Sec15700 - Chiller Specifications - LETC.pdf

DOCJT - FUNDERBURK CHILLER PURCHASE

JUSTICE CABINET- DIVISION OF CRIMINAL JUSTICE TRAINING

LAW ENFORCEMENT TRAINING CENTER

RICHMOND, KY

FILE NO. 525-C8XA-CJ08-00

PRE-PURCHASED WATER CHILLERS 15700 - 1

SECTION 15700 - PRE-PURCHASED WATER CHILLERS 1

PART 1 - GENERAL 4

DESCRIPTION OF WORK 7

Extent of water chiller work is indicated by requirements of this 9 section. 10 Types of water chiller specified in this section include the following: 12 Centrifugal compressor machine (conventionally oiled) -- open or 14 closed motor; 15

OR 17

Magnetic-bearing (oil-less) machine – closed motor 19

Ingress: The vendor will verify the actual dimensions and routing to 22 ensure that the chiller can pass through the required spaces. If required 23 for installation, supervision of disassembly and re-assembly of the 24 chiller (by the Installing Contractor), shall be the responsibility of 25 the vendor. 26 Electrical: Furnish electrical field-wiring diagrams to installing 28 contractor power wiring and starters for water chiller, and control 29 wiring for field-mounted controls. Wiring will be the responsibility of 30 the installing contractor. 31

WORK BY OTHERS 34

Under separate contract, the Installing Contractor will be responsible 36 for receiving, unloading, temporary on-site storage (if needed) and 37 installing the equipment and material at the delivery point as described 38 in the Special Conditions. The chiller vendor shall be responsible for 39 coordination of the delivery and required work (as specified herein) with 40 the Installing Contractor. 41

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QUALITY ASSURANCE 1

Regulatory Requirements: 3 Kentucky Building Code: Chiller shall comply with all relative sections 5 of the latest edition. 6 AHRI Compliance: Provide certified capacity ratings for water chiller 8 in accordance with Air-Conditioning Heating and Refrigeration 9 Institute (AHRI) Standard 550/590, current version as of this bid date 10 (hereinafter referred to as “AHRI Standard(s)”). NOTE: these 11 specifications take certain exceptions to AHRI Standards in selection 12 and testing requirements. 13 ASHRAE Compliance: Construct refrigerating system of water chiller in 15 accordance with American Society of Heating, Refrigerating, and Air 16 Conditioning Engineers (ASHRAE) Standard ANSI/ASHRAE 15 "Safety Code for 17 Mechanical Refrigeration". Include all proposed safety features and/or 18 devices required by ASHRAE for refrigerants declared to be toxic. 19 Chiller shall meet ASHRAE 90.1 2016 efficiency requirements at standard 21 AHRI 550-590 conditions. Chiller manufacturer shall provide ARI 22 certified performance data showing compliance. 23 ASME Compliance: When required by code, construct and test water chiller 25 in accordance with American Society of Mechanical Engineers (ASME) Boiler 26 and Pressure Vessel Code, Section VIII. 27 National Testing Approval: Chillers and accessories (where applicable) 29 shall be approved by Underwriter’s Laboratories, Inc. or other nationally 30 recognized testing agency. 31

SUBMITTALS: 34

Product Data: Submit manufacturer's technical product data, including 37 rated capacities of selected model clearly indicated, weights (shipping, 38 installed, and operating), furnished specialties and accessories; and 39 installation and start-up instructions. 40 Submittal Drawings: Submit manufacturer’s drawings indicating dimensions, 42 weight loadings, required clearances, and methods of assembly of 43 components. 44 Wiring Diagrams: Submit ladder-type wiring diagrams for power and control 46 wiring required for final installation of water chiller and controls. 47 Clearly differentiate between portions of wiring that are factory-48 installed and portions to be field-installed. 49

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Maintenance Data: Manufacturer shall submit maintenance/operational 1 manuals, and parts list for each water chiller, control, and accessory; 2 including "trouble-shooting" maintenance guide. Include current 3 service/repair/overhaul manuals. Furnish to owner any updated or newly 4 released related materials when available during the first five years of 5 service. 6 If equipment rebuild/overhaul intervals are required within the twenty-8 year life-cycle period, provide the required service items, frequency or 9 milestone points for such service, estimated downtime for the service, 10 and estimated number of service technician hours for the service. Costs 11 for such services outside of the initial five-year service requirements 12 (years six through twenty) shall be listed, but the costs will not be 13 included in the purchase price. 14 Service Task(s) ________________________ 16 Frequency/Milestone ________________________ 17 Estimated downtime for task(s) ________________________ 18 Estimated technician hours for task(s) ________________________ 19

CHILLER OPERATION AND MAINTENANCE MANUALS 22

Provide five(5) bound final installation, training, operation, 24 maintenance and repair manuals to be turned over to the Owner's 25 Representative and approved for content by the Engineer prior to 26 acceptance of substantial completion. 27 Manuals provided must be of sufficient detail to enable customer to 29 install, calibrate, train, operate, maintain, service and repair every 30 system, subsystem, and/or piece of equipment installed on or as part of 31 this contract. Manual must contain: 32

Project Title, Project number, Location, dates of submittals, names 34 of Engineer, Engineer, Contractor, and Contractor's Sub-contractors. 35 Provide phone numbers and addresses for Contractor and Sub-36 contractors. 37

Equipment Index that includes vendor’s name, address, and telephone 39 number for all equipment purchased on the project. 40

Emergency instructions with phone numbers and names of contact 42 persons on warranty items. 43

All manuals in binders shall be original copies provided by the 45 manufacturer. At minimum these binders must include: 46

Installation manuals, Calibration manuals 48 Training manuals, Operation manuals 49

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Service Manual, Repair manuals 1 Parts list, Wire list 2 Reviewed submittals. 3 Certification that owner is to receive all published service, 4 repair and overhaul manuals by being placed on the current 5 mailing list. 6

Copies of all inspection and guarantee certificates. 7 Copies of all manufacturers' warranties as filed for all 8 equipment provided and/or installed, with the “Commonwealth of 9 Kentucky” listed as the owner 10

Manuals: Bound in hard cover three (3) ring (D-type) binder, 1", 1.5" or 13 2" maximum, white vinyl, presentation type with clear vinyl view cover on 14 front, back and spine and with pockets on front and back. Contents shall 15 be indexed in CSI format, tabbed (4,5,8 or 16th cut), with no more than 16 80% binder fill. Maximum drawing size in binder shall be folded 11"x17" 17 and shall be hole-punched and reinforcements added. Do not put drawings 18 in pockets. Top of all drawings shall be at top or spine side of the 19 manual. Complete drawings must be viewed without opening rings. Provide 20 binders as manufactured by Universal Office Products, Des Plaines, IL. 21 1"(S# B2-20742), 1.5"(B2-20744), or 2"(B2-20746) or equal. 22 If the binder includes manuals from any one vendor covering several 24 different model numbers, the model used on the project must be 25 highlighted. 26 Alternative Submittal Format: 28 In lieu of hard copies, the owner may elect to receive these documents 29 electronically in PDF or a mutually-agreeable alternative format, through 30 the DECA e-Communication electronic document management system. 31

REQUIRED SUBMITTALS: 35

The following chart is supplied for the benefit of the Owner, Engineer 37 and Contractor to assure a complete submission of required information. 38 It is a reference listing of documents required by the Specifications 39 under this Section. 40

SHOP M & O PARTS CERTIFICATION 42

ITEM DWG. MANUAL LIST 43

Chiller* X X X X 45

* Provide wiring diagrams. 48

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PART 2 - PRODUCTS 1

WATER CHILLERS -- GENERAL 4

Provide electric-driven, hermetic or open, centrifugal chillers as 6 specified hereafter. Chillers shall be provided with all parts as 7 necessary for automatic operation. 8

CENTRIFUGAL WATER CHILLERS: 11

General 13 Chillers shall be manufactured as complete package, factory assembled and 15 wired. If manufacturer does not provide unit as a complete factory 16 package, then furnish the necessary labor and material to complete the 17 assembly and erection and insulation of the machine in the field. 18 If an open-drive motor/compressor design is used, the chiller size must 20 be increased to handle the added chilled water load from the drive motor. 21 Dimensional Restrictions (exclusive of service clearances): 23 Maximum width, including all controls and electrical panels: 5’2” 25 Maximum length, including all water boxes: 13’4” 27 Maximum height: 7’0” 29 The vendor shall coordinate all requirements for disassembly and 31 reassembly (if required) with the Installing Contractor, prior to 32 shipment. 33 Indicate detailed methods for how the chiller will be split for partial 35 disassembly, in the product submittals. 36 Evaporator and Condenser piping connections shall be as shown on the 38 layout drawing, as included with this solicitation. 39 Variable-Flow Primary Requirements 42 The centrifugal chillers on this project will be applied using a 44 variable water-flow primary pumping system. The chilled water 45 evaporators must be selected by the chiller manufacturer to allow 46 trouble-free chiller operation with a reduced chilled water flow rate 47 of 40% (minimum) of the design chilled water flow rate. The 48 manufacturer shall submit certified selections showing this 49 capability. 50

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Acceptable Refrigerants: 3

Centrifugal --- R-l34a; R-123; R-513A; R-1233zd 5 Surging: Chiller shall provide surge-free operation at l00% to 25% 7 capacity at maximum operating conditions specified including, but not 8 limited to, 42 deg.F. leaving chilled water temperature and 85 deg.F. 9 entering condenser water temperature with specified water flows. 10 Sound: Each chiller sound pressure level (SPL), in decibels (dB), with a 12 reference pressure of 20 micropascals, shall not exceed the values listed 13 herein. All ratings shall be in accordance with AHRI Standard 575-08, 14 "Method of Measuring Machinery Sound Within Equipment Rooms". 15

No reduction of entering condenser water or raising of leaving 17 chilled water temperatures will be allowed in the sound levels. 18 Making such a temperature adjustment does not represent the loudest 19 operating condition the chiller will experience while on the job, 20 and could mask sound problems that would otherwise occur. A minimum 21 of 75% of the sound data points along the length of the machine 22 shall be taken, and established as the minimum percentage of total 23 possible points used to determine sound levels. 24

Water chillers shall be complete with compressor and motor, evaporator, 27 condenser, lubrication system, capacity control and controller, motor 28 starter, instrument and control panel mounted and factory wired on the 29 machine, purge system, mounting isolation and other items as herein 30 specified. 31 Centrifugal Compressors: 34

Compressors shall be single or multi-stage centrifugal type. 36 Impellers must be high strength aluminum alloy balanced both 37 statically and dynamically. Impellers shall be proof tested at 38 least 15 percent above design operating speed. 39 Automatic capacity control shall modulate performance from 15 to 100 41 percent of rated unit capacity at design conditions. Compressor 42 shall always start unloaded. 43

Compressor(s) shall be field serviceable. 45 If multiple compressors are used, the evaporator sides and the 47 expansion valve shall be common, and the chiller shall be capable of 48 running one compressor at design cooling tower water temperatures at 49

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full compressor capacity with the other compressor(s) or related 1 auxiliaries out of service. 2

Conventional Compressors (Optional Alternative): 4

Forced-fed lubrication system with a hermetic motor-driven oil pump 6 shall be furnished as part of the water chiller. System shall be 7 complete with oil pump, oil cooler, pressure regulator, oil filters, 8 thermostatically controller oil heater and necessary motor control. 9 Oil pumps shall be energized prior to chiller motor energization. 10 Oil pump starter shall be factory supplied and mounted on the 11 chiller and factory wired with only field power leads required. 12

Oil-less/Magnetic Bearing Compressors (Optional Alternative): 14

Chillers shall have no more than three (3) oil-free, magnetic-16 bearing, semi-hermetic compressors. The compressors shall have 17 an integrated variable-frequency drive operating in concert with 18 (optional) inlet guide vanes, for optimized full- and part-load 19 efficiencies. 20

Compressors shall be single or multi-stage, magnetic bearing, 22 centrifugal type. Impellers must be high strength aluminum alloy 23 balanced both statically and dynamically. Impellers shall be proof 24 tested at least 15 percent above design operating speed. 25 Automatic capacity control shall modulate performance from 15 to 100 27 percent of rated unit capacity at design conditions. Compressor 28 shall always start unloaded. 29

Magnetic-Bearing Compressor: 31

Magnetic Bearings: 33

Levitated shaft position shall be actively controlled 35 and monitored by an X-,Y- and Z-axis digital position 36 sensor. 37

The compressor shall be capable of coming to a 39 controlled, safe stop in the event of a power failure by 40 diverting stored power from the DC bus to the magnetic 41 bearing control system. 42 The backup power system shall be designed to last the 44 life of the chiller. If routine maintenance of the 45 backup power system (capacitor replacements), then this 46 shall be indicated below on frequency of time, time 47 required to have the chiller off to replace, and cost 48 associated with the part/labor per compressor. 49

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Inlet Guide Vanes: 1 If used, pre-rotation guide vanes shall be positioned by solid rod 2 linkage and connected to an easily serviceable, externally mounted 3 electric actuator. Pre-rotation vanes, if used, shall be constructed out 4 of cast-manganese bronze in an airfoil shaped design. Plastic pre-5 rotation vanes are not acceptable. 6

Mechanical linkage system shall continuously monitor compressor-8 discharge gas characteristics and optimize diffuser spacing to 9 minimize impeller gas- flow disruptions. 10

Compressor/Motor Unit Assembly: 12 The driveline (compressor and motor) and chiller starter shall be 13 individual unit assemblies, allowing for independent inspection, service 14 and repair/replacement. If an integrated driveline and starter package 15 is used which is not field-repairable by the OEM, the supplier must 16 provide on spare package with the unit. 17

Evaporator and condenser shall be fabricated with high performance 19 integrally finned copper tubing rolled into the tube sheets in both the 20 evaporator and condenser as well as expanded into the tube support sheets 21 in the evaporator. Tubing shall be finned except in the area adjacent to 22 and in contact with the tube and tube support sheets. Tube support sheet 23 shall be spaced at intervals to maintain proper tube spacing and to 24 minimize tube vibration and wear. 25

Tubes shall be removable from either end of the heat exchanger. 27 Provide stub out water connections having Victaulic grooves. 29 Provide vent and drain connections with plugs. 31

Minimum tube wall thickness shall be 0.028 inches. 33

Construction and materials for the heat exchangers shall conform to 35 ANSI/ASHRAE 15-1994 Safety Code for mechanical refrigeration (which 36 in turn requires conformance to the ASME Code for Unfired Pressure 37 Vessels where applicable). 38

Provide true marine water boxes on both ends of condenser (hinged 40 heads; removable without disconnection of piping). Provide factory-41 mounted pivoting gantries at both ends of condenser to allow removal 42 of marine water box covers without the need for auxiliary hoists. 43 Hinged, davited marine water box covers that will allow the cover to 44 be opened and hinged out of the way without disturbing or removing 45 the piping are an acceptable alternative to the pivoting gantries. 46

Unit(s) shall be equipped with a factory-mounted, spring-loaded 48 reseating relief valve designed for exterior venting. 49

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Provide purge system, factory installed, wired and piped; system shall be 1 self-contained. Provide any necessary devices for separating and 2 returning refrigerant to the system. 3

Low-pressure hermetic chillers (HCFC-123) must have a separate high-5 efficiency purge system that operates independently of the unit. 6 Include a purge pressure gauge, number of starts counter, and an 7 hour meter in the purge system. 8 Low-pressure open-drive chillers (HCFC-123) must have a separate 10 high-efficiency purge system. Include a purge pressure gauge, number 11 of starts counter, and an hour meter in the purge system. If purge 12 system does not operate when chiller is off, include a refrigerant 13 warming system to maintain refrigerant at sufficient temperature to 14 prevent negative pressure within the chiller. 15

Units operating with refrigerants having positive pressure (R-134a) 17 at 75 Deg. F. shall have isolation valves so that chiller has the 18 capability of storing the refrigerant charge in the condenser. 19 Provide the isolating valves at the chiller compressor discharge and 20 the refrigerant liquid line, so that the refrigerant charge can be 21 isolated in the condenser. If the condenser does not have the 22 capacity to store a minimum of 80% of the total refrigerant charge, 23 provide a separate storage receiver. 24

Demand limiter -- Demand limiter device shall be provided within the 27 standard control panel so that maximum current may be manually set to any 28 fraction between 30% and 100% of full load amperes. 29 Unit Controller: 31 The unit shall be equipped with a complete microprocessor control system. 33 This system shall consist of control transformer, temperature and 34 pressure (thermistor and transducer) sensors, Input/Output (I/O) board, 35 power supply board, main processor board and interface board with display 36 and keypad. All devices and sensors shall be factory mounted and wired. 37 These devices shall be capable of self-diagnostics. All sensors shall 38 be hard-wired with quick-disconnect devices for easy removal. 39

The interface device shall be equipped with individual touch-41 sensitive membrane key switches. 42 Control center shall be capable of interfacing (via BACnet protocol) 44 with the existing Johnson Controls Building Automation System. 45 Required interface points shall provide for remote chiller 46 start/stop; reset of chilled water temperature; reset of current 47 limit; and status messages indicting chiller is ready to start, 48 chiller is operating, chiller is shutdown on a safety requiring 49 reset, and chiller is shutdown on a recycling safety. Provide run 50

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time meter and start counter. Provide additional monitoring points 1 to comply with ASHRAE Standard 147. 2 Provide hard-wired contact interface points for remote start, 4 shutdown and alarm trouble status for interfacing with the campus 5 chilled water packaged pumping system. 6 The chiller shall have the necessary controls to allow the chiller 8 to start with 50oF condenser water temperature and 50oF. return 9 chilled water temperature. 10 The chilled water controller of each chiller shall include 12 variable water-flow compensation capability to allow the chiller 13 to respond quickly to accelerating or decelerating water. The 14 variable water-flow control algorithm shall automatically adjust 15 the control gain so that large changes in water-flow rate can be 16 tolerated. The variable water-flow compensation capability shall 17 allow control of the leaving chilled water temperature to within 18 +/- 0.5F at a water flow rate change of 25% per minute and to 19 within +/- 1.5F at a water flow rate change of 50% per minute. 20 This option shall include factory mounted transducers to read 21 the differential evaporator water pressure (psid) and condenser 22 water pressure (psid). 23 The variable flow compensation option shall also display the 25 following data on the chiller control panel display: 26

1. Entering / leaving evaporator water pressure 28 (psid) 29

2. Entering / leaving condenser water pressure 30 (psid) 31

3. Evaporator differential pressure (psid) 32

4. Condenser differential pressure (psid) 33

5. Evaporator water flow rate (GPM) 34

6. Condenser water flow rate (GPM) 35

Starters shall be furnished for all auxiliary motors, such as oil pump, 37 purge and transfer unit. 38 Provide chilled-water flow switch for field installation by Installing 40 Contractor. 41

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All wiring shall meet or exceed the National Electrical Code (latest 1 edition) and shall be in metal conduit. 2 Insulation: The manufacturer shall provide field-installed insulation for 4 each chiller, with 0.75” fire retardant flexible closed cell plastic type 5 painted insulation, including heads on evaporator. 6 Insulation shall be field-painted in the standard manufacturer’s chiller 8 color. 9 Vibration Isolation: Provide vibration isolation pads for each chiller 11 according to isolator manufacturer’s recommendations. 12 Motors: 14 Motors for conventional (oiled) compressor units shall be single-speed, 16 non-reversing squirrel-cage induction type, and shall be suitable for 17 voltage indicated herein. Motor stator shall be arranged for service or 18 removal without complete compressor disassembly or breaking of main 19 refrigerant piping connections. Full load operation of the motor shall 20 not exceed nameplate rating. Motor shall be built for connection to Wye-21 Delta type reduced-voltage starter. 22 Motors for oil-less/magnetic bearing units shall be semi-hermetic, 24 permanent-magnet type or high speed induction motor, of sufficient size 25 to efficiently fulfill compressor power requirements. Semi-hermetic 26 motors shall include motor winding sensors (one per phase). The motor 27 shall be compatible with variable frequency drive operation. Motor 28 electrical connection: steel terminal box with gasketed front access 29 cover, overload and overcurrent transformers. 30 Unit-Mounted Starter: 33 Unit-mounted starter for chiller compressor motor shall be closed 35 transition, Wye-Delta (Star-Delta) or solid state type starter in a NEMA 36 1 enclosure. Starter shall be capable of handling the maximum locked 37 rotor and maximum full load running currents for the size chiller motor. 38 Chiller starter continuous amperage rating shall not exceed the maximum 39 full load amperage rating of the motor provided by the chiller 40 manufacturer. 41 Provide an overload in each phase set at 104%-107% (per manufacturer’s 43 recommendation) of the rated load amps of the connected motor. Overloads 44 shall be manual reset and shall de-energize the main contactor when over 45 current occurs. The overload shall be adjustable and selected for mid-46 range. The overload relays herein before mentioned shall be ambient 47 temperature compensated manual re-setting bi-metallic type overload 48 relays. Overloads may be electronic for solid-state starters. Provide 49 inherent low voltage protection and inherent motor protection against 50

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single phasing and phase reversal on all three legs. 1

The Wye-Delta starter shall provide 58% starting voltage and shall limit 3 amperage inrush to 33% of locked rotor. Provide starter with the control 4 features (current transformers for load limiter, transformer for chiller 5 controls, relays and interlocks) required by the chiller manufacturer. 6 Starters shall be braced for 65,000 symmetrical amps and shall be UL 7 listed and labeled. Provide inherent low voltage protection and inherent 8 motor protection against single phasing. 9 Provide an ammeter and voltage meter mounted in chiller starter (or as a 11 part of chiller control panel). Each ammeter shall have a full-scale 12 reading of 1000 amperes with a 5-ampere load. Provide ammeters with 13 selector switch for each phase. In conjunction with each ammeter, provide 14 a current transformer on one leg of each starter. This current 15 transformer is for use by the load limiter. 16 All bussing, conductors, control wiring, interlock wiring and connectors 18 utilized in the chiller starters shall be 98% conductivity copper. 19 Provide circuit-breaker/disconnect in each chiller starter. 21 Chillers shall operate with a minimum power factor of 95 percent. If 23 power factor correction devices are required to meet 95 percent, the 24 manufacturer shall provide the necessary labor and material to install 25 power factor correction equipment for each chiller. Correction equipment 26 may be factory- or field-installed. 27 The chiller starter shall be factory-mounted. 29 Chiller starter shall be as manufactured by Square D, Westinghouse, 31 General Electric, Cutler-Hammer or the chiller vendor. 32

ADJUSTABLE FREQUENCY DRIVES: 35

Chiller using adjustable-frequency drives (AFD’s) are acceptable, and may 37 be proposed at the vendor’s option. If adjustable-frequency drives are 38 proposed, the drive electrical losses must be listed in the appropriate 39 space on the Form of Proposal. Such drives shall conform to the 40 following: 41 Basic Description: 43

The adjustable frequency controller (AFC) shall be solid state, 45 with a Pulse-Width-Modulated (PWM) output waveform. The AFD 46 package as specified herein shall be enclosed in a single NEMA 1 47 enclosure, completely assembled and tested by the manufacturer. 48 The AFD shall employ a full-wave rectifier (to prevent input line 49 notching), DC Line Reactor, capacitors, and Insulated Gate 50

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Bipolar Transistors (IGBT’s) as the output switching device 1 (SCR’s, GTO’s and Darlington transistors are not acceptable). 2 The drive efficiency shall be 97% or better at full speed and 3 full load. Fundamental power factor shall be 0.95 at all speeds 4 and loads. 5 All programmable settings shall be held in non-volatile memory 7 and shall not be affected by power outages, brownouts, power 8 dips, etc. 9 Control Logic: Independently control motor speed and pre- 11 rotation vane (PRV, if used) position for optimum efficiency and 12 operational stability. Base motor speed and PRV position on a 13 minimum of 4 inputs: leaving chilled water temperature, return 14 chilled water temperature, evaporator refrigerant pressure, 15 condenser refrigerant pressure; Verify motor speed and PRV 16 position and also use as inputs to the control logic. 17

Codes/Standards: 20 The controller and options shall comply with the applicable requirement 22 of the latest standards of ANSI; NEMA ICS-6 for controls and systems; 23 National Electric Code NEC; IEC 801-2, 801-4, 256-4; IEEE-519-2014, 24 Special Application Criteria. 25 Unit shall be braced for 65,000 symmetrical amps and shall be UL listed 27 and labeled. 28 Quality Assurance: 31 The AFC controller shall be subject, but not limited, to the following 33 quality assurance controls, procedures and tests. 34 If other than the chiller manufacturer, the drive manufacturer shall have 36 been actively and continuously engaged in the production of adjustable 37 frequency controllers for a period of at least 10 years and have 38 experience of at least 8 years in commercial applications. 39 Adjustable Frequency Controller: 41 The AFC manufacturer shall provide, at minimum, the electromechanical 43 construction, basic features, adjustments, general options and 44 modifications and special options as outlined in this specification. 45 Basic Features: 47 The AFC shall have the following basic features: 49

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The AFC shall incorporate a full alpha/numeric customer interface panel 2 showing all settings, parameters, operating screens, operating data, 3 supervision information and faults in plain English. Display may be 4 incorporated with the chiller control panel. 5 The optional main input disconnect shall provide a positive disconnect 7 between the controller and all phases of the incoming A-C line. This 8 disconnect shall be mounted inside the controller enclosure and have 9 through-the-door interlocking toggle with provisions for padlocking. 10 Harmonic Distortion: The AFD shall not produce more than 10% notching and 12 3% total harmonic current distortion, measured at the input lugs, per 13 IEEE-54-2014. If a filter or other correction device is required, the 14 resulting electrical losses must be included in the AFC loss calculations 15 in the bid form. 16

If the chiller does not have a harmonic filter included within the 18 package, the Vendor is responsible to include a 3rd party harmonic 19 filter to meet the needs. 20 The Vendor is responsible for the installation and wiring of the 22 harmonic filter if not included within the chiller starter cabinet. 23 The Vendor is responsible for compensating for the efficiency loses 25 of a harmonic filter and shall be shown on their performance 26 reports. 27 The Vendor shall test the current distortion for the installed 29 chiller and provide a written report of final distortion readings. 30

Protective Circuits and Features: 32 The AFC shall include the following protective circuits and features: 34

Fast-acting semiconductor fuses specifically sized for protection of 36 the AFC. 37

Instantaneous Electronic Trip for the following faults: 39 Output phase-to-phase circuit condition 41 Total ground fault under any operating condition 43 High input line voltage 45 Low input line voltage 47 Service Conditions: 49

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The AFC shall be designed and constructed to operate within the following 1 service conditions: 2

Continuous operation at an ambient temperature between 0oC. and 4 40oC. Maximum altitude - 3300 feet. Maximum humidity (non-5 condensing) – 95%. 6

Alternating-current line variation of 414 (-10%) to 508 (+10%) 8 volts; plus/minus 2% frequency. 9

Refrigerant Vapor Detection 12 Refrigerant monitor and system will be furnished and installed by the 14 Owner outside of this contract. 15

Self-Contained Breathing Equipment 17 Additional safety and breathing equipment, required by ASHRAE 15 – 1994 19 and located outside the limits of the mechanical room, will be furnished 20 and installed by the Owner. 21

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CHILLERS Nos. 1 & 2 - TWO centrifugal machines required 1

Nominal Capacity 3 Cooling capacity, minimum (full load, zero tolerance): 255.0 5 Tons. 6 Evaporator 9 Chilled water flow 612 GPM 11 Pressure drop (maximum) 15.0 Ft. 12 Entering water temperature 55.0 deg. F. 13 Leaving water temperature 45.0 deg. F. 14 Maximum tube velocity 12.0 FPS 15 Water side working pressure 150 PSIG 16 Fouling factor 0.00010 17 Number of passes 3 18 Condenser 20 Condenser water flow 1068 GPM 22 Pressure drop (maximum) 19.0 Ft. 23 Entering water temperature 85.0 deg. F. 24 Leaving water temperature 94.3 deg. F. 25 Maximum tube velocity 12.0 FPS 26 Water side working pressure 150 PSIG 27 Fouling factor 0.00025 28 Number of passes 2 29 Reference the document “Chiller Prepurchase - Equipment Requirements - 31 Revised 8-9-18.pdf” (attached) for layout requirements, 32 Electrical characteristics: Chiller Starter 34

460v/3 ph/60 Hz 460 volt 35

Maximum overcurrent protection – 300 amps. 37

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Sound Table: 1

Not to exceed Octave Band Sound Pressure Levels (measured in accordance 3 with AHRI standard 575-08, +/- 3Dba variations): 4 % Load dB,A Weighted 6 100 1 (63 Hz)- 67 7

2 (125 Hz) – 67 8 3 (250 Hz) – 70 9 4 (500 Hz) – 70 10 5 (1000 Hz) – 70 11 6 (2000 Hz) – 71 12 7 (4000 Hz) – 70 13 8 (8000 Hz) - 65 14

25 89 (Surge pass/fail test) 16

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PART 3 - EXECUTION 1

FACTORY ACCEPTANCE TESTING 4

Each chiller shall be run-tested in accordance with AHRI Standards using 6 an AHRI-approved test stand in the manufacturer's factory or laboratory. 7 The test shall simulate full- and part-load conditions to check 8 performance (capacity and energy consumption), noise, vibration and 9 operating/safety controls. 10 The Engineer and Owner's Representative shall be notified to review the 12 installation and witness the factory test. The Owner will witness testing 13 only during normal working hours. 14 The vendor shall submit for approval before scheduling the testing 16 procedures including the following: 17

* Data sheets showing the acceptable maximum/minimum points as well as 19 the anticipated values. 20

* The test load points with guaranteed KW/ton (include corrections for 21 open-drive motors and/or variable-speed drives as well as fouling 22 factors). 23

* Test equipment. 24

* Overall schedule 25

* Test stand layout. 26

* Activity schedule 27

* Vibration testing methods 28 Unless the test results are in complete conformance with the requirements 31 stated herein, the Owner will not accept the chillers or authorize the 32 chillers to be shipped from the factory. 33

If the equipment fails to perform within allowable specified tolerances, 35 the manufacturer may make necessary revisions to the equipment and retest 36 as required. If necessary to extend the testing period by additional 37 day(s), and/or make return trip(s) to the test site, the manufacturer 38 shall assume all expenses incurred by the Owner and/or his representative 39 to witness the retest. 40

Full Load Capacity Test: Chiller shall be tested at full load to 42 verify the tonnage produced and the KW/Ton consumed. The chiller 43 shall meet or exceed 100% of the specified minimum cooling tons 44 required. No AHRI tolerances will be acceptable for the specified 45 minimum cooling tons. 46

Full Load Efficiency Test: The chiller shall meet 100% of the 48 maximum KW-per-ton value that manufacturer submitted on the life 49

LAW ENFORCEMENT TRAINING CENTER

PRE-PURCHASED WATER CHILLERS 15700 - 20

cycle cost bid form. No AHRI tolerances will be acceptable for the 1 full load KW-per-ton value. 2 Partial-Load Efficiency Tests: Chiller shall be tested at 4 three additional partial-load points, chosen in advance by the 5 owner from the points listed in the Form of Proposal. No AHRI 6 tolerances will be acceptable for the partial-load KW/ton values. 7

Maintain constant leaving chilled water temperature and entering 9 condensing water temperature as listed in the energy cost 10 analysis chart of the Form of Proposal. 11

BEARING VIBRATION TEST (Oil-lubricated units only) – The vendor shall 14 test, monitor, record, and analyze the vibration levels of each chiller 15 bearing on the following occasions: 16

* As part of factory acceptance testing 18

* After initial installation/start-up 19

* At least two (2) months prior to the end of the chiller warranty 20 period. 21 Vibration Test Methods: The vendor shall monitor and record the 23 vibration levels of the horizontal and vertical axes of all chiller 24 bearings. Additionally, the vendor shall monitor and record the 25 axial vibration levels of outboard chiller bearings. The vendor 26 shall permanently locate all transducer attachment points on the 27 chiller during the factory acceptance tests. These transducer 28 attachment points are to be used during subsequent vibration 29 monitoring tests performed in the field. The vibration test shall 30 be a narrowband test. The results shall be reported in peak 31 velocity (in./sec.) vs. frequency. 32 Vibration Test Procedures: All vibration tests shall be performed 34 in accordance with approved vibration test procedures. The vendor 35 shall submit both factory acceptance test and field test procedures 36 to the owner for review/concurrence with the equipment submittals. 37 The vibration test procedures shall identify the test equipment 38 setup and test methods to be utilized. 39 Documentation and Analysis: The vendor shall summarize the results 41 of each vibration test in a vibration test report. The final test 42 report shall compare the results of field tests with the test 43 results obtained from factory acceptance testing. The vendor shall 44 provide the owner with a written assessment of the acceptability of 45 the test results and recommend how often future vibration tests 46 should be performed in order to monitor chiller performance in a 47 cost-effective manner. The vendor shall also identify vibration 48 levels that are considered by the vendor to warrant specific 49 corrective actions. 50

LAW ENFORCEMENT TRAINING CENTER

PRE-PURCHASED WATER CHILLERS 15700 - 21

Sound Pressure Test -- Each chiller shall have sound tests conducted at 3 the factory prior to shipment to confirm the Sound Pressure Levels as 4 listed herein. All data must be measured and presented in strict 5 accordance with AHRI Standard 575-08. 6

The sound data points shall be measured simultaneously during the 8 factory verification of capacity and efficiency. Sound tests will be 9 run at 100% and 25% load points. If the 25% load point is not one 10 selected by the owner for acceptance, an additional test at 25%/85 11 deg. EWT will be performed for sound testing only. The chiller must 12 not surge during this test condition. 13

In the event that a chiller does not meet the submitted dBA sound 15 pressure level, the manufacturer must, at his expense, provide 16 sufficient attenuation to the machine to meet the submitted value. 17 This attenuation shall be applied in such a manner that it does not 18 hinder the operation or routine maintenance procedures of the 19 chiller. 20

If the unit cannot be modified to meet the submitted sound levels, 22 unit will be rejected. 23

Final Testing Report: Provide to the Owner's representative and the 26 Consulting Engineer a factory-certified test report, certifying that the 27 proposed chillers perform as specified. 28

LAW ENFORCEMENT TRAINING CENTER

PRE-PURCHASED WATER CHILLERS 15700 - 22

PRODUCT DELIVERY AND HANDLING 1

Handle water chiller and components carefully to prevent damage, 3 breaking, denting and scoring. Do not ship damaged water chiller or 4 components; replace with new. 5 Ship the entire refrigerant charge in separate containers. 7

INSTALLATION 10

Supervision: Inspect the chillers for “as-arrived” condition and confirm 12 suitable condition for installation. Supervise unloading of the chillers 13 by the installing contractor. 14 Coordination: The vendor shall have a factory-qualified representative 16 present when the chiller components are rigged into the mechanical 17 room by installing contractor. 18 When required for ingress, the vendor shall have a factory-qualified 20 representative present to supervise the Installing Contractor’s work 21 for the chiller disassembly and reassembly. 22 Start-Up: 24 Chiller and accessories shall be installed, tested, evacuated, dehydrated 26 and charged under the direct supervision of a manufacturer-trained 27 service engineer (“factory engineer”). The factory engineer shall be 28 present at all progress meetings and be present during all erection, 29 calibration, evacuation/charging and the initial operation of each water 30 chiller. 31 Furnish and install the initial charge of refrigerant and oil. 33 Test and adjust chiller controls and safeties. Lubricate rotating parts. 35 Verify that motor amperage conforms to manufacturer's data. 36 After the chiller has been thoroughly tested and is running, the factory 38 engineer will provide 24 hours operation based on three 8-hour days for 39 each chiller. The factory service engineer shall log all operating 40 conditions each hour during the 24 hours of operation and submit the logs 41 to the Engineer for his review and approval. 42 The 24 hours will include instructing the Owner's representative and 44 familiarizing the Owner in the correct means of logging all pressures and 45 temperatures in connection with the chiller. The manufacturer's service 46 engineer shall visit the job three (3) times per year during the Warranty 47 period: summer, spring, or fall and winter after acceptance for any 48 adjustments necessary for proper operation. 49

LAW ENFORCEMENT TRAINING CENTER

PRE-PURCHASED WATER CHILLERS 15700 - 23

Demonstration for Owner: Provide two separate sessions with the factory 1 engineer to demonstrate and train Owner's personnel as specified below: 2

Start chiller and verify performance. Demonstrate operation to 4 Owner. 5

Train Owner's personnel on procedures and schedules for startup, 7 shutdown, troubleshooting, servicing, and preventive maintenance. 8

Review data in operating and maintenance manuals. 10

Schedule training with the Owner through the Engineer with at least 12 7 days' notice. 13

WARRANTY 16

Warranty: Warranty services for the chiller equipment, as specified 18 herein, are to be performed directly for the owner. The installing 19 contractor is only responsible for warranty items that are directly 20 associated with the installation (i.e. not the chiller performance). 21 The manufacturer shall provide a five-year parts and labor warranty for 23 the entire chiller assembly, including starter/AFC and controls. 24 The warranty shall commence upon Substantial Completion for each chiller. 26 The manufacturer's representative will have a service engineer available 28 to service any breakdown in 24 hours after notification, and the number 29 of trips will not be limited during the warranty. 30 Shared-Refrigeration Circuits with Dual Compressors: For dual 32 compressor chiller designs where two compressors share a single 33 (common) refrigeration circuit, the entire refrigerant and oil charges 34 and both compressor/motor assemblies shall be replaced in the event of 35 a failure of either compressor/motor assembly. 36 Refrigerant Loss: The manufacturer shall replace at no expense to the 38 Owner any loss of refrigerant and oil (unless due to negligence of the 39 Owner) during a five-year period from the date of substantial completion. 40

MAINTENANCE AGREEMENT 43

The chiller manufacturer shall include a five-year maintenance agreement 45 for each of the chiller(s). The maintenance agreement shall include a 46 minimum of three (3) eight-hour inspections each year of operation for 47 each of the chiller(s). The costs for all materials, parts, oil, oil 48 filters, refrigerant, gaskets, shaft seals, O-rings, couplings, etc., for 49 each year maintenance agreement shall be included. Each inspection shall 50

LAW ENFORCEMENT TRAINING CENTER

PRE-PURCHASED WATER CHILLERS 15700 - 24

include a written standardized service and maintenance report indicating 1 all items checked and serviced. Signed reports shall be submitted to the 2 Owner for review and approval at the end of each inspection. Reports 3 shall note any irregularities in operation of each system and tracked 4 over time in an attempt to predict component replacement and/or downtime. 5 Each Yearly Maintenance Service shall include the following: 7 Electrical System Check: Operational verification of relays, overload 9 dashpot fluid level, starter contacts, tightening of power wiring, and 10 megohmeter test of compressor motor(s), and overload calibration. 11 Machine Safety Control Check: Calibration of all unit safety control 13 devices. 14 Lubrication System Service: All oil filter changes, inspection of oil 16 heater, oil cooler, pressure regulator, and heater controls, to be 17 performed at end of first cooling season and each year thereafter. 18 Purge Service: Provide service as recommended by the purge unit 20 manufacturer’s written recommendations, including replacement of dryers 21 and cores. 22 Refrigerant Charge Service: The chiller shall be checked for proper 24 refrigerant charge at each of the specified inspections. Refrigerant 25 shall be added as required at no charge to the Owner. 26 Shaft Seal Service: The compressor motor shaft seal(s)of open motor 28 driven chillers shall be tested for refrigerant and excessive oil leakage 29 in the presence of the Owner at each of the specified inspections. 30 “Excessive” is defined as exceeding 8 oz. of oil/refrigerant per 1000 31 hours of operation. 32 Drive Alignment Service: The alignment of open-drive chillers and 34 couplings shall be checked at each of the specified inspections. 35 Speed-Increasing Gear Set Service: The speed-increasing gear set shall be 37 checked at each of the specified inspections. 38 Condenser Tube Service: Condenser heads shall be removed at both ends of 40 the chiller. Tubes and tube sheets shall be inspected for fouling. 41 Oil Analysis Service - After the first cooling season, and annually 42 thereafter, oil analysis shall be performed, measuring acid, moisture, 43 and wear metals content. The manufacturer shall review the laboratory 44 results and submit a written report. 45 Refrigerant Analysis Service - An analysis of the refrigerant shall be 47 performed annually measuring acid, moisture content, and check for system 48 contamination. The manufacturer’s field supervisor shall make a review 49 of the laboratory results and a written report shall be submitted. 50

LAW ENFORCEMENT TRAINING CENTER

PRE-PURCHASED WATER CHILLERS 15700 - 25

Vibration Analysis Service (conventional/oiled compressors only) – After 2 the first cooling season, and annually thereafter, a vibration 3 test/analysis shall be performed per the above referenced Bearing 4 Vibration Testing procedures. The manufacturer shall review the results 5 and submit a written report. 6

END OF SECTION 15700 9