact local Trane sales office

Condenser Proof of Flow - Thermal Dispersion A factory provided, field installed thermal dispersion type proof of flow switch (IFM) is provided. The thermal dispersion controller is mounted in the chiller control panel, the piping probe and wiring is shipped lose for field installation in the ship with components box. Follow the installation instructions in the chiller installation manual. Reference specific IFM Installation manual (PART-SVN223*-EN) notes shipped with your flow switch /contact local Trane sales office

Paint All CenTraVac(TM) painted surfaces are coated with a primer and an air-dry beige primer-finisher prior to shipment.

Isolation All units ship with neoprene isolator pads as standard, except when spring isolators are chosen.

Enough pads are provided to cover the area under the chiller supports.

Spring Isolators:

Spring Isolators direct ship from the supplier. With this option neoprene isolation pads are not furnished. Restrained type, (aka. seismic certified or "snubbed"), isolators are not available from Trane. CAUTION: Standard spring isolators are NOTfor use as seismic isolation devices!

Reference specific Chiller Installation manual installation notes shipped with your chiller/contact local Trane sales office.

Shipment All units are of hermetic design, leak tested, charged to 5.00 psi and shipped as a single factory assembled package. Full oil charge shipped in oil sump. Refrigerant shipped to jobsite from refrigerant manufacturer. The entire chiller is shrink wrapped for protection.

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Insulation Factory applied insulation. All low temperature surfaces are covered with 3/4" Armaflex ll or equal (thermal conductivity=0.28 BTU/hr-ft sq.) (1.59 W/m2-K), including the evaporator, water boxes and suction elbow. The economizer is insulated with 3/8" insulation. The chiller feet are not insulated. On units with the water box hinges option, the hinges are not factory insulated. On units with the free cooling option, the condenser is not factory insulated.

RuptureGuard-Relief Valve-Field Install RuptureGuard is a Trane supplied field installed refrigerant containment system that replaces a chiller's rupture disk. The system consists of a non-fragmenting rupture disk and a pressure relief valve that can be applied to all low pressure centrifugal chillers. This system functions as the chiller's primary pressure relieving device and provides a leak free seal between the chiller and atmosphere.

The pressure relief valve is installed in place of the factory shipped rupture disk (which must be removed) and functions as an interim primary pressure relieving device and seal. When the chiller's internal pressure exceeds 15 psig [104 kPa], the non-fragmenting rupture disk bursts allowing the pressure to be relived through the relief valve. After the chiller's pressure is reduced, the pressure relief valve recloses stopping the flow of refrigerant to the atmosphere. A pressure switch is included with the RuptureGuard package as standard. This switch has single pole, double throw contacts for interface to external monitoring systems. The switch has a trip setting of 11 psig, reset values of 8 psig, and is rated for 5A at 220 volts. Reference specific Rupture guard Installation manual (CTV- SVX06*-EN) notes shipped with your rupture guard /contact local Trane sales office.

TRANE Adaptive Frequency Drive (AFD) The Trane AFD is a closed-loop, liquid refrigerant cooled, microprocessor based pulsed width modulation design. The AFD is both voltage and current regulated. Output power devices: IGBT transistors.

The AFD is factory mounted on the chiller and ships completely assembled, wired and tested.

Patented Trane AFD control logic is specifically designed to interface with the centrifugal water chiller controls. AFD control adapts to the operating ranges and specific characteristics of the chiller, and chiller efficiency is optimized by coordinating compressor motor speed and compressor inlet guide vane position. Chilled water control and AFD control work together to maintain the chilled water setpoint, improve efficiency and avoid surge. If a surge is detected, AFD surge avoidance logic will make adjustments to move away from and avoid surge at similar conditions in the future. Use only copper conductors for terminal connections. Failure to do so may cause corrosion or overheating, and starter damage.

This unit mounted AFD is supported by three cantilevered support brackets. These support brackets are normally welded to the side of the evaporator shell and extend out the depth of the AFD. For some AFD sizes and chiller configurations, the support brackets have a bolt plate which allows the majority of the length of these support brackets to be removable.

Frame 3 (405A/608A): AFD Support brackets are welded to the evaporator shell.

Exceptions: The following compressor/shell combinations have supports with bolt plate as standard for a Frame 3 AFD:

- compressor sizes 620/760/870 on 080 evaporator with 080 condenser shells

- compressor sizes 1070/1300 on 142 evaporator with 210 condenser shells.

Frame 4 (900A/1210A): AFD Support brackets have bolt plate so most of the bracket is removable.

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

AFD Design Features

* NEMA 1 ventilated enclosure with a hinged, locking door is tested to a short circuit rating of 65,000 amps. It includes a padlockable door-mounted circuit breaker/shunt trip with AIC rating of 65,000 amps. The circuit breaker is NOT interlocked with the enclosure door.The entire package is UL/CUL listed.

* Simple modular construction.

* The drive is rated for maximum 480/60/3 input power, +/-10%.

* Displacement power factor of 0.98 at full load, and 0.96 at part load.

* Minimum efficiency of 97% at rated load and 60 hertz.

* Full motor voltage is applied regardless of the input voltage.

* Soft-start; linear acceleration; coast to stop.

* Adjustable output frequency from 38 to 60 hertz.

* All control circuit voltages are physically and electrically isolated from power circuit voltage.

* 150% instantaneous torque available for improved surge control.

* Output line-to-line and line-to-ground short circuit protection.

* Harmonic attenuation- integrated active rectification control of the building AC power assures low line -generated harmonics back to the user's power grid. The AFD has less than or equal to 5% current total demand distortion (TDD) as measured at the AFD. This is based on an electrical system with voltage distortion less than 1.5 %.

Chiller Unit Control Features for AFD Chiller Unit Control Features for AFD The chiller unit control panel capabilities provide for the control/configuration interface to, and the retrieval/display of, AFD-related data. AFD standard design features controlled through AdaptiView include:

* Current limited to 100%

* Motor overload protection.

* Motor overtemperature protection.

* Phase loss, reversal, imbalance protection.

* Overvoltage/undervoltage protection.

Digitally displayed on the AdaptiView panel: output speed in hertz, input frequency, output speed in rpm, input line voltage, output voltage, input line kw, output kw, input line amps per phase, average input line amps, output/motor amps average current in % RLA, load power factor, fault, AFD transistor temperature.

Environmental Ratings:

* 32F to 104 (0C to 40) operating ambient temperature

* Altitude to 3300 feet (1000m), amperage derate of 1% per every 300 feet above 3300 feet

* Humidity, 95% non-condensing

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Required Installer Responsibilities The following are considered functions normally required of the equipment installer./n

Install unit on a foundation with flat support surfaces level within 1/16" and of sufficient length to support concentrated loading. (Spring isolators should be considered whenever chiller installation is planned for an upper story location.)

Place isolation pads or optional spring type isolators provided by the chiller manufacturer under the unit. When spring isolators are chosen, no pads are provided.

Install unit per applicable Trane Installation Manual.

Complete all water and electrical connections.

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

Furnish and install a flow switch or equivalent device in both the chilled water and condenser water piping properly interlocked to insure that unit can operate only when water flow is established.

Furnish and install taps for thermometers and pressure gauges in water piping adjacent to inlet and outlet connections of both evaporator and condenser.

Furnish and install drain valves to each water box.

Install vent cocks on each water box.

Furnish and install strainers upstream of chiller evaporator and condenser bundles to protect tubes from potential damage caused by debris in the circulating water. Note: Failure to install strainers in all water piping entering the chiller could result in tube plugging conditions that could damage unit components. If the circulating pumps are immediately upstream of the chiller bundles, then the strainer can be installed immediately ahead of the pumps. If the circulating pumps are downstream of the chiller bundles, then the strainers should be installed immediately ahead of the chiller bundles.

Furnish sufficient refrigerant 25.0 lb per machine and dry nitrogen 50.0 lb per machine for pressure testing under manufacturer's supervision.

Start-up unit under supervision of a qualified Trane field engineer.

Where specified, insulate evaporator and any other portions of machine required to prevent sweating under normal operating conditions.

Water connection piping must not transfer forces to the chiller. Because of cumulative tolerances in manufacture and field installation, prepiping of water connections closer than 36" is not recommended.

Any problems associated with prepiping of water connections closer than 36" to the chiller are the responsibility of the installing contractor.

Furnish and install vent lines for rupture disk and purge venting to atmosphere per ASHRAE 15 and unit installation manual. If RuptureGuard-Relief Valve option is ordered, remove factory rupture disk and install RuptureGuard-Relief Valve per the IOM manual. In some chiller configurations the RuptureGuard may not bolt directly to the chiller flange. Locally sourced and approved piping may be required between the chiller and the RuptureGuard.

Field Disassembly With chillers that may require field disassembly (for example due to clearance concerns during unit installation) reference the Disassembly and Reassembly manual and your Trane Sales representative prior to the order being placed. Caution: if certain components are removed in the field, for example the economizer, the necessary components (gaskets, seals, etc.) are not provided as standard.

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

Leak-Tight Warranty The CenTraVac chiller features a 5-year limited Leak-Tight Warranty which is valid for the lesser of 60 months from initial start-up or 66 months from date of shipment. The limited Leak-Tight Warranty covers models CVHE/F/L, CVHS, CVHM and CDHF chillers installed in the United States or Canada.

The Company's obligations and liabilities under this warranty are limited to furnishing replacement refrigerant; no other parts or labor are covered under this limited warranty. No liability whatever shall attach to the Company until appropriate actions have been taken (acceptable to Company) to eliminate the source of the leak, and then said liability shall be limited to furnishing the replacement refrigerant.

If the chiller is placed under a comprehensive Trane service and maintenance agreement (Trane Select Agreement or better) prior to the expiration of the standard Leak-Tight Warranty, the protection against refrigerant loss shall continue under the Trane Select Agreement for as long as an active Trane Select Agreement remains in effect without interruption.

If a 10-Year Parts, Labor and Refrigerant Warranty was purchased for the chiller and the chiller is placed under a Trane Select Agreement (or better) prior to the expiration of the 10-Year Parts, Labor and Refrigerant Warranty, the protection against refrigerant loss shall continue under the Trane Select Agreement for as long as an active Trane Select Agreement remains in effect without interruption

Job Name: USDA Athens GA Unit Tag: CH-2 Prepared For: Quantity: 1

WPD vs Flow Rate

541749174417391734172917241719171417

Flow Rate (gpm) Version 31.08, REVL 55287

W

PD

(ft H

2O

WPD vs Flow Rate

537348734373387333732873237318731373873

Flow Rate (gpm) Version 31.08, REVL 55287

W

PD

(ft H

2O

PRODUCT DATA

ITEM NO. MODEL NO.

IMPELLER DIAMETER

GPM

HEAD/FT

WEIGHT

VOLTAGE

RPM

PUMP/MOTOR

HORSEPOWER

JOB:

ENGINEER:

REPRESENTATIVE:

CONTRACTOR:

English dimensions are in inches. Metric dimensions are in millimeters.

Metric data is presented in ( ). Do not use for construction purposes unless certified.

OPERATING SPECIFICATIONS

FLANGE PRESSURE TEMPERATURE

ANSI Class

175 PSIG*

(1210 KPA)

250°F (120°C)

ANSI Class

300 PSIG**

(2070 KPA)

250°F (120°C)

Motors: All NEMA Standard (T Frame)

* In accordance with ANSI Standard B16.1 Class 125 ** In accordance with ANSI Standard B16.1 Class 250

DIMENSIONS

HORSEPOWER 50 60 75 100 125 150 200

O D

P

MOTOR FRAME 326T 364T 365T 404T 405T 444T 445T

G MAX 23.69

(601) 29.83 (757) 37.10

(942) 34.59 (879)

39.84 (1012)

39.69 (1008)

MAXIMUM

ASSEMBLY

WEIGHT

LBS. (KG)

1533 (695) 2007 (911) 2215 (1005) 2909 (1319)

TE

FC

MOTOR FRAME 326T 364T 365T 405T 444T 445T 447T

G MAX 30.52

(775) 33.61 (853) 38.17

(959) 44.88 (114) 48.37 (1128)

MAXIMUM

ASSEMBLY

WEIGHT

LBS. (KG)

1533 (695) 2007 (911) 2215 (1005) 2909 (1319) 3647

(1654)

A ANSI Class 125: 10 (254)

ANSI Class 250: 10.69 (271)

B ANSI Class 125: 19 (483)

ANSI Class 250: 19.5 (495)

C 25.17 (639)

D 60.0 (1524) 74.0 (1880)

E ANSI Class 125: 2.38 (60)

ANSI Class 250: 1.69 (43)

F 16.59 (421)

J ANSI Class 125: 31.63 (803)

ANSI Class 250: 32.32 (821)

K 23.67 (601)

N 2 (51)

P 56.0 (1422) 70.0 (1778)

8013D

Model No. | 8013D Flange Size (Suction x Discharge) | 10 x 8 (254 x 203)

FI Series Pump | Submittal Data Submittal No: 301-1489D | Model: 8013D | RPM: 1760 - 60 Hz | Effective: January 27, 2020 | Supersedes: August 16, 2019

Configuration DOE Basic Model Number PEI Value Energy

Rating

Bare Pump FI8013D-4P-BP PEIcl 0.94 6

Pump + Motor FI8013D-4P-PM PEIcl 0.94 6

F E E T

REQUIRED NPSH

0 1000 2000 3000 4000 5000

FLOW IN GALLONS PER MINUTE

H E A D

I N

F E E T

9.5"(241mm)

10.5"(267mm)

11.5"(292mm)

12.5"(318mm)

13.5"(343mm)

CURVES BASED ON CLEAR WATER

WITH SPECIFIC GRAVITY OF 1.0

H

P

K

W

H

P

K

W

H

P

K

W

H

P

K

W

H

P

K

W

H

P

K

W

H

P

K

W

H E A D

I N

M E T E R S

0 50 100 150 200 250 300

L/SEC

H E A D

I N

K I L O P A S C A L S

M E T E R S

K P A

FI Series | Model: 8013D | 1760 RPM

Curve No. 4088 | Min. Imp. Dia. 9.5" | Size 10x8x13.5 | January 22, 2020

Energy Efficiency Rating: DOE Basic Model Number: FI8013D-4P-PM

Pump & Motor: PEI

CL

: 0.94 | ER

CL

: 6

PC-4088 Rev A 1220

COMMENTS

N/A - Not Available

MATERIALS OF

CONSTRUCTION CASING COVER IMPELLER WEAR RING SHAFT SHAFT

SLEEVE

MECHANICAL

SEAL

SEAL

FLUSH LINE

ASSEMBLY

STANDARD

CONSTRUCTION

125#

FLANGE

Cast Iron ASTM A48/ A48M-03 Class 30A

Cast Iron ASTM A48/A48M-03

Class 30A

Bronze ASTM

B584 ALLOY

C83600 or C84400 N/A

Stainless Steel

TYPE 416”T

ASTM A582

Bronze ASTM B584-98A C92200 Ceramic/EPT N/A

250#

FLANGE

Ductile Iron ASTM A536-84

Grade 65-45-12

Cast Iron ASTM A48/A48M-03

Class 30A

Bronze ASTM

B584 ALLOY

C83600 or C84400 N/A

Stainless Steel

TYPE 416”T

ASTM A582

Bronze ASTM B584-98A C92200 Ceramic/EPT N/A

OPTIONAL 125# OR

250# N/A N/A

Stainless Steel

ASTM A351/A

351M-08

Bronze ASTM B584-98A C92200 N/A

Stainless Steel

TYPE 303 ASTM

A276

Tyngsten Carbide /EPT or Silicon-

Carbide/EPT

Copper & Brass C3600

T ag

P

-2 F lo w

R at e (G

P M

H ea d (F

T

W or ki ng

F lu id

W at er

F

E ffi ci en cy

C on st ru ct io n:

Ir on

D es ig n

H p:

.8

N ol

H p:

.6

M ot or H p:

.0

N ps h (F t)

R P

M

Im p

D ia

.0

N ot es

B as e-m o u n te d e n d s u ct io n P u m p s

M o d el

F

I8

3D

USDA - Ath...

P-2 SD120100-5 10"

USDA - Ath...

P-2 MPV120-4 120"