Amend 0003_11 20 00.pdf

Climatic Cold Chambers Rev. 2020-04-29 Cold Regions Research and Engineering Laboratory (CRREL)

SECTION 11 20 00

MEDIUM COLD CHAMBER ENCLOSURE

03/19

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2016) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 189.1 (2014) Standard for the Design of High-Performance Green Buildings Except Low-Rise Residential Buildings

ASTM INTERNATIONAL (ASTM)

ASTM B117 (2016) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM E84 (2018a) Standard Test Method for Surface Burning Characteristics of Building Materials

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017; ERTA 1-2 2017; TIA 17-1; TIA 17-2;

TIA 17-3; TIA 17-4; TIA 17-5; TIA 17-6;

TIA 17-7; TIA 17-8; TIA 17-9; TIA 17-10;

TIA 17-11; TIA 17-12; TIA 17-13; TIA

17-14; TIA 17-15; TIA 17-16; TIA 17-17 )

National Electrical Code

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION

(SMACNA)

SMACNA 1520 (1999) Round Industrial Duct Construction Standards, 3rd Edition

SMACNA 1922 (2004) Rectangular Industrial Duct Construction Standards, 2nd Edition

SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition

UNDERWRITERS LABORATORIES (UL)

UL 1598 (2008; Reprint Oct 2012) Luminaires

SECTION 11 20 00 Page 1

UL 723 (2018) UL Standard for Safety Test for Surface Burning Characteristics of Building Materials

1.2 GENERAL REQUIREMENTS

1.2.1 Single Source Responsibility

The work of this Specification Section shall be furnished and installed by a single supplier which shall be responsible for the complete and operational Medium Cold Chamber and related systems and equipment, and for the engineering and design of this work. The supplier shall be the Cold Chamber Manufacturer.

a. The Cold Chamber Manufacturer shall manufacture major components of the cold chamber and related systems, including the chamber enclosure, conditioning plenums and their refrigeration systems, desiccant dryer, and controllers and LCD control panels. The Cold Chamber Manufacturer shall assemble the electrical power distribution panel.

b. The Cold Chamber Manufacturer may purchase system components and equipment, other than those listed above, including sub-componenents of those listed above, from other suppliers and manufacturers.

c. The Cold Chamber Manufacturer may engage subcontractors to perform portions of the work, under the full supervision of the Medium Cold Chamber supplier.

1.2.2 Cold Chamber Manufacturer Pre-Qualifications

1.2.2.1 Submittal

Submit Qualification Of Cold Chamber Manufacturer within 21 calendar days of award of the Contract.

Qualifications shall include examples of previous projects of the same size/scale of the cold chamber and refrigeration systems. Provide a minimum of three projects for reference with qualifications.

1.2.2.2 Pre-Qualified Manufacturers

The following have been pre-qualified as potential manufacturers of the cold chamber:

a. Basis of Design Manufacturer: Cincinnati Sub-Zero (CSZ) - a division of Weiss Technik North America, Inc., Cincinnati, Ohio. Product line: Modular Walk-In/Drive-In Temperature Environmental Test Chambers.

b. ESPEC North America, Inc., Hudsonville, Michigan. Product line:

ESPEC Walk-in Drive-in Chambers.

Tenney Environmental, Inc., Hermitage, Pennsylvania. Product line:

Walk-in Temperature-only Chambers.

SECTION 11 20 00 Page 2

1.3 Cold Chamber Installer Pre-Qualifications

1.3.1 Submittal

Submit Qualification Of Cold Chamber Installer within 90 calendar days of award of the Contract.

Qualifications shall include examples of previous projects of the same size/scale of the cold chamber and refrigeration systems. Provide a minimum of three projects for reference with personnel qualifications for the installers. The installers shall have a minimum of 5 years experience installing similarly sized and type of systems.

The qualifications shall also include a certified letter on the letterhead of the cold chamber manufacturer indicating the personnel are qualified to perform the installation in accordance with the manufacturers installation requirements and recommendations.

1.4 DESCRIPTION OF WORK

The work includes furnishing and installing a medium cold chamber including equipment and all related work necessary to provide a complete installation. Verify existing dimensions, site conditions, and required utility connections prior to commencement of work. Coordinate delivery of components with finished openings and other vertical handling limitations within the building. Advise the Contracting Officer of discrepancies prior to procurement and installation of equipment. Submit Contractor's Field Verification Data prior to the preconstruction meeting.

Provide rough-in and utility connections to equipment in accord with requirements specified in other sections of this specification.

Coordinate physical dimensions, capacities, manufacturer's instructions, and other requirements of the equipment furnished.

1.4.1 Design Requirements

The cold chamber must meet the following design requirements:

a. Minimum clear interior dimensions of 12'x24'x10'(H)

b. Single door at entrance to chamber

c. Vestibule (ante-room/airlock) at entrance with single door

d. Vehicle entrance of 10'x10' (minimum clear) with ramp

e. Power connection using 480V, three phase power

f. Maintain and sustain temperatures within the following range: -54 C (-65.2 degrees F) to 50C 122 degrees F with an integral 8,500 lb dead load of steel and 1/3 of a 59,656 watt live load; the basis of the dead and live loads is an HMMWV (High Mobility Multipurpose Wheeled Vehicle, colloquially referred to as a military-grade Humvee). Rates of change within temperatures shall be as follows:

(1). Cooling rate of change from +24°C to -40°C with the specified dead load and no applied live load in 60 minutes.

(2). Heating rate of change from -40°C to +50°C with the specified

SECTION 11 20 00 Page 3 dead load and no applied live load in approximately 360 minutes at an average (non-linear) rate of 0.25°C per minute.

g. Maintain humidity at 20% to 95% relative humidity . Relative humidity control is not required.

h. Comply with NFPA 70 (NEC) Article 501, location Class 1 Div 2 Group D for hazardous classification

i. Provide following power outlets inside chamber: 1 (qty) - 208V single phase, 2 (qty) - 120 V outlets

j. Provide exhaust port with insulated connector of size to vent the exhaust from a HMMWV running inside the chamber at full power

k. Provide makeup air to the chamber at a rate of 500 CFM and conditions of 0 degrees F dry bulb temperature and minus 40 C dew point. The source of the air shall be a rotary desiccant dryer, which shall draw its intake air from the ambient indoor air surrounding the chamber and dryer (unconditioned building).

l. Base the design on an ambient temperature range surrounding the chamber (unconditioned building) of minus 13 to plus 94 degrees F.

m. Provide the following fire alarm devices inside chamber and vestibule, and conduit to exterior of chamber as indicated on Drawing FA-101: 1 (qty) Heat detector, 2 (qty) Panic Buttons, and 2 (qty) Horn/Strobes.

1.5 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance with Section 01 33 29 SUSTAINABILITY REPORTING. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Qualification Of Cold Chamber Manufacturer; G

Qualification Of Cold Chamber Installer; G

Contractor's Field Verification Data; G, AE

Point Of Origin Certification; G

SD-02 Shop Drawings

Manufacturer's Detail Drawings; G, AE

Custom Fabricated Equipment; G, AE

Installation Instructions and Diagrams; G, AE

Piping System And Installation And Support

SD-03 Product Data

SECTION 11 20 00 Page 4

Medium Cold Chamber; G, AE

SD-05 Design Data

Manufacturer's Descriptive and Technical Literature; G, AE

SD-06 Test Reports

Manufacturer's Test Data; G, AE

Field Test Reports; G, AE

24 Hour Test; G

Vehicle Test; G

SD-07 Certificates

UL Certification; G

SD-08 Manufacturer's Instructions

Manufacturer's Instructions; G for Shipping, Handling, Storage, Installation, and Start-Up.

SD-10 Operation and Maintenance Data

Operation And Maintenance Manuals; G

SD-11 Closeout Submittals

Manufacturer's Warranty; G

Contractor's Warranty for Installation; G

Video Recording; G

List Of Authorized Local Service And Repair Entities; G

1.6 DESIGN DRAWINGS

Submit detail drawings for all cold chamber enclosures and accessories.

Drawings must be 1/4 inch scale minimum.

Submit a complete Medium Cold Chamber Schedule, material data, and drawings as specified. Provide detail drawings showing complete wiring, piping, and schematic diagrams, and any other details required to demonstrate that the system is coordinated and properly functions as a unit. Drawings must show proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work, including clearances for maintenance and operation.

a. Detail drawings by Contractor must be separate drawings and be the Contractor's standard sheet size, but not smaller than the contract drawings, indicating cold storage assemblies with itemized schedule, special conditions drawings indicating size and location of slab depressions, cores, wall openings, blockouts, ceiling pockets, blocking grounds, ceiling access panels, rough-in plumbing/mechanical

SECTION 11 20 00 Page 5 systems and rough-in electrical systems.

b. Detail drawings by manufacturer must be separate drawings;

manufacturer's standard size and indicate item number, name, and quantity, construction details, sections, and elevations, adjacent walls, columns, and equipment, plumbing and electrical schematics, and fabricated fixtures with single electrical or plumbing connection, and service access panels required for maintenance or replacement of mechanical or electrical components.

1.7 SHOP DRAWINGS

Submit manufacturer's detail drawings and custom fabricated equipment drawings for each enclosure. Include insulation details, utility connections, and installation instructions and diagrams. Base shop drawings on verified field measurements and include contractor's field verification data.

Submit Piping System And Installation And Support for field-installed piping including but not limited to refrigeration piping and condensate drainage piping. Include piping details, support details and lists of support materials, insulation materials and details, and installation methods. Include information as appropriate for piping locations, including indoor and outdoor locations. Indicate any points of support which interface with the work of other trades.

1.8 QUALITY ASSURANCE

1.8.1 Standard Products

Materials and equipment must be the standard products of manufacturer regularly engaged in the manufacture of the products and be essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Applications must be for equipment and materials under similar circumstances and of similar size. When two or more of the same products are supplied they must be products of one manufacturer.

Equipment must be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

1.8.2 Nameplates

Provide each item of equipment bearing a stainless steel, aluminum, or engraved polyester nameplate, as standard with the manufacturer, located in a conspicuous position and permanently fastened to the equipment. Make name or identification plates the size standard with the manufacturer for the particular piece of equipment provided. Name plates must indicate the name of the manufacturer/trade name, serial number, make, and model number, pertinent ratings, operating characteristics, and other information as standard with the manufacturer, date of manufacture, electrical characteristics, and other applicable data, such as flow rate, temperature, pressure, capacity, and material of construction. Securely fasten separate equipment identification plates with the contract number marked thereon, to the surface of each piece of equipment.

1.8.3 Pre-Installation Conference

Thirty days prior to commencement of work, notify the Contracting Officer that the following items are prepared and ready for review:

SECTION 11 20 00 Page 6

a. Shop Drawings, product data and installation instructions

(1) Manufacturer's detail drawings

(2) Custom fabricated equipment drawings and data

(3) Installation instructions and diagrams

b. Product Data

c. Design Data

(1) Manufacturer's descriptive and technical literature

(2) Manufacturer's Test Data

d. Manufacturer's Instructions

For shipping, handling, storage, installation, and start-up.

1.8.4 Factory Tests and Certifications

Submit Manufacturer's Test Data and certifications, including UL Certification.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Insulation

Provide insulation materials for all equipment as follows:

a. Insulated components must have a complete surface enclosure of not less than 0.032 inches of aluminum or corrosion resistant steel having a base metal thickness of not less than 0.0160 inches at any point.

b. Insulation must comply with flame spread index limits of not more than 75 and smoke developed index of not more than 450 when tested, in the maximum thickness intended for use, in accordance with ASTM E84 or

UL 723 .

2.2 CONSTRUCTION OF FABRICATED EQUIPMENT

2.2.1 Grinding, Polishing, and Finishing

Grind smooth all exposed welded joints and finish to match the adjoining material. Wherever materials have been depressed or sunken by welding operation, hammer and peen such depressions flush with the adjoining surface, and again grind to eliminate high spots. Polish and buff ground surfaces to match adjoining surfaces. Exercise care in the grinding operations to avoid excessive heating of the metal and metal discoloration. Abrasives, wheels, and belts used in grinding must be free of iron and not previously used on carbon steel. In all cases, the grain of rough grinding must be removed by several successively finer polishing operations. Final polishing operation must be uniform, smooth, and consistent. Make the grain direction of horizontal stainless steel surface longitudinal, including the splash back. Provide a mitered appearance when polishing at right angle corners. Provide close fit butt

SECTION 11 20 00 Page 7 and contact joints not requiring solder as a filler. Wherever brake bends occur, the bends must be free of open texture or orange peel appearance.

Where brake work does mar the uniform appearance of the material, remove such marks by grinding, polishing, and finishing. Make sheared edges free of burrs, projections, and fins. Where miters or bullnosed corners occur, finish such miters and corners with the underage of the material and grind to a uniform condition. Overlapping of material is not acceptable.

Provide No. 3 finish for all exposed stainless steel surfaces. Finishes of materials, other than stainless steel, must be comparable in appearance to commercial mill finish. Exposed surfaces include:

a. Exterior surfaces exposed to view.

b. Interior surfaces exposed to view in doorless cabinets.

c. Undersides of shelves with a ground finish of No. 90 grit or finer.

2.2.2 Fastening Devices

Provide fastening devices of the same material as the metal being joined when joint pieces are of similar metal. Fastening devices must be stainless steel, ASTM A666 when stainless steel is joined to dissimilar metal. Provide minimum 1/4-20 stainless steel stud bolts with length necessary to accept washers, and required nuts, and weld 9 inches on center maximum. Exposed surfaces of equipment must be free of bolts, screws, and rivet heads. Use stainless steel stud bolts to fasten tops of counters or tables to angle framing and trim to other surfaces. Such bolts must be the concealed type. Cap threads of stud bolts which are on the inside of fixtures and are either visible or might come in contact with a wiping cloth, with chrome plated washers, lock washers, and chromium-plated brass cap nuts. Wherever bolts are welded to the underside of trim or tops, uniformly finish the reverse side of the welds with the adjoining surface of the trim or the top. Dimples at these points are not be acceptable.

2.2.3 Welding

2.2.3.1 Welds

Use tungsten inert gas process. Use filler metal compatible with the material being welded. Do not use carbon arc welding on tops of counters, tables, or exposed shelving. Make welds ductile and of same color as adjoining surfaces.

2.2.3.2 Welding Rods

Perform all welding with welding rods of the same composition as the sheets or parts welded. Factory weld long section components to the greatest lengths possible to minimize field welded joints.

2.2.3.3 Weld Quality

Weld quality must conform to the requirements of AWS A5.8/A5.8M , AWS D1.1/D1.1M , AWS D10.4 and AWS D9.1/D9.1M . Factory weld long section components to the greatest lengths possible to minimize field welded joint.

2.2.4 Built-in Equipment Lighting

Built-in lighting must conform to UL 1598 .

SECTION 11 20 00 Page 8

2.3 MEDIUM COLD CHAMBER ENCLOSURE

Provide walk-in unit, with an entry vestibule, with appropriate insulated floor assemblies and anti-slip finish floor.

2.3.1 Panel Construction

Interchangeable, 4 feet maximum width, 4 inch thick, filled with insulation. Provide preformed corner panels extending not less than 12 inches in each direction. Panels to have tongue and groove edges or flush joints with double seal serrated neoprene rubber gaskets to assure air and vapor tight joints. Provide panels for separating sections.

a. Insulation: 6 inch minimum foamed-in-place polyurethane with manufacturer's rated "K" factor of not more than 0.15, free rise density of not less than 1.7 pounds per cubic foot, or in-place density of not less than 2 pounds per cubic foot. Provide floor screeds with minimum of 2 1/2 inches of foamed insulation.

b. Closures: Close the exposed exterior of the walk-in unit adjacent to walls and ceiling with panels of same material as used for exterior of walk-in unit panels.

c. I-Beam Supports: Wherever compartment dimension exceeds the clear-span ability of ceiling panels, provide I-beam supports on the exterior of the ceiling or supported by spline-hangers. Provide external beams or posts and accessories to support the ceiling weight onto the chamber enclosure wall structure or onto the building floor slab. Beams or posts within compartments are not allowed.

d. Protective Bumpers: Equip the exterior sides of chamber that are not installed against each other or against a wall with protective bumpers.

e. Gasket: Provide either natural or synthetic rubber gaskets and in accordance with NSF/ANSI 2 . Where frames are used, the panels must fit together with gaskets that are designed for 50 percent compression.

d. Finish:

(1) Exterior: Aluminum with two coats of baked-on enamel paint, in manufacturer's standard color.

(2) Interior: Galvanized steel (white).

2.3.2 Prefabricated Floor Panels

Provide prefabricated floor panels of the same construction as wall/ceiling except with 14 gauge galvanized skin, sealed watertight.

Field apply one hard alloy aluminum tread plate, 3/16 inch thick, with all joints caulked. Provide prefabricated floor panels laid on, with sloping interior floor ramps at exterior entrance doors. The ramp shall have anti-slip surface. Furnish two sets of erection tools, compatible with fasteners, with each unit.

2.3.2.1 Floor Load

The floor shall be capable of supporting a 10,000 lb floor load, including the 8,500 lb weight of the proposed test vehicle (a military Humvee)..

SECTION 11 20 00 Page 9

2.3.2.2 Air Convection

Provide dry-deck tile under the chamber floor for air convection.

2.3.3 Doors

2.3.3.1 Vehicle Entrance Door

Provide one per unit, with 4 inch thickness, filled with insulation. Door design shall be double-overlap swing type, with a "fog-free" heated viewing window in each door section. Provide anti-condensing strip heaters around the perimeter of door panel jambs. Provide top and each side of door with a resilient, non-magnetic, or thermoplastic-with-magnetic-steel-core gasket. On bottom edge of door, provide a replaceable, adjustable rubber or vinyl wiper gasket.

Provide a vehicle entrance door with minimum clear dimensions of 10 x 10 feet.

a. Hardware Polished Stainless Steel: Provide two self-closing, spring-loaded hinges for each door. Include plated steel pin and cam-lift type bearing. Provide door latch with cylinder lock and with provisions for padlock. Include safety-release handle to permit opening from inside when locked.

b. Door Stops: Provide door stops where necessary, to prevent doors from striking adjacent walls or equipment when door is open.

c. Entrance Ramp: Provide a metal ramp; HS-20 loading. Provide fastening to the Cold Chamber's structural base frame. Provide anchoring to the building floor slab as necessary, to resist anticipated lateral forces from the test vehicle.

2.3.3.2 Vestibule Personnel Doors

Provide one inner door and one outer door per vestibule, with 4 inch thickness, filled with insulation. Provide anti-condensing strip heaters around the perimeter of door panel jambs. Provide top and each side of door with a resilient gasket, of non-magnetic type, or of type constructed of thermoplastic with magnetic steel core. On bottom edge of door, provide a replaceable, adjustable rubber or vinyl wiper gasket.

Provide vestibule personnel doors with minimum clear dimensions of 32 x 72 inches.

a. Hardware Polished Stainless Steel: Provide two self-closing, spring-loaded hinges for each door. Include plated steel pin and cam-lift type bearing. Provide door latch with cylinder lock and with provisions for padlock. Include safety-release handle to permit opening from inside when locked.

b. Door Stops: Provide door stops where necessary, to prevent doors from striking adjacent walls or equipment when door is open.

2.3.4 Air flow Inhibiting Strip Curtains

Provide transparent flexible vinyl reinforced strip curtains anchored at top and able to be replaced individually. Provide strips a minimum of 8

SECTION 11 20 00 Page 10 inch wide and 0.08 inch thick.

2.3.5 Windows

Provide viewing windows in wall panels and doors where indicated on the contract drawings.

a. Windows shall be of the sizes indicated on the contract drawings.

b. Windows shall be triple-pane type with spaces between panes filled with argon. Perimeters of panes shall be set in airtight sealants with rigid spacers. Glazing shall be tempered glass to resist breakage. Outer frames of windows shall be structurally reinforced, and installed into wall and door panels at the factory. Frames shall include electric defrost heaters with controllers.

2.3.6 Other Factory-Installed Openings

Factory-installed openings shall include a chamber pressure relief/equalization vent, chamber drains, openings for electrical power, controls, and fire alarm systems, openings for vehicle exhaust and makeup air, openings for conditioning air, and an access port for a water hose.

a. General openings shall include factory sealing and insulation.

b. Vehicle exhaust opening shall include a stainless steel airtight assembly to protect combustible materials from the heat of the exhaust, and double-wall insulated stainless steel vehicle exhaust pipe extension into the cold chamber. Provide an outer termination suitable for field connection of an insulated double-wall engine exhaust system. Provide removable inner insulated stainless steel cap with sealing gasket and stainless steel latch fasteners, for users to attach to the vehicle exhaust pipe when the vehicle is not connected to it.

c. Water hose access port shall include a hinged door with inner and outer latches and padlocking capability, and inner flexible and insulated closure device to close the opening around the hose when in use.

2.3.7 Lights

Provide explosion proof, high efficiency rated light-emitting diode (LED) lamps in vaporproof fixtures with safety shields. Provide lighting in accordance with UL 1598 . Provide diffuser and ballast capable of operating in minus 60 degrees F temperature. Run lights the full length of walk-in units starting 2 feet from front panel and extending within 2 feet of back panel.

2.3.8 Identification Signs

Mount engraved phenolic or acrylic plastic compartment identification signs 12 by 2 inch high in selected color with one inch high letters on door.

2.3.9 Electrical

All electrical equipment shall conform to the appropriate standards listed in the applicable NFPA and NEMA industry regulations, as well as industry accepted norms.

SECTION 11 20 00 Page 11

2.3.9.1 Power Sources

a. A single 480V, 3 phase, 60 Hz connection for equipment power.

Coordinate overcurrent protection rating with electrician. Connection shall include a power distribution panel with circuit breakers, and transformers as necessary, to provide power to components including but not limited to the control systems, cold chamber and its receptacles, the chamber conditioning plenums with refrigeration systems, piping electric heat trace, the desiccant dryer, and the remote condensers.

b. A single 20A, 120V, 1 phase, 60 Hz connection for enclosure lighting.

2.3.9.2 Grounding

All exposed, non-current carrying metal parts on the equipment shall be maintained at common, zero ground potential. None of the primary circuits in the equipment shall be connected to ground. A grounding stud/lug on the equipment shall provide a means for grounding the equipment.

2.3.9.3 Electrical Outlets

Provide six (6) 120V outlets. All conduit and device boxes shall be sealed to prevent condensation buildup.

2.3.10 Water

Provide one hose bib with valves to drain pipes.

2.4 REFRIGERATION UNIT SYSTEMS

2.4.1 Refrigeration

Provide refrigeration systems to meet the design requirements.

a. The interior of the Cold Chamber and the interior airstreams of the conditioning plenums shall be classified as a hazardous location as specified in the Article "DESCRIPTION OF WORK" in this Section.

b. Systems shall include two separate refrigeration systems housed in insulated conditioning plenums. The systems shall be capable of operating independently.

c. The refrigeration systems shall be cascade type using R-404A medium temperature and R-508B low temperature refrigerants in the respective portions of the cascades.

d. The conditioning plenums shall include the air distribution evaporator coils, drain pans, centrifugal blowers with non-sparking blower wheels, and explosion-proof electric resistance supply-air heating coils. Coil and drain pan defrost shall be hot gas type, supplied from the refrigeration system.

e. The refrigeration systems shall be sized so that one system can maintain chamber temperature while the other system is in defrost mode.

SECTION 11 20 00 Page 12

2.4.2 Monitoring Alarm System

Provide an electronic monitoring and alarm system for the chamber. Alarm is to warn of abnormally low and high temperatures.

a. System components: Detecting thermostat, master LCD control panel, interconnecting wiring, remote, labeled, and audible alarm. Provide dials showing temperatures and pilot lights, warning lights, switches, transformer, and buzzer, all as a part of the master control panel.

Provide master control panel and remote audible alarm. Provide power fuse to protect system components.

b. System operation: Set alarms at 10 degrees F above and below specified operating temperatures.

2.4.3 Personnel Alarm

For each unit, provide separate audible alarm system operable from inside unit, for use of personnel unable to exit unit. Locate remote audible alarm inside facility.

2.4.3.1 Gas Monitoring Systems

Provide monitoring systems to detect gases shall be installed and the system shall integrate into the SCADA system. See the Article "CONTROLS" in this Section for requirements.

2.4.4 Fire Alarm

Provide notification and detection devices as part of the cold chamber assembly and connect to the fire alarm control panel in the building.

2.4.5 Data Passage

Provide conduit pathway to route insulated cable leads for analog and digital controls and data to the control panel.

2.5 CONTROLS

Provide a system of controls to operate the Medium Cold Chamber and related systems and equipment.

2.5.1 Description

Controls shall include an LCD color touch screen controller with at least 7 inch viewing area dimension, remote monitoring, sensors, detectors, and accessories. Controls shall provide remote desktop access over an ethernet with virtual network computing software.

a. The central controls shall control the compressor staging, evaporator coils and fans, hot gas defrost, space heating coils, condensers, and other equipment to maintain the Cold Chamber at the setpoint. The controls shall be capable of sequencing one refrigeration plenum module into its defrost mode, while cycling the other module to maintain the setpoint. The controls shall provide automatic ramp/soak operation, program run, continue, hold, end, wait, previous step, and next step functions, user-selectable event outputs, low-to-high and high-to-low transitions, chamber alarms, and other input alarms.

SECTION 11 20 00 Page 13

b. The controls shall provide: Unlimited profiles with up to 99 steps each; automated FTP back-up of data files via Ethernet for ease of file management; USB port for download of profiles, alarm files, audit trail files and data files, and import of profiles for transfer among multiple chambers; data file access directly from controller or PC via RS-232/RS-485; alarm notification system to sends email and/or text phone messages via Ethernet; capability to email alarm history & audit trail files directly from the controller; data logging with custom file names, batch & lot numbers, operator events and digital signatures; help menu providing text and voice assistance in multiple languages; real time and historical trend graphs, printable with drag-and-zoom viewing control; profile status view showing detailed information including the stop date and time; profile autostart function; fully configurable alarm settings for the inputs; system security control allowing up to 30 different users with three different levels of security; audit trail function to track changes in settings by each user; adaptive tuning technology to optimize chamber performance and control stability; product control feature to accelerate temperature cycling of the device under test; product high/low limit with separate thermocouple; selectable power failure/recovery options; and capability for remote control by EIA-232/485 Modbus Communications.

c. Provide extension panels and accessories as required to provide the quantity and types of data points required for remote monitoring.

d. Provide interface to the SCADA (supervisory control and data acquisition) specified in Section 23 09 00 INSTRUMENTATION AND CONTROL FOR HVAC and Section 25 10 10.00 SCADA SYSTEM FRONT END AND INTEGRATION. Provide remotely accessible control points including at least eight digital inputs and at least 15 digital outputs. The control points shall be programmable within the Cold Chamber's controller to select based on the user's needs, including inputs for start, stop, and hold, and outputs for events, chamber temperature alarms, and refrigeration system alarms.

e. Provide refrigerant leak detection systems to simultaneously monitor for every type of refrigerant used in the cascade refrigeration systems. See the Article "REFRIGERATION UNIT SYSTEMS" in this Section for refrigerant types. The refrigerant monitors shall be multi-zone type, with infrared sensor technology, high performance sampling pump, capable of up to 16 remote areas, with large graphic LCD display and LED status indicators, capable of detecting the refrigerants at 1 to 8,000 ppm. Provide filtered sampling ports in the Cold Chamber, in the refrigeration conditioning plenum housings surrounding the compressors and cascade systems, and in the Staging Enclosure adjacent to the conditioning plenums, with interconnecting tubing to the refrigerant monitors. Locate sampling ports at suitable heights for the relative buoyancy of the refrigerants in air, and provide protection from impact, and from intrusion of dust, dirt, and liquids.

f. Provide gas monitoring of the atmosphere in the Cold Chamber, including hydrogen gas, carbon monoxide, and nitrogen dioxide, and for experimental refrigerants. Locate controllers outside the chamber, with remote sensors or aspirating devices in the chamber to transmit signals or room air to the controllers.

g. The monitor for experimental refrigerants shall be a multi-zone high precision refrigerant monitor, with infrared sensor technology, high

SECTION 11 20 00 Page 14 performance sampling pump, and capable of up to 16 remote areas.

Interface shall include a large graphic LCD display and LED status indicators. Monitor shall be capable of detecting the following user-selectable refrigerants at 1 to 8,000 ppm: R-11, R-12, R-13B1 (H-1301), R-21, R-22, R-23, R-113, R-114 (H-2402), R-123, R-124, R-125, R-134a, R-227, R-236fa, R-245fa, R-404A, R-407A, R-407C, R-410A, R-438A, R-500, R-502, R-507, R-513A, and R-514A.

h. Provide for leak detection and gas monitoring systems, remote audio and visual alarm indicators within the Cold Chamber. Indicators shall be similar to, but distinctly different in color and sound from, the fire alarm indicating devices, and shall have red engraved identifying nameplates affixed with metal fasteners to the interior wall of the Cold Chamber.

i. Controllers and sensors shall be suitable for the anticipated temperature and humidity conditions in their operating environment.

For devices mounted in the unconditioned building, anticipated temperature range shall include -20 to 120 degrees F (-28.8 to 48.8 C).

For controllers which require warmer temperatures, provide enclosure panels with transparent viewing panels and electric resistance internal heating. The LCD touchscreen shall be capable of operating in -15 degrees F (-26.1 C) ambient temperature, and shall be mounted with its touch surface exposed within the Staging Enclosure for easy access.

2.6 ROTARY DESICCANT DRYER

Provide a rotary desiccant dryer to supply conditioned combustion air makeup to the cold chamber.

2.6.1 Description

The dryer shall be a factory assembly including heavy-gauge galvanized steel housing with hinged and latched access panels and internal insulation, centrifugal air supply fan, pre- and post-conditioning systems including desiccant to condition the air to meet the design requirements, electric regeneration heater, direct-drive centrifugal fans for regeneration air and combustion air supply, electrical power supply connections with disconnect switch, and electronic controller.

a. Dryer shall be designed to mount on the building's indoor floor slab, with legs or rails to raise the unit above the floor.

b. Dryer shall be designed to intake ambient makeup air from the building interior surrounding the dryer, and supply the makeup air to the refrigeration system conditioning chambers. The desiccant regeneration air fan shall intake air from the building interior, and discharge it to outdoors. Interconnecting ductwork shall be provided under the work of this specification section.

2.7 REMOTE REFRIGERATION CONDENSERS

Provide remote air-cooled refrigeration condensers, to reject the refrigeration system heat to outdoors.

2.7.1 Description

Factory-assembled condenser with galvanized steel cabinet and supports.

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Copper coils with internally enhanced tubes sized to reduce refrigerant operating charge, aluminum fins arranged for easy cleaning, flexible coil supports to prevent tube failure, and dual circuiting for primary and desuperheating circuits. Electronically commutated (EC) dual-voltage fan motors with individual plug disconnect connections, moisture slingers and rain shields. Low-speed 850-RPM axial fans with swept wing design or equivalent for quiet operation and high efficiency. Individually baffled fan sections with full-height partitions and cleanout panels. Electrical power and control sections with terminal blocks, individual fan cycling and speed controls, and hinged and bolted access covers. Reduced voltage controls with transformer.

2.7.2 Coil Coating

Provide a factory-applied water-based epoxy polymer coating to the entire refrigerant coils including fins and tubing. The coating shall be thin and permanently flexible with high edge building and low bridging properties, shall provide corrosion resistance and hydrophilic properties, and shall not reduce coil heat transfer. Coating process shall ensure a uniform dry film thickness from 0.6 to 1.2 mils. Coating shall have 10,000 hours salt spray resistance per ASTM B117 Coating shall have a 5-year limited warranty. A spray-applied 2K polyurethane black topcoat shall be applied after the epoxy coating has cured, in a dry film thickness of 50 to 60 µm to prevent UV degredation of the epoxy film.

2.7.3 Supports

Provide 48-inch high extended-height legs and base framing suitable for field mounting outdoors on individual raised concrete piers; coordinate with piers indicated on the structural drawings, including verifying their sizes and locations. Verify leg length to ensure unrestricted airflow, including an allowance for drifting snow, with bottom edge of condenser coil cabinet and air inlet at least 5 feet above grade, and to coordinate piping entry into the building. Provide removable stainless steel fasteners for attachment to the piers.

2.7.4 Accessories

Provide the following, furnished by the condenser manufacturer with each condenser: Disconnect switch, non-fused. Motor overcurrent protection, individual fan motor fusing. Head pressure control valves, with ORI/ORD valves on R-404a circuit. Service valves on inlets and outlets of both circuits. Heated and insulated receiver, 12.75 by 96 inches with pressure relief valve, dial gauge, and inlet and outlet service valves. Check valve in liquid line upstream of receiver. Splitting relay, with controlling transducer mounted on R-404a circuit. Circuit connections for R-404a and R-508b. Circuiting for R-508B designed for minimum pressure drop.

2.8 UTILITIES AND INTERCONNECTIONS

Provide field-installed utilities and interconnections for a complete and functional system. Utilities and interconnections to the condensers shall penetrate the building wall in the metal siding, above the concrete wall base.

2.8.1 Refrigeration Piping

Provide refrigerant piping between components including but not limited to

SECTION 11 20 00 Page 16 the chambers, condensers, and receivers. Piping shall be copper Type ACR with brazed joints. Supports shall be resilient to allow expansion and contraction without damage to the piping; clamps to supports shall have plastic cushion linings. Install piping in accordance with UFGS 23 23 00 Refrigerant Piping, most current version (date of original issue 10-01-2007).

2.8.2 Condensate Piping

Provide condensate drainage piping from components such as the conditioning plenums, to the drainage point provided under the plumbing portion of the contract documents. Provide insulation and electric heat trace sized to prevent freezing in the ambient conditions described in the design requirements in this section.

2.8.3 Electrical Power and Controls

Provide a 480V, 3-phase power distribution panel, with circuit breakers and accessories to supply power to the cold chamber refrigeration systems and to the condensers. Provide control panel(s) to house controllers;

provide electric resistance heat within the panels where required by the controllers for operation at room temperature of -15 degrees F (-26 C).

Provide interconnecting power circuits and control wiring including but not limited to wiring and metallic conduit, with suitable supports.

Provide interconnecting control tubing, with protective conduits or other suitable raceways and supports. Make final connections to vibration-isolated equipment with flexible leads and conduits. Make connections to outdoor equipment liquid tight and weatherproof. Provide disconnect switches at each item of equipment.

2.8.4 Ductwork

Provide ductwork to interconnect the desiccant combustion air makeup system to the chamber evaporator plenum boxes. Provide flexible duct connections to equipment. Provide supports to the building structure, and intermediate galvanized steel supports where necessary. Provide vibration isolation on supports where necessary to reduce transmission of equipment vibration to the building and the cold chamber. Construct ductwork in accordance with SMACNA 1520, SMACNA 1922, and SMACNA 1966 as applicable to the system pressures and velocities. Provide air balancing devices such as blast gates and dampers.

PART 3 EXECUTION

3.1 MANUFACTURER'S FIT-UP TEST

The Contractor shall demonstrate all equipment and components associated with the medium cold chamber have been fit up and integrated for a complete and coordinate assembly. All hardware and accessories shall be included in the fit-up to ensure the medium cold chamber is a complete assembly when shipped to the site.

The Contractor shall provide a 21 calendar days notice to the Government prior to the fit-up test being conducted, for the Government to attend at their discretion.

This Point of Origin Certification shall be submitted to the Government and approved prior to shipping any equipment to the site.

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3.2 INSTALLATION

Prior to commencement of installation, perform a complete walk through of the facility with the Contracting Officer to verify readiness for installation.

Provide adequate protection of all finished surfaces, fixtures, and other equipment to prevent any damage during the installation work.

Conduct installation procedures in accordance with ANSI/ASHRAE 15 & 34 , ASHRAE 189.1 , and UL standards stated herein, and with the manufacturer's instructions.

3.2.1 Equipment Connections

Complete equipment connections for all utilities.

Submit Piping System And Installation And Support prior to commencement of equipment connections.

3.2.2 Plumbing Work

Tag all plumbing final connection points of equipment, indicating item number, name of devices or components, and type of utility (water, gas, drain).

3.3 OPERATION AND MAINTENANCE MANUALS

Submit six copies of operating instructions outlining the step-by-step procedures required for equipment start-up, operation and shutdown.

Include the manufacturer's name, model number, service manual, parts list, and a brief description of equipment and basic operating features.

Submit 6 copies of maintenance manuals listing routine maintenance procedures, possible breakdowns and repairs, trouble shooting guides, and containing the following:

a. Front and rear protective covers with labeled project name.

b. Index indicating item number, quantity, description, manufacturer's name, and model number.

c. Maintenance instructions for stainless steel and plastic laminate.

d. Manufacturer's catalog specification sheets and manufacturer's detail and control drawings.

e. Manufacturer's operation manual outlining the step-by-step procedures for equipment installation, startup, basic operation features, and operation shutdown.

f. Manufacturer's maintenance manual listing routine maintenance procedures, possible breakdowns, repairs, and troubleshooting guides.

Include simplified diagrams for the equipment as installed.

g. Manufacturer's list of parts and supplies with current unit price and address of manufacturer's parts supply warehouse.

Include simplified wiring diagrams in the instructions. Framed

SECTION 11 20 00 Page 18 instructions under glass or in laminated plastic, including wiring and control diagrams showing the complete layout of the entire system, must be posted where directed. Prepare in typed form, condensed operating instructions explaining preventative maintenance procedures, methods of checking the system for normal safe operation, and procedures for safely starting and stopping the system, framed as specified above for the wiring and control diagrams, and posted beside the diagrams. Submit proposed diagrams, instructions, and other sheets, prior to posting. Post the framed instructions, including wiring and control diagrams, before acceptance testing of the systems.

3.4 INSTRUCTIONS TO GOVERNMENT PERSONNEL

Prepare and conduct a training course for the operating staff as designated by the Contracting Officer. The training must consist of a total 8 hours of normal working time and start after the system is functionally completed but prior to final acceptance tests. Cover in the field instructions the items contained in the operating and maintenance instructions, as well as demonstrations of routine maintenance operations. Notify the Contracting Officer at least 14 days prior to date of proposed conduction of the training course.

Submit a list of authorized local service and repair entities to the Contracting Officer 14 days prior to conducting the training course.

Provide a video recording of the training conducted and provide four (4) copies of the video on a DVD to the Government.

3.5 TESTS

Perform the tests as specified. Notify the Contracting Officer in writing, 10 days prior to performing tests. Perform tests in the presence of the manufacturer's representative and the Contracting Officer.

3.5.1 Initial Start-Up and Operational Test

Provide all lubricants and accessories before initial start-up. Start and operate all equipment. Follow the manufacturer's procedures and place the systems in all modes of operation. Supplement initial charges of lubricating oil to ensure maximum operating capacity. Adjust all safety and automatic control instruments. Record manufacturer's recommended readings hourly. Operational tests must cover a period of not less than 1 day.

Upon completion of start-up and operational tests submit a list of authorized local service and repair entities.

3.5.2 Test Reports

Submit final field test reports for each system tested, describing test apparatus, instrumentation calculations, and equipment data based on industry standard forms or reasonable facsimiles thereof.

3.5.3 24 Hour Test

The Contractor shall demonstrate the medium cold chamber can meet the temperature and humidity requirements for a 24 hour period. Temperature monitoring shall measure at a maximum of 15 second intervals.

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3.5.4 Vehicle Test

The Contractor shall demonstrate the capability of performing a vehicle test within the cold chamber. The test vehicle, as described in paragraph 1.4.1.f. in this Section, will be provided by the Government. The tests shall demonstrate the vehicle for at least 30 minutes each test, once with the vehicle at full power, and once with the vehicle at varying engine RPM. The test acceptance criteria shall be to maintain the chamber inner temperature at -54 degrees C (-65.2 degrees F) with a tolerance of +/-5 degrees C during these test periods.

3.6 MANUFACTURER'S WARRANTY

Submit all manufacturers' signed warranties to Contracting Officer prior to final commissioning and acceptance.

3.7 CONTRACTOR'S WARRANTY for INSTALLATION

Submit contractor's warranty for installation to the Contracting Officer prior to final commissioning and acceptance.

-- End of Section --

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