MINA AL SULTAN QABOOS WATERFRONT

MUSCAT, OMAN

BAB ALMINA ZONE

PHASE 1A – BUILDINGS
PLOT 101 (H2-R5) – BP01

MEP WORKS PACKAGE

(MECHANICAL)

Volume 2 – Specifications
August 2019
 Mechanical Specifications

SECTION 15780
DIRECT EXPANSION AIR-CONDITIONERS
PART 1 GENERAL

1.01 SECTION INCLUDES

A. Unitary air conditioners.
B. Controls.

1.02 RELATED REQUIREMENTS

A. Section 23 0513 -Common Motor Requirements for HVAC Equipment: Evaporator and
condenser fan motors.
B. Section 23 2300 -Refrigerant Piping.
C. Section 23 0913 -Instrumentation and Control Devices for HVAC: Installation and wiring
of thermostats and other control components.
D. Section 26 2717 -Equipment Wiring: Electrical characteristics and wiring connections.

1.03 REFERENCE STANDARDS

A. NEMA MG 1 -Motors and Generators; National Electrical Manufacturers Association;
2011.
B. NFPA 90A -Standard for the Installation of Air-Conditioning and Ventilation Systems;
National Fire Protection Association; 2012.

1.04 SUBMITTALS
A. See Section 23 0000 -General Requirements, for submittal procedures.
B. Product Data: Provide data for manufactured products and assemblies. Indicate water,
drain, thermostatic valves, and electrical rough-in connections with electrical
characteristics and connection requirements. Provide details of airflow, cooling capacity,
pressure drop as per the project requirements.
C. Manufacturer's Instructions: Indicate assembly, support details, connection requirements,
and include start-up instructions.
D. Warranty: Submit manufacturer's warranty and ensure forms have been filled out in
Owner's name and registered with manufacturer.
E. Maintenance Materials: Furnish the following for Owner's use in maintenance of project.
1. See Section 23 0000 -General Requirements, for additional provisions.
2. Extra Filters: One set for each unit.
3. Extra Fan Belts: One set for each unit.

1.05 QUALITY ASSURANCE

A. Unit meets ASHRAE 90.1 minimum efficiency requirements.
B. Unit shall be rated in accordance with AHRI Standard 340/360.

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C. Unit shall be designed to conform to ASHRAE 15.

D. Insulation and adhesive shall meet NFPA 90A requirements for flame spread and smoke
generation.
E. Unit casing shall be capable of withstanding 500-hour salt spray exposure per ASTM
B117 (scribed specimen).
F. Unit casing shall be capable of withstanding Federal Test Method Standard No. 141
(Method 6061) 5000--hour salt spray.
G. Unit shall be designed in accordance with ISO 9001, and shall be manufactured in a
facility registered by ISO 9001.
H. Unit shall be subjected to a completely automated run test on the assembly line. The data
for each unit will be stored at the factory, and must be available upon request.
I. Unit shake tested to assurance level 1, ASTM D4169 to ensure shipping reliability

1.06 DELIVERY, STORAGE, AND HANDLING

A. Unit shall be stored and handled per manufacturer’s recommendations.
B. Lifted by crane requires either shipping top panel or spreader bars.
C. Unit shall only be stored or positioned in the upright position.

1.07 OPERATING CHARACTERISTICS

A. Unit shall be capable of starting and running at 50 Deg.C ambient outdoor temperature,
meeting maximum load criteria of AHRI Standard 340/360 at ± 10% voltage.
B. Compressor with standard controls shall be capable of operation from 4 Deg.C (40
Deg.F) , ambient outdoor temperatures.
C. Accessory kits are necessary if mechanically cooling at ambient temperatures below 4
Deg.C (40 Deg.F).
D. Unit shall discharge supply air vertically or horizontally as shown on contract drawings.
E. Unit shall be factory configured and ordered for vertical supply & return configurations.
F. Unit shall be factory furnished for either vertical or horizontal configuration without the
use of special conversion kits. No field kits conversion is possible.
G. Unit shall be capable of mixed operation: vertical supply with horizontal return or
horizontal supply with vertical return.

1.08 WARRANTY
A. Provide a five year warranty to include coverage for refrigeration compressors.

PART 2 PRODUCTS

2.0 MANUFACTURERS
A. Refer to the manufacturer list or the BOQ.

2.01 PACKAGED AIR CONDITIONING UNITS

(Reversible Heat pump when specified in the schedule of equipment )

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A. Description: Packaged, self -contained, factory assembled, prewired unit, consisting of

cabinet, compressor, condensing coil, evaporator fan, evaporator coil, air filters, and
controls; fully charged with refrigerant and filled with oil.
B. Electrical Characteristics:
1. Refer to Section 26 2717.
2. Disconnect Switch: Factory mount disconnect switch on equipment under
provisions of Section 26 2717.

A. CABINET

1. Frame and Panels: Galvanized steel and shall be bonderized and coated with
baked enamel finish, easily removed access doors or panels with quick fasteners.
2. Insulation: Minimum 1/2 inch (13 mm) thick acoustic duct liner for lining cabinet
interior.
3. Drain Pan: Galvanized steel with corrosion -resistant coating.
4. Unit cabinet exterior paint shall be: film thickness, (dry) 0.076mm/0.003 inches
minimum, gloss (per ASTM D523, 16 Deg.C/60 Deg.F): 60
5. Evaporator fan compartment interior cabinet insulation shall conform to AHRI
Standards 340/360 minimum exterior sweat criteria. Interior surfaces shall be
insulated with a minimum 13mm (1/2in.) thick, .45 kg (1lb) density, flexible
fiberglass insulation, neoprene coated on the air side. Aluminum foil --faced
fiberglass insulation shall be used in the heat compartment.
6. Base of unit shall have a minimum of four locations for factory thru-the-base
electrical connections. Connections shall be internal to the cabinet to protect from
environmental issues.
7. Base Rail
a. Unit shall have base rails on a minimum of 2 sides.
b. Holes shall be provided in the base rails for rigging shackles to facilitate
maneuvering and overhead rigging.
c. Holes shall be provided in the base rail for moving the rooftop by fork
truck.
d. Base rail shall be a minimum of 16 gauge thickness.

8. Condensate pan and connections:

a. Shall be a sloped condensate drain pan made of a non--corrosive

material.
b. Shall comply with ASHRAE Standard 62.
c. Shall use a 19mm (3/4--in.) --14 NPT drain connection at the end of the
drain pan. Connection shall be made per manufacturer’s
recommendations.

9. Top panel:

a. Shall be a multi--piece top panel linked with water tight flanges and
interlocking systems.
10. Electrical Connections

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a. All un. it power wiring shall enter unit cabinet at a single, factory--
prepared, knockout location
b. Thru--the--base capability
1. Standard unit shall have a thru--the--base electrical location(s)
using a raised, embossed portion of the unit base pan.
2. Optional, factory--approved, water--tight connection method
must be used for thru--the--base electrical connections.
3. No base pan penetration, other than those authorized by the
manufacturer, is permitted.

11. Component access panels (standard)

a. Cabinet panels shall be easily removable for servicing.

b. Unit shall have one factory installed, tool--less, removable, filter access
panel.
c. Panels covering control box and filters shall have molded composite
handles while the blower access door shall have an integrated flange for
easy removal.
d. Handles shall be UV modified, composite. permanently attached, and
recessed into the panel.
e. Screws on the vertical portion of all removable access panel shall engage
into heat resistant, molded composite collars.
f. Collars shall be removable and easily replaceable using manufacturer
recommended parts.

B. COILS

1. Aluminum fin --Copper Tube Coils:

a. Standard evaporator and condenser coils shall have aluminum lanced

plate fins mechanically bonded to seamless internally grooved copper
tubes with all joints brazed.
b. Evaporator coils shall be leak tested to 150 psig, pressure tested to 450
psig.
c. Condenser coils shall be leak tested to 150 psig, pressure tested to 650
psig.
d. Coating process shall ensure complete coil encapsulation of tubes, fins
and headers.
e. Color shall be high gloss black with gloss per ASTM D523-89.
f. Uniform dry film thickness from 0.8 to 1.2 mil on all surface areas
including fin edges.
g. Superior hardness characteristics of 2H per ASTM D3363-92A and
cross-hatch adhesion of 4B--5B per ASTM D3359--93.
h. Impact resistance shall be up to 160 in.--lb (ASTM D2794-93).
i. Humidity and water immersion resistance shall be up to minimum 1000
and 250 hours respectively (ASTM D2247-92 and ASTM D870-92).
j. Corrosion durability shall be confirmed through testing to be no less than
1000 hours salt spray per ASTM B117 -90.

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C. EVAPORATOR FAN
1. Evaporator fan motor:
a. Shall have inherent automatic --reset thermal overload protection or
circuit breaker.
b. Shall have a maximum continuous bhp rating for continuous duty
operation; no safety factors above that rating shall be required.

2. Belt --driven Evaporator Fan:

a. Belt drive shall include an adjustable --pitch motor pulley and belt break
protection system. Variable and adjustable pitch motor sheave selected
so required rpm is obtained with sheaves set at mid -position as
recommended by manufacturer or minimum 1.5 times nameplate rating
of the motor.
b. Shall use rigid pillow block bearing system with lubricate fittings at are
accessible or lubrication line.
c. Blower fan shall be double --inlet type with forward --curved blades.
d. Shall be constructed from steel with a corrosion resistant finish and
dynamically balance

3. High -static motor(s)and drive(s)shall be factory –installed to provide additional

performance range.

D. COMPRESSOR
1. Hermetically sealed, 3600 rpm maximum, resiliently mounted with positive
lubrication and internal motor protection.
2. Unit shall use one fully hermetic, scroll compressor for each independent
refrigeration circuit.
3. Compressor motors shall be cooled by refrigerant gas passing through motor
windings.
4. Compressors shall be internally protected from high discharge temperature
conditions.
5. Compressors shall be protected from an over –temperature and over –amperage
conditions by an internal, motor overload device.
6. Compressor shall be factory mounted on rubber grommets.
7. Compressor motors shall have internal line break thermal, current overload and
high pressure differential protection.
8. Crankcase heaters shall not be required for normal operating range, unless
provided by the factory

E. EVAPORATOR COIL
1. Direct expansion coiling coil of seamless copper tubes expanded into aluminum
fins.
2. Refrigeration circuit with externally equalized thermal expansion valve, filter -
drier, and charging valves.
F. CONDENSER
1. Terminate suction and liquid refrigerant piping with service valves within unit.
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2. Condenser fan motors:

a. Shall be a totally enclosed motor.
b. Shall use permanently lubricated bearings.
c. Shall have inherent thermal overload protection with an automatic reset
feature.
d. Shall use a shaft -down design.

3. Condenser Fans:
a. Shall be a direct --driven propeller type fan.
b. Shall have aluminum blades riveted to corrosion -resistant steel spiders
and shall be dynamically balanced.

G. AIR FILTERS
1. Easily removed 2 inch (50 mm) thick disposable glass fiber panel filters.

H. REFRIGERANT COMPONENTS
1. Refrigerant circuit shall include the following control, safety, and maintenance
features:
a. Fixed orifice metering system shall prevent mal -distribution of two -
phase refrigerant by including multiple fixed orifice devices in each
refrigeration circuit. Each orifice is to be optimized to the coil circuit it
serves.
b. Refrigerant filter drier.
c. Service gauge connections on suction and discharge lines.
d. Pressure gauge access through a specially designed screen on the side of
the unit.

I. UNIT -MOUNTED,NON -FUSEDDISCONNECTSWITCH:

1. Switch shall be factory -installed, internally mounted.

2. National Electric Code (NEC) non -fused switch shall provide unit power
shutoff.
3. Shall be accessible from outside the unit
4. Shall provide local shutdown and lockout capability.

J. CONTROLS
1. Factory wired controls shall include contactor, high and low pressure cutouts,
internal winding thermostat for compressor, control circuit transformer, non -
cycling reset relay.
2. Provide thermostat to cycle cooling, mounted within unit with 'fan -off -cool'
switch allowing continuous fan operation, or cycling fan on call for cooling.
3. Fan/Filter Status Switch:
a. Switch shall provide status of indoor evaporator fan (ON/OFF) or filter
(CLEAN/DIRTY).
b. Status shall be displayed either over communication bus (when use d
with direct digital controls) or with an indicator light at the thermostat.

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4. Provide room thermostat to control cooling with 'cool -off' selector switch and
'auto -on' fan control switch.
5. Head Pressure Control Package:
a. Controller shall control coil head pressure by condenser -fan speed
modulation or condenser --fancycling and wind baffles.
b. Shall consist of solid -state control and condenser -coil temperature sensor
to maintain condensing temperature between 32 Deg. C (90 Deg.F) and 43
Deg.C (110 Deg.F) at outdoor ambient temperatures down to -29 Deg.C ( -
20 Deg.F).

6. Refer to Section 23 0913.

K. SMOKE DETECTORS:
1. Shall be a Four -Wire Controller and Detector.
2. Shall be environmental compensated with differential sensing for reliable, stable,
and drift--free sensitivity.
3. Shall use magnet --activated test/reset sensor switches.
4. Shall have tool --less connection terminal access.
5. Shall have a recessed momentary switch for testing and resetting the detector.
6. Controller shall include:

a. One set of normally open alarm initiation contacts for connection to an

initiating device circuit on a fire
b. alarm control panel.
c. Two Form --C auxiliary alarm relays for interface with rooftop unit or other
equipment.
d. One Form --C supervision (trouble) relay to control the operation of the
Trouble LED on a remote test/reset station.
e. Capable of direct connection to two individual detector modules.
f. Can be wired to up to 14 other duct smoke detectors for multiple fan
shutdown applications.

L. TIME GUARD
1. ovidinga5 –minute delay(±2minutes)before restarting a compressor after shutdown
for any reason.
2. One device shall be required per compressor.

M. TWO—POSITION MOTORIZED DAMPER

1. Two—Position Damper. Damper travel shall be from the full closed position to the
field adjustable %--open set point.
2. Damper shall include adjustable damper travel from 25% to 100% (full open).
3. Damper shall include single or dual blade, gear driven dampers and actuator motor.
4. Actuator shall be direct coupled to damper gear. No linkage arms or control rods
shall be acceptable.
5. Damper will admit up to 100% outdoor air for applicable rooftop units.

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6. Damper shall close upon indoor (evaporator) fan shutoff and/or loss of power.
7. The damper actuator shall plug into the rooftop unit’s wiring harness plug. No hard
wiring shall be required.
8. Outside air hood shall include aluminum water entrainment filter

N. MANUAL DAMPER
1. Manual damper package shall consist of damper, air inlet screen, and rain hood
which can be preset to admit up to 25% outdoor air for year round ventilation.

2.02 SPLIT DIRECT EXPANSION AC UNITS

A. General
Units shall consist of a ceiling-concealed ducted indoor evaporator unit, an outdoor
condensing unit and shall be factory assembled and fully charged with R-22 or R 407c or
R410A.
Both indoor & outdoor units shall be manufactured in the same factory and shall be checked
under a strict quality control system to ensure compatibility of indoor with outdoor unit,
reliability of operation and performance stated in manufacturer’s catalogue. The units shall
be easily connected together with the refrigerant pipes. They shall be designed to operate at
the outdoor temperature as high as 50 °C DB. Cooling capacities shall be rated in
accordance with latest edition of ARI Standard 210 or Euro vent specification. If required,
the capacities shall be supported by third party independent test certificates. Independent
assessment of the quality management system to be applied subject to independent third
party assessment and approval to ISO 9001 or BS 5750, Part II, International Standard for
Quality Systems.
The refrigerant suction and discharge lines shall be sized in accordance with the manufacturer’s
recommendations and shall be verified and certified by the Manufacturer prior to ordering and
execution of works. Installation of all buried and above ground refrigerant pipework shall be as
per Manufacturer’s recommendation with due consideration for insulation jacketing, protective
enclosure in pipe sleeves for all buried piping, oil drains, etc. whether shown on drawings or not.
Refrigerant piping installation shall be in accordance with ASHARE 15.

B. Condensing Unit (Side Discharge)

1. Furnish and install all air-cooled condensing units (Heat Pump) in the locations and
manner shown on the plans. The units shall be properly assembled and tested at the
factory.
2. Condenser coils shall be made of seamless copper tube mechanically bonded to
aluminum fins. Each coil shall be leak tested at 150psig (1034 Kpa) and pressure
tested at 300psig (2068 Kpa). Each circuit shall have correctly sized multi staged
capillary tube based expansion device, with liquid line filter and shut off valves for
both refrigerant lines. Condenser coil shall be protected with reinforced plastic
galvanized mesh guard.

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3. Condenser Fans and Motors

Fans shall be propeller type reinforced engineering blades directly driven by
electric motor designed to reduce energy requirement, discharging air sideward or
upward and ensure quite operation.
A single-phase motor totally enclosed shall be used to drive the condenser fans for
all units. Motor shall have class ‘F’ insulation. Shafts shall be corrosion resistant.
Motor shall be equipped with permanently lubricated ball bearings, built in
current/thermal protection and factory wired using PVC insulated wires which can
0
be used up to 105115 C. Complete fan assembly shall have a suitable hybrid (epoxy
+ Polyethylene ) powder painted fan guard with heavy gauge galvanized wire.
Fan blades shall be statically and dynamically balanced.
Controls shall be included for cycling fans(s) for intermediate season operation.
4. Compressor(s)
Condensing units shall have high efficiency scroll/rotary hermetic compressors
equipped with internal pressure relief valve, over-current relay and evaporator
sensor switches as standard. Units shall have high pressure and low-pressure
switches. All the control options should be factory installed, wired & tested to high
quality standard. Compressor shall be covered in acoustic lining jackets to reduce
noise levels.
Compressors shall be with external spring isolators and shall have an automatically
reversible oil pump when specified. Compressor shall unload in response to suction
pressure down to 25% of full capacity in 3 steps minimum for partial load
operation. Compressor shall be located in a section separated from condenser fans
and coil.
Multiple compressor units shall have step-start fans and coils. Compressor motor(s)
shall have part-winding , across the line start.
5. Controls
Standards protection devices for overload, anti recycle relay, delay relay,
evaporator temperature sensor and internal pressure relief valves shall be provided
on the units.

The thermostats shall be with twin thermistor system to sense to temperatures in the
room in the return air with an option of selecting one or both depending on the
application.
Controls shall be factory wired and located in a separate enclosure. Unit wiring
shall incorporate a positive acting timer to prevent short cycling of compressor if
power is interrupted. Timer shall prevent compressor from restarting for
approximately 5 minutes after shutoff. Units shall be factory wired to operate on
single pump-out control.
6. Casing :
The entire casing panels shall be designed to be leak-proof against rain and ensure

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control casing to be made of zinc coated galvanized steel sheets phosphated and
painted with oven baked enamel paint.
Unit construction will comply with latest edition of ANSI/ASHRAE.

Casing panel finish & coating shall pass 500 hours salt spray testing at 95°F as per
ASTM B117-85. Openings shall be provided for power and refrigerant connections.
Panel shall be removable to provide access for servicing.

7. Vibration Isolation
All motors and compressors shall have anti-vibration mountings.
C. Evaporator Unit (Indoor unit)
1. General
Fan coil units shall be two-pipe, with a minimum of three rows of copper coils, fans
and filters.
2. Casing (Ducted type)
Unit casing shall be of single-skinned construction with heavy gauge galvanized
steel, with 15 mm of internal Elastomeric insulation. The cabinet of exposed units
shall be 1.3 mm thick steel panels, primed and baked enamelled finish to a colour
approved by the Consultant.
The maximum height of the units shall be not more than 370 millimeters. Face
velocity at the coil shall not exceed 400FPM. Unit shall be equipped with factory-
installed brackets for hanging. Control box shall be easy for replacement with an
option of fixing on both right-hand side or left hand side of the unit at site.
3. Casing (Decorative)
Manufacturer standard to architect /ID approval.

4. Filters
Units shall have accessible filters.
Units shall have anti bacteria and washable permanent filter.

5. Cooling Coils
Unit coils shall be A.R.I. rated, at least 15 mm O.D. size, copper tubes with
aluminum fins, fitted with manual air vent.
Coils shall be made of staggered heavy wall seamless copper tubing mechanically
bonded to aluminium fins with number of rows and fins per inch as per
manufacturers design to provide stated performance and shall be factory leak tested
2
at a pressure of 33 kg/cm . They shall preferably be provided with 3-step expansion
rd
system with steps 1 & 2 capillary tube provided in the outdoor unit and the 3 step
in the indoor unit. Coils shall be coated to prevent aging and reduce wettability at
full load condition.
6. Fans
Fans shall be centrifugal, forward curved, statically and dynamically balanced, with
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wheels and housings.

Units up to 6 tons shall be direct drive.
An engineered reinforced plastic fan for linear motor application shall be used to
deliver an accurate airflow at a low noise level. The fan and motor assembly shall
have a rubber isolator to reduce noise & vibration. The motors shall have thermal
overload protection. Sleeve bearings with oil tubes and oil reservoirs shall be
provided. The motors shall be permanent split capacitor type. The fan switch shall
be located as directed by the Consultant and should be capable of remote operation.
A single-phase motor shall be used to drive the evaporator fans for units up to 6
tons. The motor shall have a connection to facilitate at least 3-speed adjustment to
control the external static pressure requirement to suit the duct application. Motor
shall have at least class ‘B’ insulation but the basic material should be class ‘F’.
Wherever required units shall have an option of low static motors for short length
of ducts and high static units for longer length of ducts. A linear motor for universal
application of low static & high static with the same motor is preferred.
7. Controls
Unit operation shall be controlled via wall mounted indoor thermostats having
ON/OFF control, Lo-Med-High fan speed control, temperature setting facility &
space temperature sensor.
8. Drain pans
Each unit shall be equipped with either reinforced plastic or galvanized steel drain
pan, projected under the entire length and width of the cooling coil, including the
headers and return bends coated with hybrid epoxy powder painting (epoxy +
polyester) and insulated with 10mm thick polyurethane foam. It shall have drain
connection and pitched for positive drainage with the unit installed level. In the
event of space constraint with smaller false ceiling heights, units shall have an
option of factory installed/tested drain pump with minimum 700mm head for
positive drainage of condensate.
9. Noise levels
Where noise criteria are specified elsewhere, the fan coils must also meet these
requirements, and the unit cooling ratings will be determined only at those speeds
which produce noise levels within the acceptable limits.

2.03 F RESH AIR HANDLING UNITS (FAHU)

DX (Reversible when specified in schedules)
A. Units shall be factory fabricated complete with the following:
1. Supply air Fan sections with centrifugal, airfoil BI fans DWDI design, as specified.
2. V-belt drive and belt guard.
3. Cooling coil section with condensate pan
4. 410 mm wide access section between two cooling coil sections
5. Heat Recovery wheel section.
6. Bag filter section with filters
7. Flat filter section with filters
8. Access doors into fan section, coil section and mixed air sections.

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9. Electric heating coil complete (when specified in the schedule of equipment) with
safeties (high limit, sail switch, airflow interlock), SCR controls and panels, where
indicated on schedules.

B. Casings
1. Unit shall be constructed of a complete frame with removable panels. Removal of
side panels must not affect the structural integrity of each module. The casing must
be able to withstand up to six inches positive or four inches negative static pressure.
All exterior wall panels shall be made of minimum 18-gauge steel sheet. Closed-
cell foam gaskets shall be provided where modules are joined. Casing shall be
painted with dry powder coated finish.

2. Unit shall be double-wall constructed to prevent fiberglass erosion into the air
stream and to allow cleaning of the unit interior. Interior wall shall be two inches
thick of either 20gauge solid or 18-guage perforated plate steel sheet with dry
powder coated finish. Foil faced insulation is not acceptable.

3 Condensate drain pan under cooling coils shall be insulated double wall anti
corrosive construction. Drain connections are to be provided on both sides of the
unit. 4 Interior of all units shall be coated with Bronze-glow anti-corrosion coating
Bly gold or two layers of epoxy coating. Coatings shall be factory applied.

5 Unit shall be internally insulated with 50mm thick 4.5 pound density rigid
neoprene coated fibre glass insulation and lined with perforated sheet metal liner
attached to casing. All connecting channels shall be insulated to prevent sweating.
Insulation shall meet NFPA-90A requirements.
6 Access doors minimum size 900mm H x 600mm W shall be provided for motor
access and coil access. Access doors shall be gasketted and attached to casing
using piano hinges. Vent locks shall be provided on doors.
7 All panels shall be flush fitting into the frame and close upon an effective rubber
gasket or O-ring fixed to provide an air tight seal. Panels shall be securely fixed by
captive locks requiring the use of a special key to open from inside the unit.
8 All doors shall be open able with keys or tools from the inside in the event of being
accidentally closed.
9 Access panels shall be fitted with lift off type heavy duty hinges and fridge type
handles. Where hinged access panels are not suitable then the panels shall be
retained by captive screw up latches to be complete with lifting handles. Hinge
positions and handle locations to be standardized on all similar units to enable
panels to be interchangeable on similar type units.
10 Test holes shall be provided in each casing before and after each coil. These holes
shall be plugged by rubber grommets when not in use.
11 The casing panel to the fan sections shall include a glazed view ports. Within the
sections, lighting shall comprise bulkhead luminaries with fluorescent lamp to be
externally switched from a fixed panel.
12 The power supply to the lamp switch shall be derived from a 6A MCB, to comply
with local regulations and European Standards, located within the control panel
serving the air handling unit.
13 Provide minimum 300 wide hinged access panel between each section of the unit.
14 Air intakes and exhausts on all air handling units shall be fitted with motorized

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dampers to prevent air leakage when the unit is not in operation.

C. Frames

1 All sections shall comprise a heavy duty frame work formed from hollow
rectangular sections mild steel tube of preformed pressed steel Penta-post. Cross
members and carrier rails should be of the same section to provide the maximum
rigidity and strength.
2 Where sections are bolted together a suitable sealant shall be supplied by the
manufacturer for application by the installer on site. 3

On completion of the frame including reinforced lifting points, all welds shall be
ground smooth, the whole shall be de-greased and painted with one coat of primer,
one coat of undercoat and one coat of gloss to BS or RAL color to be specified.
4 Where required by the operating temperatures the frames shall be fully insulated
and incorporated thermal breaks to ensure condensation will not occur on external
surfaces of the unit.

5 All air handling unit sections shall be provided with heavy duty removable lifting
lugs treated with primer. Plugs shall be provided to seal holes once lugs are
removed.

6 External units shall have a factory applied epoxy paint finish to BS or RAL color as
advised by the Architect. Air intakes and exhausts on all air handling units shall be
fitted with motorized dampers to prevent air leakage when the unit is not in
operation.

D. Fan Section

1 Fan section shall have aerofoil, backward inclined centrifugal fans, as indicated,
mounted on a vibration isolation frame on four heavy duty spring isolators
providing 98% isolation efficiency. Fan wheels and drive shaft assembly shall be
statically and dynamically factory balanced and shall operate quietly and without
pulsation. All bearings shall have lubrication lines extended to accessible locations.
Published performance fan ratings shall be obtained in accordance with the
procedures as set forth by the AMCA test code for air moving devices. Submit the
manufacturer's certified sound power ratings with an octave band analysis and the
basis on which they have been established to the Engineer for review as part of the
fan shop drawings. Make one set of these curves available to the supplier of sound
and vibration isolation equipment.

2 The complete fan and motor assembly shall be mounted on springs. Provide
flexible connection between the fan outlet and unit casing. Complete fan and
housing to be epoxy coated. Fan motor shall be TEFC type, high efficiency motor.

3 V-belt drive shall be designed for 150% of motor nameplate rating. Motor sheave
shall be adjustable pitch type or fixed pitch type which shall be replaced with
correct sheave after air balancing. Base for motor shall have adjustable slide rail.
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Fan bearings shall be selected for a minimum life of 200,000 hours. Grease nipples
on fan bearings shall be extended to exterior of unit casing for ease of maintenance.
Fan shall be double inlet double width design and be selected for quite operation.

4 Selected fans to operate at peak efficiency (minimum 80%) and with due regard to
noise criteria.

5 The fan casing shall be of welded steel construction. The casing shall be
constructed with a horizontal bolted joint to allow removal of the impeller
assembly.

6 Open fan inlets shall have a protective guard installed.

7 Fans shall be supplied with flexible connections on the fan discharge complete with
appropriate flanged connection.

8 The casings on all fans located external to air handling units shall be complete with
a powder coated finish to match the color and finish of the associated air handling
unit.

E. Fan Drives

1 The fan shall be driven through a V belt drive and pulleys by a TEFV motor,
suitable for a 3-phase electrical supply. A minimum of two belts shall be provided.
A fan guard shall be provided with separate removable access to both drive shafts
to allow use of a tachometer.
2 All motors shall be rated for continuous duty and the windings shall have class F
insulation minimum. For 3-phase motors the 6-phase ends from the stator winding
shall be brought out to the terminal box. A thermistor shall be incorporated within
the motor stator windings with terminals brought separately to the connector block.
3 Motors shall be selected so that a under design conditions they are operating at no
more than 80% of their maximum rated load.
4 The design of all motors shall be such to allow for switching direct on to the supply
at full voltage and the starting current under these conditions shall not exceed six
times the full load value whilst the torque exerted shall not be less than twice the
full load torque. The speed torque curve shall be such that the torque available at
the moment of starting does not fall away so rapidly as to made the machine slow
in accelerating to full speed under load.
5 Motors shall be provided with a prominent label of durable material having the
legend clearly inscribed in characters 25mm high (red on white background). The
labels shall be mounted in a conspicuous location clearly associated with the motor
relating to it. Final size shall be agreed with the engineer. The legend shall read:
1. DANGER THIS MOTOR IS AUTOMATICALLY CONTROLLED AND
MAY START WITHOUT WARNING. ISOLATE BEFORE
INSPECTION

The label shall clearly show both English and the local language translation of the
above text.

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 Mechanical Specifications

6 All motors shall conform to the requirements of BS5000, BS4999 and BS EN

50347.
7 The motor shall be mounted on adjustable slide rails. The motor shall be adjusted
by means of a bolt, acting against the motor through a gimbaled end cap, and
sliding guide, to restrict the bolt flexing under load. The entire drive assembly shall
be enclosed by a wire mesh guard. The guard shall be of sufficient size to allow for
the full travel of the motor in the slide rails. The guard shall be so constructed to
allow access for measurement of the fan and motor speeds and checking of bolt
tension without removing the whole guard.
8 The whole fan, motor and drive assembly shall be mounted on an independent sub
frame which shall be completely isolated from the main bases frame by spring anti-
vibration mountings shall provide a degree of isolation efficiency of not less than
95%.
9 Motor selection shall be based on the calculated external static pressure, internal
pressure losses, and medium dirty filters plus 25% of the resulting total static
pressure.
10 All lubrication and test points shall be extended to a readily accessible position.
11 The fan shall be selected to enable a 20% increase in system resistance, without the
need to replace the fan motor.

F. Coil Section

1. Coils shall be of copper tube with turbulators, aluminum fin construction with
heavy gauge galvanized steel frame. Coils handling any fresh air shall be copper
tube and aluminum fin construction. Coils for mounting in ductwork shall have
holes in frame for bolting to flanged ductwork. Cooling coils shall have fins spaced
not closer than 3mm (8 to the inch). Water coils shall have serpentine circuiting
arranged for counter-flow between the air and water, suitable for 1550 kPa (225
psig) water pressure and complete with plugged drain and vent connection, readily
accessible. Face velocity shall not exceed 2.54m/s (500 fpm) for cooling coils. All
coils shall have ARI or Eurovent certification in accordance with standard 410.
Provide proof of certification along with submittal.
2. Mounted within the air handling unit on slide rails to allow full withdrawal of the
coil without requiring the unit section to be dismantled.
3. Constructed from copper tube of minimum 0.50mm wall thickness with aluminium
fins of minimum 0.175mm thickness.
4. The manufacturer shall guarantee that each coil can meet the specified duty.
5. Coils shall be pitched and installed as required in the manufacturer's installation
instructions. For coils handling fresh air, provide moisture eliminators downstream
of coils. Where coils are stacked, provide condensate pan for each coil. Pipe upper
pan drain to lower condensate pan.

6. Coils shall be sized on chilled water conditions as indicated on the schedules.

1. Maximum water side friction shall be 35 kPa.
7. Provide coils in accordance with Coils Schedule shown in the equipment schedule.
8. Condensate pan shall be insulated and extended full width and length of coil
including headers.

G. Filters

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 Mechanical Specifications

1 Fresh air units shall be complete with disposable flat filters located upstream of the
bag filters.
2 All Filters shall be tested in accordance with ASHRAE 52.1-2004, Gravimetric and
Dust Spot Procedures for Testing Air Cleaning Devices Used in General
Ventilation for Removing Particulate Matter.
3 Flat Filter Section shall consist of 50mm (2") thick throw away filter media in
permanent frame with media efficiency 90 -92% arrestance. Filter frames shall be
designed for sliding filters in through hinged access door on side of unit. Flat filter
section shall be supplied on all units.
4 Bag Cartridge Filter Section: Bag filters shall be supplied on all units with fresh air
capability. Bag filters shall have an arrestance efficiency of 90-95%, and shall be
constructed of Micro-fine fiberglass fibers with a protective coating. This filter
shall be sealed into a metal frame assembled in a rigid manner.
5 Filter gauge shall be provided for each filter bank.

H. Rotary Heat Exchanger (Thermal Heat Wheel)

1 The thermal wheels with life span similar to that of FAHU are to be selected. ARI
approved & labelled synthetic Desiccant wheels are acceptable subjected to
minimum life span with specified performance, not less than 15-20 years.
2 The wheel shall be made of layers of corrugated and intervening flat foil/synthetic
desiccant of uniform width to ensure smooth surface. This wheel material shall be
bonded together to form a rigid transfer medium forming a multitude of narrow
channels thus ensuring a laminar flow. The rotary heat exchanger shall be of
hygroscopic type for the transfer of sensible and latent heat.
3 The whole rotor shall be chemically treated for corrosion and oxidizing protection
to produce hygroscopic layer if aluminium foil is used. The chemically attached
layer should have high affinity to moisture. Pre-coated aluminium foil should not
be used.

4 Synthetic media is preferable. Aluminum will be accepted only if the chemical

treatment process is acceptable to the engineer and the sensible and latent
efficiencies are achievable. (The minimum heat transfer efficiency of the wheel
shall be 70 %.), Exhaustive details of the treatment process shall be submitted for
review. Silica gel will not be accepted.
5 Rotor shall be mounted in a sturdy casing with an access door and sealed against
casing by means of wear resistant, adjustable seal. The casing shall be equipped
with purging sector. The wheel shall be cleanable by spraying its surface with
compressed air, Low temperature steam, hot water or by vacuum cleaning without
affecting its latent heat recovery properties. The casing shall be equipped with
adjustable brush seals which minimize carry-over to max 0.5-0.2%. The wheel shall
be belt driven along its perimeter. A constant speed drive motor shall be used. The
motors shall be mounted on a self- adjusting base to provide correct belt tension.
The rotary wheel should confirm to ASHRAE 84-78, EN 29001 and BS 7550.
6 For one-piece rotor, hub and spoke shall be in aluminium. On wheels with rotors in
sectors, hub shall be made of steel, painted with anti-corrosion paint, and
galvanised sheet steel spokes.
7 The direction of airflow through the rotor should be reversing continuously to give
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 Mechanical Specifications

excellent self-cleaning effect. In order to prevent fouling and clogging of the rotor,
a standard EU-4 filter (synthetic washable) should be in position and the rotor
should always be rotating when the fans in the system are running. A double glass
inspection window should be provided in this section.
I. Performance Testing
1 One example of each type of AHU shall be performance tested at the factory for air,
water, acoustic and vibration parameters specified and/or selected in accordance
with respective testing standards.
J. Execution
1. Install equipment in accordance with manufacturers written instructions. Provide
letter from manufacturer certifying acceptance of installation.
2. Provide air-handling units in accordance with air handling units’ schedule.
3. Submit external static pressure calculations based on actual shop drawings for
review before final selection or ordering of units.
4. Provide neoprene isolators between base of unit and concrete supports with
minimum static deflection of 10 mm.
5. Pipe condensate pan drain outlet to floor drain complete with minimum 75mm deep
seal trap.
K. Air Cooled Condensing Units (Heat pump) for AHU / FAHU:

1. General

2. SYSTEM DESCRIPTION

Outdoor-mounted, air-cooled condensing unit suitable for rooftop installation. Unit shall be
factory assembled and fully charged with R-410a. Unit shall consist of a semi-hermetic
reciprocating compressor, an air-cooled coil, propeller-type condenser fans, and a control
box. Unit shall discharge supply air upward as shown on contract drawings. Unit shall be
used in a refrigeration circuit to match a packaged air-handling unit.

3 QUALITY ASSURANCE
A. Unit performance shall be rated in accordance with ARI Standard 365,
latest edition.
B. Unit shall be manufactured in a facility registered to the ISO 9001:2000
manufacturing quality standard.
C. Unit construction shall comply with ANSI/ASHRAE 15 latest revision
safety code and comply with NEC (U.S.A. standards).
D. Unit cabinet shall be capable of withstanding 500-hour salt spray exposure
per ASTM B117 (scribed specimen).
E. Air-cooled condenser coils shall be leak tested at 150 psig (1034 kPa) and
pressure tested at 480 psig (3310 kPa).

4. DELIVERY, STORAGE AND HANDLING

Unit shall be shipped as single package only, and shall be stored and handled per
unit manufacturer’s recommendations.

5. WARRANTY

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 Mechanical Specifications

A. Unit shall be guaranteed for 1 year from the date of handing over
B. Compressor shall be guaranteed for 5 years from the date of handing over.

6. Products

7. EQUIPMENT

A. General:

Factory assembled, single piece, air-cooled condensing unit. Contained

within the unit enclosure shall be all factory wiring, piping, controls,
compressor, nitrogen holding charge, and special features required prior to
field start-up.

B. Unit Cabinet:
1 Unit cabinet shall be constructed of galvanized steel, bonderized
and coated with a pre painted, baked enamel finish.
2 End unit access panel shall be hinged for compressor and control
box service access.
3 Lifting holes shall be provided to facilitate rigging.

C. Fans:
1 Condenser fans shall be direct-drive propeller type, discharging air
vertically upward.
2 Condenser fan motors shall be totally enclosed, 3-phase type with
class B insulation and permanently lubricated bearings.
3 Shafts shall have inherent corrosion resistance.
4 Fan blades shall be statically and dynamically balanced.
5 Condenser fan openings shall be equipped with PVC-coated steel
wire safety guards.

D. Compressor:
1 Compressor shall be serviceable, reciprocating, semi-hermetic
type.
2 Compressor shall be equipped with an automatically reversible oil
pump ( when specified), operating oil charge, suction and
discharge shutoff valves, and an insert-type, factory-sized
crankcase heater to control oil dilution.
3 Compressor shall be mounted on spring vibration isolators with an
isolation efficiency of no less than 95%.
4 Compressor speed shall not exceed 1450 rpm (24.2 r/s).
5 Compressor shall unload using suction cutoff unloading (electrical
solenoid unloading shall be available as an accessory).

E. Condenser Coil:
1 Condenser coil shall be air cooled, circuited for integral sub cooler.
2 Coil shall be constructed of aluminium fins mechanically bonded
to internally grooved, seamless copper tubes which are then
cleaned, dehydrated, and sealed.
3 Coil shall be protected by a sheet metal casing to eliminate the
need for wind baffles for low ambient temperature operation.
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 Mechanical Specifications

4 Coil shall be protected to avoid damage due to the elements and

vandalism.

F. Refrigeration Components:

Refrigeration circuit components shall include hot gas muffler, high-side

pressure relief device, liquid line shut-off valve, suction and discharge
shutoff valves, nitrogen holding charge, and compressor oil.

G. Controls and Safeties:

1. Minimum control functions shall include:

a. Power and control terminal blocks.
b. Three-minute anti-short-cycling timer to prevent compressor short-
cycling.
c. Lockout on auto-reset safety until reset from thermostat.
d. Capacity control on the compressor shall be by suction cut off un
loaders in response to compressor suction pressure. Electric
solenoid unloading shall be available as an accessory.
e. A 115-v solenoid shall be provided for solenoid drop control.
f. Head pressure control to 35 F (60 Hz units) or 31 F (-6 C) (50 Hz
units) by fan cycling. One condenser fan shall be cycled by
discharge pressure to maintain proper head pressure.
g. Winter start control to prevent nuisance tri pouts at low ambient
temperatures.

H. Minimum safety devices shall include: Automatic reset (after resetting first
at control circuit power supply)
a. High discharge-pressure cut out.
b. Low suction-pressure cut out.
c. Condenser fan motors to be protected against overload or single-
phase condition by internal overloads.

Manual reset at the unit:

a. Low oil-pressure cut out.
b. Compressor electrical overload protection through the use of
definite-purpose contactors and calibrated, ambient-compensated,
magnetic-trip circuit breakers. Circuit breakers shall open all 3
phases in the event of an overload in any one of the phases or a
single-phase condition.

I. Operating Characteristics:
1 The capacity of the condensing unit shall not be less than the
capacity as indicated on the contract drawing.
2 The combination of the condensing unit and the evaporator or fan
coil unit shall provide the total net cooling capacity greater than the
capacity as mentioned in the drawing at specified conditions.
3 The system shall have an EER of 10.2 or greater at standard ARI

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 Mechanical Specifications

conditions.

J. Electrical Requirements:

1 Nominal unit electrical characteristics shall be 380 v, 3-ph, 50 were

applicable. The unit shall be capable of satisfactory operation
within voltage limits of 380 v to 400 v.
2 Unit electrical power shall be single point connection.
3 Unit control circuit shall contain a 24-v transformer for unit
control, with capacity to operate an indoor fan interlock.

K. Special Features:

1. Electric Solenoid Unloader :

Unloader valve piston, coil, and hardware shall be supplied to
convert any pressure-operated compressor. Accessory
ModuPanel™ control box or field-supplied step controller shall be
provided for electrical unloading.
2. Hot-Gas Bypass: A hot-gas bypass valve and a pilot line solenoid
valve shall be provided for low-load operation of the refrigeration
system.
3. Gage Panel: A gage panel package shall be provided which
includes a suction and discharge pressure gage for the refrigerant
circuit.

4. The FAHU & Condensing unit shall be provided with DDC based
controller for smooth operation of the system. DDC based
controller shall control & monitoring of FAHU & Condensing unit
operation based on attached Data Point Schedule. In addition, the
units shall be interlocked with the fire alarm panel to trip in case of
a fire.

L. Execution:
1 Install equipment in accordance with manufacturers written
instructions. Provide letter from manufacturer certifying
acceptance of installation.
2 Provide condensing units in accordance with Equipment schedule.
3 Submit calculation for refrigerant pipe sizing for AHU/FAHU with
matching condensing units.
4 Provide Vibration isolator between base of unit and concrete
supports.
5 Maintain space around the condensing unit for the proper air
circulation and maintenance as per the manufactures
recommendation.
M. Automatic Controls
1. The control system shall comprise of microprocessor based Direct
Digital controllers (DDC) system for Air Handling Units (AHU)
and Extract fans.
2. AHU Controls The AHU panel will house door interlocked

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 Mechanical Specifications

isolator, MCCB, ELCB, under voltage relay, starter, HOA switch

and DDC Controls. The AHU panels shall be supplied and
commissioned by the controls manufacturer.
3. Peripheral devices: Air flow proving & Dirty filter pressure
switches shall be of differential pressure type housed in a IP54
housing and with field adjustable settings. The temperature sensor
shall be with silicon sensor having positive temperature coefficient
and shall be linear over the range 0-50 deg C. The sensor shall be
field wired using an unscreened cable to a base plate so that the
sensor can be easily removed without disturbing the wiring
connections.

2.04 CLOSE CONTROL UNITS

A. Cabinet

The cabinets shall be with rounded corners with flush fitting panels and compression locks
for effective sealing.
The units shall have a rigid angle frame with hinged / lift off panels to provide access for
installation and servicing. Panels are lined with fire resistant, Class ‘O’ non – eroding
insulation material with thermal and acoustic properties.

B. Microprocessor Controls

The units shall have easy to use and fully informative designed systems for precise
monitoring and control of room conditions, equipment status and alarm warning. The
control system shall be also includes a graphical display with real time trend logging.

C. Switchgear
The electrical switchgear shall includes the following :
1. Bottom entry gland plate with grommeted cable entry holes.
2. Interlocked door isolator.
3. MCBs and contactors for fans, heaters, humidifier and compressors as appropriate.
4. MCBs for remote condensing units.
5. MCBs plus fan speed controllers for remote condensers.
6. Easy connect customer terminals.
7. Colour coded and numbered cabling, neatly run in trunking segregating high and
low voltages. All wiring complies with IEC60204-1.
D. Filters
The filter shall be and disposable and have an efficiency of 30 percent ASHRAE 52/76,
Eurovent 4/5 arrestance value of 90 percent (G4). Fitted in the return air stream, these shall
be held by quick release retaining clips and are accessible from the front of the unit.

E. Cooling Coil

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 Mechanical Specifications

Dual ‘V’ frame or equivalent optimized coils as specified in the schedule of equiptments
shall be multi-row constructed from rifled copper tubes with aluminium fins. Sloped
stainless steel drain trays ensure efficient removal of condensate via factory fitted
transparent traps.

F. Heaters
Electric heaters (when specified in schedule of equiptment) shall be fitted as standard, have
incoloy elements with stainless steel finning. Balanced over three phases, they incorporate
safety over – heat protection. The heaters shall be thyristor controlled.

G. Fans

Low speed fans shall be forward curved impellers and ‘sealed for life’ bearings are used.
Each failure – alarmed fan shall have its own TEFC motor which can be inverter controlled.
Pressure sensors monitor airflow shall be provided.

H. Humidifier

(when specified in schedule of equiptment)

A ‘fail safe’ electrode boiler humidifier, located in the air stream shall provides clean sterile
steam. The output shall be controlled and the microprocessor controller (Humidifier self –
cleaning system) shall be provided.

I. Compressor (for DX System) The compressors shall be scroll type and have the following
characteristics :
1. High EER / COP
2. Axial and radial compliance.
3. Liquid tolerance design – the compressor shall ingest liquid refrigerant without
damage.

4. High volumetric efficiency – no clearance volume and no valves shall be provided.

5. Low vibration level – continuous compression process (3 rotations) and vibration

amplitude shall be less than 0.1mm.

6. Light load start, smooth starting torque. Low motor torque variation.

J. Air Cooled Condensers The condensers shall be copper tube with aluminium fins.

K. Controls

The controller shall be stand alone with the following feature. Also the unit shall be
interconnected to BMS for monitoring.

1. User friendly simply easy to use graphic display.

2. Non – volatile memory.
3. 16 bit surface mounted technology.

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 Mechanical Specifications

4. Real time trend logging.

5. Modular software and hardware.
6. Full networking facility.
7. 32 point alarm annunciation.
8. Main function icon display.

L. Leak Detection system:

Water leak detection systems shall be provided along with the CCU units

1. Local audible and Visual alarm (displayed until cable dried and system reset)
a. Status Indication
b. Alarm mute button
c. Full alarm state relays
d. 24 hour battery back up
e. Indication of low battery charge
f. Self test facility.

The systems shall comprise length of leak detection cable, resistant to both corrosion and
contamination and capable of drying quickly. The cables shall be fixed in position by metal clips or
tie wrap pads secured to the base floor by a suitable adhesive. Junction boxes shall be installed at
the ends of each detector cable and at the zone change points.

Installation of leak detection systems shall only be carried out after completion of construction work
in the designated area and after testing and commissioning of all wet systems in designated area.

PART 3 EXECUTIONS

3.01 INSTALLATION
A. Install in accordance with manufacturer's instructions.
B. Install in accordance with requirements of NFPA 90A.
C. Pipe condensate from drain pan to nearest floor drain.

15780 -Direct Expansion Air Conditioners Rev 01 Page 24