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SECTION 15625 - CENTRIFUGAL WATER CHILLERS

PART 1 - GENERAL

0.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 1 Specification Sections, apply to this Section.

0.2 SUMMARY

A. This Section includes electrically driven, water-cooled, centrifugal water chillers.

B. Related Sections include the following:

1. Division 15 Section "Equipment Insulation" for chiller evaporator insulation

requirements.
2. Division 15 Section "HVAC Water Treatment" for chemically treating chilled and
condenser water.
3. Division 15 Section "Mechanical Vibration Controls and Seismic Restraints" for
chiller vibration isolation requirements.
4. Division 15 Section "HVAC Instrumentation and Controls" for temperature-control
devices for chillers.
5. Division 15 Section "Sequence of Operation" for temperature-control sequences for
chillers.
6. Division 15 Section "Testing, Adjusting and Balancing".

0.3 SUBMITTALS

A. Product Data: Include refrigerant; rated capacities; shipping, installed, and operating
weights; noise criteria; furnished specialties; and accessories for each model indicated. Data
shall also include performance data showing the energy input versus cooling load output
from 100% to 20% of full load with constant entering condenser water temperature.

B. Material, Equipment, and Fixture Lists shall be submitted for centrifugal chiller systems in
accordance with paragraph entitled, "General Requirements," of this section.

C. Product Data: Equipment Foundation Data shall be submitted for the following items in
accordance with paragraph entitled, "General Requirements," of this section.

1. Evaporator.
2. Compressor.
3. Condenser.
4. Purge System.
5. Motors.
6. Control Panel.
7. Equipment and Performance Data shall be submitted for centrifugal water chillers in
accordance with paragraph entitled, "General Requirements," of this section.

D. Manufacturer's catalog data shall be submitted for the following items:

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1. Evaporator.
2. Compressor.
3. Condenser.
4. Cooler.
5. Purge System.
6. Motors.
7. Control and Control Panels.
8. Insulation.
9. Vibration Isolation.
10. Accessories.
11. Special Tools.
12. Spare Parts.

E. Samples: Manufacturer's Standard Color Chart shall be submitted in accordance with Article
entitled, "General Requirements," of this section.

F. Sample Warranty: Copy of manufacturer's proposed warranty, stating obligations,

remedies, limitations, and exclusions.

G. Shop Drawings: Signed and sealed by a qualified professional engineer. Drawings shall
indicate the physical layout of all controls, and internal tubing and wiring details

H. Connection diagrams shall be submitted indicating the relations and connections of the
following items.

1. Evaporator.
2. Compressor.
3. Condenser.
4. Cooler.
5. Purge System.
6. Motors.
7. Control and Control Panels.
8. Control Diagrams shall be submitted for centrifugal chiller units in accordance with
paragraph entitled, "General Requirements," of this section.
9. Installation drawings shall be submitted for centrifugal chiller systems in accordance
with the paragraph entitled, "Installation," of this section. Drawings shall indicate
overall physical features, dimensions, ratings, service requirements, and equipment
weights.
10. Wiring Diagrams: Detail wiring for power, signal, and control systems and
differentiate between manufacturer-installed and field-installed wiring.
11. Alarm Systems.

I. Design Calculations: Calculate requirements for selecting vibration isolators and seismic
restraints and for designing vibration isolation bases. Design Analysis and Calculations
shall be submitted in accordance with paragraph entitled, "General Requirements," of this
section.

J. Vibration Isolation Base Details: Detail fabrication, including anchorages and attachments
to structure and to supported equipment. Include auxiliary motor slides and rails, and base
weights.

K. Coordination Drawings: Floor plans drawn to scale and coordinating the following:

1. Structural supports.
2. Piping roughing-in requirements.
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3. Wiring roughing-in requirements. Determine spaces reserved for electrical

equipment.
4. Access requirements around other work, including working clearances to mechanical
controls and electrical equipment.
5. Required clearances for operation and maintenance.

L. As-Built Drawings shall be submitted for centrifugal chiller units in accordance with Article
entitled, "General Requirements," of this section.

M. Product Certificates: Certification of performance according to ARI 550 and that chillers
have been started and function properly.

N. Certificates: Listing of Product Installation shall be submitted for centrifugal chiller units in
accordance with Article entitled, "Installation," of this section. Certificates shall be
submitted for following items showing conformance with the referenced standards
contained in this section:

1. Evaporator.
2. Compressor.
3. Condenser.
4. Cooler.
5. Purge System.
6. Motors.
7. Control and Control Panels.
8. Insulation.
9. Vibration Isolation.
10. Special Tools.
11. Spare Parts.

O. Field Test and Commissioning Reports: Specified in "Field Quality Control",

"Commissioning" and "Seasonal Performance Test" Articles. Indicate and interpret test
results for compliance with performance requirements.

P. Operation and Maintenance Data: Operation and Maintenance Manuals shall be submitted
in accordance with paragraph entitled, "Manufacturer's Representative," of this section.

0.4 GENERAL REQUIREMENTS

A. Control Diagrams shall be submitted for centrifugal chiller units showing the physical and
functional relationship of equipment. Electrical diagrams shall show the size, type, and
capacity of the system.

B. Material, Equipment, and Fixture Lists shall be submitted for centrifugal chiller systems
including manufacturer's style or catalog numbers, specification and drawing reference
numbers, warranty information, and fabrication site information.

C. Equipment Foundation Data shall be submitted including equipment weight and operating
loads, location and projection of anchor bolts, and horizontal and vertical clearances for
installation, operation, and maintenance. Data shall also include dimensions of foundations
and relative elevations, and installation requirements such as noise abatement, vibration
isolation, and utility services.

D. Manufacturer's Standard Color Chart shall indicate the manufacturer's standard color
selections and finishes for chiller units.
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E. Design Analysis and Calculations shall be submitted for centrifugal chillers indicating the
manufacturer's recommended power ratings, rotational speeds, and piston speeds.

F. Test Reports: Factory Tests: Reports shall certify the compliance with performance
requirements and follow the format of the required testing standard for both the Chiller
Performance Tests and the Chiller Sound Tests. Test report shall include certified
calibration report of all test instrumentation. Calibration report shall include certification
that all test instrumentation has been calibrated within 6 months prior to the test date,
identification of all instrumentation, and certification that all instrumentation complies with
requirements of the test standard Test report shall be submitted one week after completion
of the factory test.

G. System Performance Factory Tests: The report shall document compliance with the
specified performance criteria upon completion and testing of the system. The report shall
indicate the number of days covered by the tests and any conclusions as to the adequacy of
the system. The report shall also include the following information and shall be taken at
least three different times at outside dry-bulb temperatures that are at least 3 deg. C apart:

1. Date and outside weather conditions.

2. The load on the system based on the following:

a. The refrigerant used in the system.

b. Condensing temperature and pressure.
c. Suction temperature and pressure.
d. Running current, voltage and proper phase sequence for each phase of all
motors.
e. The actual on-site setting of all operating and safety controls.
f. Chilled water pressure, flow and temperature in and out of the chiller.
g. The position of the [capacity-reduction gear] [gas supply control valve] at
machine off, one-third loaded, one-half loaded, two-thirds loaded, and fully
loaded.
h. Condenser water temperature based on maximum C.P specified in section
15640 or as shown on the drawings.

H. Certificates: Where the system, components, or equipment are specified to comply with
requirements of AGA, NFPA, ARI, ASHRAE, ASME, or UL, copy of proof of such
compliance shall be provided. The label or listing of the specified agency shall be
acceptable evidence. In lieu of the label or listing, a written certificate from an approved,
internationally recognized testing organization equipped to perform such services, stating
that the items have been tested and conform to the requirements and testing methods of the
specified agency may be submitted.

I. Operation and Maintenance Data:

1. Operation Manuals shall list step-by-step procedures required for system startup,
operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4
weeks prior to the first training course. The manuals shall include the manufacturer's
name, model number, service manual, and a brief description of all equipment and
their basic operating features.
2. Maintenance Manuals shall list routine maintenance procedures, possible breakdowns
and repairs, and a troubleshooting guide. The manuals shall include piping and
equipment layouts and simplified wiring and control diagrams of the system as
installed.

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0.5 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in

NFPA 70, Article 100, by a testing agency acceptable to the Engineer.

B. ASHRAE Compliance: Comply with ASHRAE 15 for chiller design, construction, leak
testing, and installation.

C. ASME Compliance: Comply with ASME Boiler and Pressure Vessel Code: Section VIII,
"Pressure Vessels," for constructing and testing evaporator and condenser pressure vessels.
Stamp with ASME label.

D. UL Compliance: Comply with UL 465.

E. Comply with latest and relevant IEC standard.

0.6 DELIVERY, STORAGE, AND HANDLING

A. Deliver centrifugal water chillers, factory charged with refrigerant and oil, and with
protective crating and covering.

B. Store chillers to prevent damage and protect from weather, dirt, fumes, water, and
construction debris in clean dry space.

C. Handle chillers according to manufacturer's written rigging and installation instructions for
unloading, transporting, and setting in final location.

0.7 COORDINATION

A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases.
Concrete, reinforcement, and formwork requirements are specified in Division 3 Section
"Cast-in-Place Concrete."

0.8 WARRANTY

A. Manufacturer's Warranty: Provide written warranty, signed by the manufacturer agreeing to

repair or replace chiller components, including replacement of refrigerant, within warranty
period(s) indicated below. Warranty covers failure due to normal conditions of use.

1. Warranty Period: [2] <Insert number> years from date of Substantial Completion.
2. Warranty Period on Compressor Motor: [5] <Insert number> years from date of
Substantial Completion.
3. Warranty Period on Compressor Bearings: [5] <Insert number> years from date of
Substantial Completion. To include any related damage, and annual tear down and
bearing inspection.

0.9 MAINTENANCE SERVICE

A. Maintenance: Submit four copies of manufacturer's "Agreement for Continued Service and
Maintenance," before Substantial Completion, for the Employer's acceptance. Offer terms
and conditions for furnishing consumables and providing continued testing, maintenance

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and servicing to include replacing materials and components. Include one-year term of
agreement, commencing at date of Substantial Completion, with option for one-year
renewal.

PART 2 - PRODUCTS

0.1 STANDARD COMMERCIAL PRODUCTS

A. Materials and equipment shall be standard products of a manufacturer regularly engaged in

the manufacturing of such products, which are of a similar material, design and
workmanship. The standard products shall have been in satisfactory commercial or
industrial use for 5 years prior to bid opening. The 5 year use shall include applications of
equipment and materials under similar circumstances and of similar size. The 5 years
experience shall be satisfactorily completed by a product that has been sold or is offered for
sale on the commercial market through advertisements, manufacturer's catalogs, or
brochures. Products having less than a 5 year field service record shall not be acceptable.
Products shall be supported by a service organization. System components shall be
environmentally suitable for the indicated locations.

0.2 WATER CHILLER DESCRIPTION

A. Factory-assembled units including compressor motor, motor starter, lubrication system,

evaporator, condenser, controls, and interconnecting piping and wiring.

B. Unit and spare parts shall conform to the applicable requirements of ARI 550, ARI 480, and
specified requirements. Energy efficiency rating shall exceed ASHRAE 90A requirements.

0.3 CHILLER PERMISSIBLE NOISE LEVELS

A. General: the following sub-section list the maximum permissible noise levels by octave
bands, for day and night operation. Limits will be the same for either the standard octave
bands or for the preferred centre frequency bands. All reports required to be submitted by
the Contractor are to indicate which standard is used. These figures are to be guaranteed
while operating at the design conditions at any location 1.0 m from chillers.

B. Acoustics Report: The Contractor is to submit a report listing the sound power level of the
chillers in dB re 10-12 W for the different octave band frequencies. These levels are to be
in the limits listed below when measured at 1.0 m from chillers.

Octave Band (Hz)

Sound Power 31.5 63 125 250 500 1K 2K 4K 8K

dB re 10-12

dB re 10-12 95 95 92 92 88 85 83 83 85

C. If the level in any one octave band exceeds those in the two adjacent bands by more than
5dB, the indicated permissible noise level for that band is to be reduced by 5dB. The above
listed maximum values are to apply to multiple units with all fans/compressors running, as

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well as single fans/compressor. Contractor has to provide the necessary treatment like
enclosure or others in order to achieve the specified resulting noise level.

D. Noise Level Outside Chillers Hall: Noise level from chillers with all chillers operating shall
not exceed 70 dB when measured with a standard sound meter on the 'A' scale at ground
level at one meter from chillers hall external wall.

0.4 COMPRESSORS

A. Description: Cast-iron casing with high-strength, cast-aluminum-alloy impeller on carbon-

or forged-steel shaft; statically and dynamically balanced compressor assembly; and
overspeed tested at 120 percent of design operating speed.

B. Compressor shall be single or multistage, centrifugal type with [gear-drive, open] [direct-
drive hermetically sealed], compressor-motor assembly.

C. Motor windings shall be [refrigerant] [water-cooled].

D. Rotor assembly shall be statically and dynamically balanced to ISO 1940/1-1986, [G6.3]
[G2.5] [G1.0].

E. Shaft main bearings shall be replaceable sleeve-insert type.

F. Lubrication system shall be of the forced-feed type with oil sump, hermetically sealed
motor-driven positive displacement pump, oil filter, and strainer. Oil temperature shall be
thermostatically controlled. A mechanically operated oil supply shall be provided to the
bearings during spin down in event of power interruption. A differential oil-pressure cutout
shall be interlocked with starting equipment and shall allow the compressor to operate only
when the required oil pressure is available at the bearings.

G. Compressor shall be provided with temperature-actuated capacity reduction and shall be of

the multiple radial blade or butterfly-damper type VFD compressor motor control to provide
automatic capacity regulation from 100 percent to 10 percent of capacity. Control system
shall include automatic stopping, when load falls below 10 percent capacity point, and
automatic unloaded restarting on load demand. Capacity modulation shall be controlled by
the temperature of the water leaving the cooler. Unit controller shall be able to maintain
leaving-water temperature at plus or minus 0.25 deg. C of the set point.

H. Refrigerant: [HCFC-123]; full operating charge of refrigerant and oil.

I. Refrigerant: [HFC-134a]; full operating charge of refrigerant and oil.

0.5 EVAPORATOR

A. Description: Shell-and-tube design with refrigerant totally enclosed in shell and water in
tubes.

B. Shell Material: Carbon-steel plate.

C. Tubes: Seamless, externally finned, individually replaceable tubes; expanded into tube
sheets.

1. Material: Copper.

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2. Size: 19 mm OD; 0.711 mm wall thickness.

3. Internal Finish: Enhanced.
4. External Finish: Enhanced.
5. Intermediate tube supports shall be provided similar to condenser.

D. Water Boxes: Marine type, removable, carbon steel, with vent and drain connection.

1. Temperature Sensor: Thermistor type, factory installed in each nozzle.

E. Refrigerant Working Pressure: 2070 kPa or, if higher, the saturation pressure of refrigerant
used at 29 deg. C (85 deg. F).

F. Water-Side Working Pressure: 1035 kPa.

G. Insulation: Factory applied and painted, to evaporator, suction lines, water boxes and other
surfaces where condensation might occur, with flexible elastomeric insulation of the
following thickness:

1. Thickness: 25 mm.

H. Eliminators: Metal screen-mesh eliminators to prevent refrigerant carryover into

compressor.

I. Cooler capacity shall be based on refrigerant suction temperature in excess of 0 deg.C (32
deg. F) and a fouling factor of 0.0005.

J. A frangible-carbon rupture disc safety relief device shall be provided. Device to be piped to
building exterior.

0.6 CONDENSER

A. Construction: Shell-and-tube design with water enclosed in tubes and refrigerant enclosed
in shell.

B. Shell Material: Carbon-steel plate.

C. Condenser Tubes: Seamless, externally finned, individually replaceable tubes; expanded

into tube sheets.

1. Material: Copper.
2. Size: 19 mm OD; 0.711 mm wall thickness.
3. Internal Finish: Enhanced. Ceramic coating shall be factory applied for all internal
surfaces of end cape and face of condenser.
4. Intermediate tube supports shall be provided so that distance between supports does
not exceed approximately 3 feet (900 millimeter). Supports shall be fitted to the
tubes in a manner that will preclude corrosion, vibration, and abrasion.
5. External Finish: Enhanced.

D. Water Boxes: Marine type, removable, carbon steel, with vent and drain connection.

1. Temperature Sensor: Thermistor type, factory installed in each nozzle.

2. Refrigerant Working Pressure: 2070 kPa or, if higher, the saturation pressure of
refrigerant used at 29 deg. C (85 deg. F).
3. Water-Side Working Pressure: 1035 kPa.

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E. Pressure Relief: Single or multiple, reseating-type, spring-loaded relief valves.

F. Condenser performance shall be based on a maximum water velocity of 10 feet per second
(fps) (3 meter per second) and a fouling factor of 0.001. Design and construction provisions
shall preclude tube failure due to erosion.

0.7 INSULATION

A. Cooler shell and suction piping between evaporator and first stage of each compressor unit
shall be insulated and vapor-sealed.

B. Water boxes shall be insulated to provide for ease of access to heads for inspection and
repair.

C. Where motors are the gas-cooled type, insulation and vapor seal shall be provided on the
cold-gas inlet connection to the motor.

D. Vapor-seal material shall be manufacturer's standard color elastomeric unicellular foam of 1

inch (25 millimeter) minimum thickness to preclude condensation of ambient moisture on
any surface under site-operating conditions. If unicellular material is black or is otherwise
coated, only polyvinylchloride lacquer shall be used for coating.

E. Any coating that cracks when unicellular material is compressed shall be removed and
replaced with specified coating at no additional expense to the Client.

0.8 PURGE UNIT

A. When HCFC-123 refrigerant is used, a high efficiency purge system shall be provided and
connected to the main refrigeration system. When in operation, the purge system shall
function to automatically remove air, water vapor, and noncondensable gases from the
refrigeration system and to condense, separate, and return to the system any refrigerant
present therein.

B. Purge system shall be manually or automatically started and stopped and shall be assembled
as a compact unit. Purge system shall be complete with operating and safety devices and
with an oil separator if recommended by the manufacturer.

C. When a positive-pressure refrigerant is used by the manufacturer in the basic liquid chiller
unit, a purge system will not be required. Units shall purge no more than 0.1 pounds (0.045
kg) of non-condensables.

0.9 CONTROL PANEL

A. Manufacturer's standard microprocessor-based chiller controls; unit mounted, and factory

wired and tested with a single-point power connection and separate control circuit.

B. Status Display: Including, but not limited to the following conditions:

1. Date and time.
2. Operating or alarm status.
3. Operating hours.
4. Entering-chilled-water temperature.
5. Leaving-chilled-water temperature.
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6. Evaporator refrigerant temperature.

7. Entering-condenser-water temperature.
8. Leaving-condenser-water temperature.
9. Condenser refrigerant temperature.
10. Oil-supply temperature.
11. Oil-sump temperature.
12. Percent motor amperage.
13. Purge suction temperature if purge system is provided (for chillers using HFC-123)
14. Purge elapsed time if purge system is provided (for chillers using HFC-123).

C. Control Functions: Including but not limited to the following:

1. Manual or automatic startup and shutdown time schedule.

2. Leaving- and entering-chilled-water temperature, control set points, and motor load
limit.
3. Current-limit and demand limit.
4. Condenser water temperature.
5. External chiller emergency stop.

D. Manually Reset Safety Controls: The following conditions shall shut down chiller and
require manual reset:

1. Evaporator low pressure.

2. Evaporator low temperature.
3. Low oil flow.
4. Low oil pressure.
5. High oil temperature.
6. High bearing temperature.
7. High condenser pressure.
8. High compressor-discharge temperature.
9. No chilled-water flow.
10. No condenser-water flow.
11. Sensor- or detection-circuit fault.
12. Processor communications loss.
13. Starter fault.
14. Extended compressor surge.

E. Interface Panel: Factory supplied interface panel to communicate and transmit data between
the chillers and BMS. All required data as from chillers as specified to be transmitted to
BMS. Interface panel to be capable for communication with the specified BMS system.

F. Remote Alarm: During the initiation of a safety shutdown, a chiller's control system shall be
capable of activating a remote alarm bell. In coordination with the chiller manufacture, the
Contractor shall provide an alarm circuit (including transformer if applicable) and a
minimum 100 mm (4 inch) diameter alarm bell. Alarm circuit shall activate bell in the
event of machine shutdown due to the chiller's monitoring of safety controls. The alarm bell
shall not sound for a chiller that uses low-pressure cutout as an operating control.

G. Chiller System Controller:

1. A chiller system controller shall communicate with the individual chiller unit
controllers. The chiller system controller shall supervise all of the chiller unit
controllers and shall determine which chillers are to start and stop.

2. The chiller unit controller shall:

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a. Initiate the chiller start up routine when it receives a request to start from the
chiller system controller.
b. Open the isolation valves on the condenser water and chilled water lines.
c. Start and stop the condenser water and chilled water pumps.
d. Once chilled water and condenser water flow is proven the chiller shall be
started if all safeties (minimum off time, flow switches, etc) permit.
e. The chiller unit controller shall undertake the chilled water supply temperature
control.

3. When a request to stop is received from the chiller system controller the chiller unit
controller shall:
a. Stop the chiller, if the minimum run time has been exceeded.
b. Stop the chilled water pump and close the chilled water isolation valve.
c. Stop the condenser water pump after a predetermined period of time.
d. Close the condenser water isolation valve when the condenser water pump has
stopped.

4. The chiller system controller shall have a data port to enable the exchange of data
from the chiller unit controllers with the BMS.

5. The chiller system controller shall communicate the following information to the
BMS via the gateway for each chiller:

a. Entering Chilled Water Temperature (monitoring point).

b. Leaving Chilled Water Temperature (monitoring point).
c. Evaporator Pressure (monitoring point).
d. Auxiliary Oil Pressure (monitoring point).
e. Bearing Pressure (monitoring point).
f. Gear Pressure (monitoring point).
g. Evaporator Differential Pressure (monitoring point).
h. Evaporator Temperature (monitoring point).
i. Suction Temperature (monitoring point).
j. Pre-Alarm (Monitoring Point).
k. Gear Box High Temperature Setting (Monitoring Point).
l. Gear Box Low Temperature Setting (Monitoring Point).
m. Oil Compressor Status (Monitoring Point).
n. Flow Safety (Monitoring Point).
o. Motor Safety (Monitoring Point).
p. Motor Run Status (Monitoring Point).
q. Rear Thrust Bearing Temperature (Monitoring Point).
r. Front Thrust Bearing Temperature (Monitoring Point).
s. Gear Oil Temperature (Monitoring Point).
t. Current Limit (Control Point).
u. Chilled Water Supply Temperature Reset (Control Point).
v. Chilled Water Pump Run Status (Monitoring Point).
w. Chilled Water Pump Alarm (Monitoring Point).
x. Condenser Water Pump Run Status (Monitoring Point).
y. Condenser Water Pump Alarm Status (Monitoring Point).
z. Entering Condenser Water Temperature (Monitoring Point).
aa. Leaving Condenser Water Temperature (Monitoring Point).
bb. Shutdown/cycling messages.
cc. A record of the last 4No. cycling or safety shutdowns for each chiller.

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0.10 MOTORS

A. Hermetically sealed motors shall conform to NEMA MG 1, ARI 520 or IP20 to IEC 60529
and to requirements for motors as specified herein.

B. Bearings shall be oil-lubricated, replaceable-sleeve, insertable type or permanently

lubricated, rolling element type.

C. If water-chilled unit or any component could be damaged by reverse motor operation, and
when proposed water-chiller unit contains a mechanically driven lubricating-oil pump, the
manufacturer's responsibility shall include providing reverse-phase rotation protection.

0.11 MOTOR STARTER

A. Factory mounted on or near chiller, and factory wired to the chiller.

B. Power Controls: Combination controller and disconnect with solid-state starting.

1. Main power disconnect.

2. External overload protection.
3. Power terminal block.
4. Control and oil-heater transformer.
5. Control circuit breaker.
6. Pilot relays for chilled-water pump, condenser-water pump, cooling tower, and
remote alarm.
7. Oil-pump circuit breaker.
8. Oil-heater circuit breaker.
9. Three-phase digital ammeter.

C. Motor-Protection Options: Including but not limited to the following:

1. High winding temperature.

2. Overvoltage protection.
3. Undervoltage protection.
4. Electrical distribution faults, including phase loss, phase unbalance, and phase
reversal.
5. Current overload protection.

0.12 ELECTRICAL WORK

A. Electrical equipment, motors, motor efficiencies, and wiring shall be in accordance with
Dsivision 16.

B. Electrical motor driven equipment specified shall be provided complete with motors, motor
starters, and controls. Electrical characteristics shall be as shown, and unless otherwise
indicated, all motors of 0.746 kW ( 1 horsepower) and above with open, dripproof, totally
enclosed, or explosion proof fan cooled enclosures, shall be high efficiency type.

C. Field wiring shall be in accordance with manufacturer's instructions. Each motor shall
conform to NEMA MG 1 and NEMA MG 2 or IEE wiring regulation 16th edition and be of
sufficient size to drive the equipment at the specified capacity without exceeding the
nameplate rating of the motor.

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D. Motors shall be continuous duty with the enclosure specified. Motor duty requirements
shall allow for maximum frequency start-stop operation and minimum encountered interval
between start and stop.

E. Motors shall be sized for the applicable loads. Motor torque shall be capable of accelerating
the connected load within 20 seconds with 80 percent of the rated voltage maintained at
motor terminals during one starting period. Motor bearings shall be fitted with grease
supply fittings and grease relief to outside of enclosure. Automated forced lube is preferred.

F. Manual or automatic control and protective or signal devices required for the operation
specified and any control wiring required for controls and devices specified, but not shown,
shall be provided.

0.13 VIBRATION CONTROL

A. Vibration Control: Chiller shall be supplied complete with vibration isolators pads
specifically designed for unit and application, shipped loose for field installation:

1. Vibration Isolators: Seismically restrained-spring isolators with minimum deflection

of 25 mm.

B. Equipment Support and Seismic Restraint: Minimum 200 mm thick, reinforced concrete
base extending 100 mm beyond chiller dimensions in each direction.

C. Vibration Probes: Proximity type probes to be provided as follows:

1. Two radial probes per journal bearing one in X-axis and one in Y-axis.
2. One for thrust bearing Z-axis on active face.
3. One keyphaser for slipping control.

0.14 REFRIGERANT LEAK DETECTOR

A. Detector shall be Infrared system in NEMA 250, Type 4 enclosure of the continuously-

operating, halogen-specific type. Detector shall be appropriate for the refrigerant in use.
Detector shall be specifically designed for area monitoring and shall include a single
sampling point installed where indicated.

B. Detector design and construction shall be compatible with the temperature, humidity,
barometric pressure and voltage fluctuations of the operating area. Detector shall have an
adjustable sensitivity such that it can detect refrigerant at or above 3 parts per million (ppm).

C. Detector shall be supplied factory-calibrated for the appropriate refrigerant(s). Detector

shall be provided with an alarm relay output which energizes when the detector detects a
refrigerant level at or above the TLV-TWA (or toxicity measurement consistent therewith)
for the refrigerant(s) in use. The detector's relay shall be capable of initiating corresponding
alarms and ventilation systems as indicated on the drawings.

D. Detector shall be provided with a failure relay output that energizes when the monitor
detects a fault in its operation. Detector shall be compatible with the Building Management
System (BMS) and shall be capable to interface with the chiller plant manager system as
well as the BMS. The BMS shall be capable of generating an electronic log of the
refrigerant level in the operating area, monitoring for detector malfunctions, and monitoring
for any refrigerant alarm conditions.

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0.15 FACTORY TESTS

A. The Contractor and proposed chiller manufacturer shall be responsible for performing the
chiller factory test to validate the specified full load capacity, full load EER, and [IPLV]
[NPLV] in accordance with ARI 550/590 except as indicated.

B. The chiller factory test shall be carried out at design ambient temperatures of 46C DB and
29C WB, as well as 52C DB with reduced capacity without mechanical failure.

C. The chiller factory test shall be performed in the presence of the Client’s and Engineer’s
representatives team. The team will comprise maximum four representatives. All expenses
to be borne by the Contractor.

D. The Contractor and chiller manufacturer shall provide to the Engineer a certified chiller
factory test report in accordance with ARI 550/590 to confirm that the chiller performs as
specified. Tests shall be conducted in an ARI certified test facility in conformance with
ARI 550/590 procedures and tolerances.

E. At a minimum, chiller capacity shall be validated to meet the scheduled requirements

indicated on the drawings. Tolerance or deviation shall be in strict accordance with ARI
550/590. Stable operation at minimum load of 10 percent of total capacity shall be
demonstrated during the factory test.

F. Temperature Adjustments: Temperature adjustments shall adhere to ARI 550/590 to adjust

from the design-fouling factor to the clean tube condition. Test temperature adjustments
shall be verified prior to testing by the manufacturer. There shall be no exceptions to
conducting the test with clean tubes with the temperature adjustments per ARI 550/590.
The manufacturer shall clean the tubes, if necessary, prior to testing to obtain a test-fouling
factor of 0.0000.

G. Test Instrumentation: The factory test instrumentation shall be per ARI 550/590 and the
calibration shall be traceable to the National Institute of Standards and Technology. All
Instrumentation shall have been calibrated within 6 month of the test date.

H. Test Report: A certified test report of all data shall be forwarded to the Engineer for
approval prior to project acceptance. Calibration curves and information sheets for all
instrumentation shall be provided.

I. Equipment Adjustments: If the equipment fails to perform within allowable tolerances, the
manufacturer shall be allowed to make necessary revisions to his equipment and retest as
required. The manufacturer shall assume all expenses incurred by the Client/Engineer to
witness the retest.

J. Chillers shall be sound tested at the factory prior to shipment to confirm the sound pressure
level specified herein. Tests and data shall be conducted and measured in strict accordance
with ARI 575 at the full load system operating conditions. The chiller sound pressure level,
in decibels (dB), with a reference pressure of 20 micropascals, shall not exceed the specified
noise level. Ratings shall be in accordance with ARI 575. No reduction of entering
condenser water temperature or raising of leaving chilled water temperature shall be
allowed. A minimum of 75 percent of the sound data points shall be taken along the length
of the machine, and established as the minimum percentage of total possible points used to
determine sound levels. In the event that the chiller does not meet the dBA sound pressure
level, the manufacturer shall, at his expense, provide sufficient attenuation to the machine to
meet the specified value. This attenuation shall be applied in such a manner that it does not
hinder the operation or routine maintenance procedures of the chiller. The attenuation
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material, adhesives, coatings, and other accessories shall have surface burning
characteristics as determined by ASTM E 84.

PART 3 - EXECUTION

0.1 EXAMINATION

A. Examine areas to receive chillers for compliance with maintenance clearance and tube pull
requirements, installation tolerances and other conditions affecting chiller performance.
Examine proposed route of moving chillers into place and verify that it is free of
interferences. Proceed with installation only after unsatisfactory conditions have been
corrected.

B. Final chiller locations indicated on Drawings are approximate. Determine exact locations
before roughing-in piping and electrical connections.

0.2 INSTALLATION

A. Refrigeration equipment and the installation thereof shall conform to ASHRAE 15.
Necessary supports shall be provided for all equipment, appurtenances, and pipe as required,
including frames or supports for compressors, pumps, cooling towers, condensers, liquid
coolers, and similar items. Compressors shall be isolated from the building structure.

B. Equipment shall be properly leveled, aligned, and secured in place in accordance with
manufacturer's instructions.

C. Install chillers level and plumb, and maintain manufacturer's recommended clearances for
service and maintenance.

D. Equipment Support and Seismic Restraint: Anchor concrete base and chiller for seismic
restraint by means and methods acceptable to the Engineer. Dowel concrete base to the
floor on 450 mm centers around perimeter. Anchor chiller to concrete base with at least
four 13 mm anchors that penetrate base and extend into the sub-floor at least 100 mm.

E. Electrical Wiring: Install electrical components, devices, and accessories furnished loose by
manufacturer, including remote flow switches.

0.3 FIELD REFRIGERANT CHARGING

A. Initial Charge: Upon completion of all the refrigerant pipe tests, the vacuum on the system
shall be broken by adding the required charge of dry refrigerant for which the system is
designed, in accordance with the manufacturer's recommendations. The Contractor shall
provide the complete charge of refrigerant in accordance with manufacturer's
recommendations. Upon satisfactory completion of the system performance tests, any
refrigerant that has been lost from the system shall be replaced. After the system is fully
operational, service valve seal caps and blanks over gauge points shall be installed and
tightened.

B. Refrigerant Leakage: If a refrigerant leak is discovered after the system has been charged,
the leaking portion of the system shall immediately be isolated from the remainder of the

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system and the refrigerant shall be pumped into the system receiver or other suitable
container. The refrigerant shall not be discharged into the atmosphere.

C. Contractor's Responsibility: The Contractor shall, at all times during the installation and
testing of the refrigeration system, take steps to prevent the release of refrigerants into the
atmosphere. The steps shall include, but not be limited to, procedures that will minimize the
release of refrigerants to the atmosphere and the use of refrigerant recovery devices to
remove refrigerant from the system and store the refrigerant for reuse or reclaim. At no
time shall more than 85 g of refrigerant be released to the atmosphere in any one
occurrence. Any system leaks within the first year shall be repaired in accordance with the
specified requirements including material, labor, and refrigerant if the leak is the result of
defective equipment, material, or installation.

0.4 CONNECTIONS

A. Piping installation requirements are specified in other Division 15 Sections. Drawings

indicate general arrangement of piping, fittings, and specialties. The following are specific
connection requirements:

1. Install piping adjacent to machine to allow service and maintenance.

2. Connect chilled- and condenser-water piping according to Division 15 Section
"Hydronic Piping." Connect to supply and return piping with shutoff valve, union,
flexible connector, and flange or mechanical joint.
3. Extend safety-relief valves or rupture-disc discharge piping from chiller and purge
condenser receiver to exterior of building.

B. Electrical: Comply with Division 16 Sections.

C. Ground equipment.

1. Tighten electrical connectors and terminals according to manufacturer's published

torque-tightening values. If manufacturer's torque values are not indicated, use those
specified in UL 486A and UL 486B.

0.5 FIELD QUALITY CONTROL

A. Manufacturer's Field Service: Engage a factory-authorized service representative to inspect

field-assembled components and chiller installation, including piping and electrical
connections. Report results in writing.

1. Test and adjust controls and safeties. Replace damaged or defective and
malfunctioning components, controls and equipment.
2. Correct deficiencies identified by observations and tests; retest until specified
requirements and satisfactory results are obtained.

0.6 CLEANING

A. After completing installation, including outlet fittings and devices, inspect unit components.
Remove paint splatters and other spots, dirt, and debris. Repair damaged finish to match
original finish.

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0.7 COMMISSIONING

A. Verify that installation complies with Contract requirements.

B. Complete installation and startup checks according to manufacturer's written instructions

and check for the following items:

1. No physical damage to unit.

2. Unit is level.
3. Chiller vibration isolation and flexible pipe connections are installed.
4. Clearances have been maintained and piping is installed for easy removal for service
and tube cleaning.
5. Chilled- and condenser-water pipes have been connected to correct ports.
6. Labels and safety instructions are clearly visible.
7. Oil levels are as recommended by the manufacturer.
8. Refrigerant charge is sufficient and chiller has been leak tested.
9. Shipping skids, blocks, and straps are removed.
10. Refrigerant pressure relief is vented to outside.
11. Thermometers and pressure gages are installed.
12. Controls and safety interlocks are installed and connected.
13. Pumps are installed, connected, and operational.

C. Start-up:

1. Chiller manufacture to provide a factory-trained representative to perform the

following services.

a. Leak testing.
b. Refrigerant pressure testing.
c. Evacuation.
d. Dehydration.
e. Charging the chiller with refrigerant.
f. Check and record performance of chiller protection devices.
g. Check and record performance of chilled- and condenser-water flow and low-
temperature interlocks.
h. Operate chiller for run-in period as recommended by the manufacturer.
i. Check static deflection of vibration isolators, including deflection during
chiller startup and shutdown.
j. Check refrigerant charge.
k. Check oil level.

2. After the above services have been performed, the same factory-trained representative
shall be available for fifteen days to instruct the owner's personnel in the proper
operation and maintenance of the chiller.

3. The Contractor shall supply the owner with the following literature as furnished by
the manufacturer prior to start-up:

a. One complete set of installation drawings

b. Wiring diagrams
c. Installation instructions
d. Start-up instructions
e. Operation and maintenance instructions.
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D. Guarantee the main electric motor starters shall be furnished and guaranteed by the
centrifugal chiller manufacturer who will be responsible for the refrigeration system
performance and its control.

0.8 FINAL ASSEMBLY, TESTING & STARTUP

A. Manufacturer shall be responsible for supervising the installation of the ship loose
components of the chiller on-site.

B. Manufacturer is responsible for the reconnection of all control wiring from the chiller to the
chiller control panel and starter.

C. Manufacturer shall perform the on site pre-commissioning, commissioning and startup of

the new chiller. These activities include the 48 hour pressure test of refrigerant side
components at factory specified test pressures, dehydration, and evacuation of refrigerant
side components. Manufacturer must provide two evacuations & dehydration tests, to be
signed off by the Owner/Engineer, before charging of system. The pressure level achieved
by each evacuation shall not exceed 100 milli-bar absolute. Charging of refrigerant and oil
to be performed by manufacturer.

D. Manufacturer shall reconfirm the proper operation of the chillers control system in all
modes of operation, including all shutdowns.

0.9 DEMONSTRATION

A. Engage a factory-authorized service representative to train the Employer's maintenance

personnel to adjust, operate, and maintain chillers. Refer to Division 1 Section
"[Demonstration and Training] [Closeout Procedures]."

1. Schedule at least eight (8) hours of training.

0.10 SEASONAL PERFORMANCE TEST

A. During the Defects Liability Period, when instructed by the Engineer, engage a factory-
authorized service representative to conduct a seasonal performance test according to
requirements of the Engineer. Report results in writing.

END OF SECTION 15625

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