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Engineering and Applied Science Building 2019-050 M19 Replace Chillers University of Colorado, Colorado Springs

CENTRIFUGAL WATER CHILLERS 23 64 17 - 10 (19162)

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MODULAR WATER CHILLERS 23 64 20 - 1 (19162)

SECTION 26 64 20 – MODULAR WATER CHILLERS

PART 1 - GENERAL

1.1 WORK INCLUDED

A. Extent of work required by this section is indicated on drawings and schedules, and by requirements of this section.

B. Types of chillers specified in this section include the following:

1. Modular water-cooled water chillers.

C. Refer to other Division 23 sections for concrete pads, piping, specialties, pumps, valves, etc., required external to chillers for installation.

D. Refer to other Division 23 sections for vibration isolation work required in conjunction with modular chillers.

E. Refer to other Division 23 sections for field-installed insulation on modular chiller evaporator and other machine surfaces subject to sweating.

F. Refer to Section 23 00 00 for equipment certification requirements.

G. Refer to Division 26 sections for the following work:

1. Power supply wiring from power source to power connection to chiller power connections as applicable.

H. Provide the following electrical work as work of this section, complying with requirements of Division 26 sections:

1. Control and interlock wiring between operating controls, indicating devices, and control panels.

1.2 SUBMITTALS

A. Product Data: Submit product data, including rated capacities, weights (shipping, installed, and operating), furnished specialties and accessories; and installation and start-up instructions.

B. Shop Drawings: Submit manufacturer's assembly type shop drawings indicating dimensions, weight loadings, required clearances, methods of assembly of components, and location and size of each field connection.

C. Wiring Diagrams: Submit manufacturer's electrical requirements for power supply wiring to units. Submit manufacturer's ladder type wiring diagrams for interlock and control wiring. Clearly differentiate between portions of wiring that are factory-installed and portions to be field installed.

D. Maintenance Data: Submit maintenance and operating data. Include this data in maintenance manual in accordance with requirements of Division-1 and Section 23 00 00.



E. Quality Control Submittals:

1. Submit certification of compliance with ARI, ASME, UL and ASHRAE fabrication requirements specified in Quality Assurance below.

2. Submit certification of compliance with performance verification requirements specified in PART 2 of this Section.

3. Submit quality control reports specified in PART 3 of this Section. 4. Submit AHRI Certification according to AHRI 590 or applicable certification program. 5. Run Test Report: Submit copy of manufacturer’s run test report.

1.3 QUALITY ASSURANCE

A. Regulatory Requirements:

1. ASHRAE Compliance: Fabricate and install chillers to comply with ASHRAE 15 "Safety Code for Mechanical Refrigeration".

2. Chiller is required to be factory run tested at manufacturer’s facility to job specific requirements, prior to shipment. Provide a copy of the report to engineer for review.

3. Modules shall be ETL listed in accordance with UL standard 1995 and shall be CSA certified per standard C22.2 #236 on all heat exchangers.

1.4 DELIVERY, STORAGE, AND HANDLING

A. Deliver chiller modules as a complete factory-assembled unit with full refrigerant charge and oil. Provide protective crating and covering.

B. Coordinate the delivery of the chiller modules in sufficient time to allow movement into the building.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Available Manufacturers: Subject to compliance with requirements, provide chillers from one of the following:

1. Basis of Design: Multistack 2. Other manufacturers (Owner pre-approval required)

2.2 OPERATING CONDITIONS

A. Chiller shall be designed for parallel evaporator water flow.

B. Each refrigerant circuit shall consist of an individual compressor, common dual circuited condenser, dual circuited evaporator, thermal expansion valve, and control system.

C. Each circuit shall be constructed to be independent of other circuits from a refrigeration and electrical stand-point. The multi-circuit chiller must be able to produce chilled water even in the event of a failure of one or more refrigerant circuits.



D. Circuits shall not contain more than capacity of R-410A refrigerant indicated on drawings.

E. General:

1. Chiller Modules shall be ETL listed in accordance with UL Standard 1995, CSA certified per Standard C22.2#236.

2. Chiller modules shall be AHRI certified. 3. Modules shall ship wired and charged with refrigerant. All modules shall be factory run

tested prior to shipment on an AHRI certified or 3rd party verified test stand. 4. Compressors, heat exchangers, piping and controls shall be mounted on a heavy gauge,

powder coated steel frame. Electrical controls, contactors, and relays for each module shall be mounted within that module.

F. The liquid to be chilled will be water containing corrosion inhibitors.

2.3 PERFORMANCE REQUIREMENTS

A. Chiller Performance: Refer to the Chiller Schedule on the drawings.

B. Altitude: Chiller shall be suitable for altitude at which installed without affecting performance indicated. Make adjustments to affected chiller components to account for site altitude.

C. Electrical: Chiller shall feature single-point power connection and shall not utilizing adjoining power cabinets as pull boxes.

D. Operation Following Loss of Normal Power: chiller shall automatically return equipment and associated controls to the operating state occurring immediately before loss of normal power without need for manual intervention by an operator when power is restored.

E. Acoustics: provide optional sound package to reduce sound pressure levels measured at 1 meter at a minimum of 12 dBA.

2.4 COMPONENTS

A. Modules shall ship wired and charged with refrigerant.

B. Each module shall be supplied with a lightweight aluminum frame with sound reduction panels. Panels are powder coated 20 gauge steel with 1” of fiberglass insulation to reduce sound levels.

C. Compressors:

1. Each module shall contain two hermetic scroll compressors independently circuited and mounted to the module with rubber-in-shear isolators.

2. Each system also includes high discharge pressure and low suction pressure manual reset safety cut-outs.

3. All compressors shall be mechanically and electrically isolated to facilitate proper maintenance, service, and or removal.

4. Provide with (2) Copeland variable speed compressors.

D. Evaporators and Condensers:



1. Each evaporator and condenser brazed plate heat exchangers and headers shall be constructed of 316 stainless steel; designed, tested, and stamped in accordance with UL 1995 code for 650 psig refrigerant side working pressure and 360 psig water side working pressure.

2. Both the condenser and evaporator heat exchanger shall be mounted below the compressor, to eliminate the effect of migration of refrigerant to the cold evaporator with consequent liquid slugging on start-up.

3. Isolation valves shall be installed between the heat exchangers and water supply mains for heat exchanger isolation and removal without the requirement to remove a module or shut down the entire chiller allowing for total access to all serviceable components.

E. Controls:

1. Scheduling of the various compressors shall be performed by a microprocessor based control system (Master Controller). A new lead compressor is selected every 24 hours to assure even distribution of compressor run time.

2. The Master Controller shall monitor and report the following on each refrigeration system: a. Discharge Pressure Fault b. Suction Pressure Fault c. Compressor Winding Temperature d. Suction Temperature e. Evaporator Leaving Chilled Water Temperature

3. The Master Controller shall be powered by the chillers single point power connection and shall monitor and report the following system parameters:

a. Chilled Water Entering and Leaving Temperature b. Condenser Water Entering and Leaving Temperature c. Chilled Water and Condenser Water Flow

4. An out of tolerance indication from these controls or sensors shall cause a “fault” indication at the Master Controller and shutdown of that compressor with the transfer of load requirements to the next available compressor. In the case of a System Fault the entire chiller will be shut down. When a fault occurs, the Master Controller shall record conditions at the time of the fault and store the data for recall. This information shall be capable of being recalled through the keypad of the Master Controller and displayed on the Master Controller’s 2 line by 40 character back-lit LCD. A history of faults shall be maintained including date and time of day of each fault (up to the last 20 occurrences).

5. Individual monitoring of leaving chilled water temperatures from each refrigeration system shall be programmed to protect against freeze-up.

6. The control system shall monitor entering and leaving chilled water temperatures to determine system load and select the number of compressor circuits required to operate. Response times and set points shall be adjustable. The system shall provide for variable time between compressor sequencing and temperature sensing, to fine tune the chiller to different existing building conditions.

7. The Chiller shall be capable of interfacing to a building automation system. Interface shall be accomplished using an Interoperability Web Portal and shall be capable of communication over BACNet, MS/TP - TCP/IP.

F. Chiller shall have a single point power connection and external inputs and outputs to be compatible with the building management system. Inputs/Outputs include:

1. Remote Start/Stop

2. Customer Alarm Relay

3. Customer Chilled/Load Limit Reset Signal

4. ECW to Mechanical Cooling Module



5. LCW from Mechanical Cooling Module

6. ECHW to Mechanical Cooling Module

7. LCHW from Mechanical Cooling Module

8. Power Phase Monitor

9. Chilled Water Flow Switch Input

10. Condenser Water Flow Switch Input

11. Full Load Indicator Relay

12. Condenser Pump Relay

13. DDRS Condenser Multiflush Relay

14. Chilled Water Pump Relay

G. Each inlet water header shall incorporate a built in 30-mesh (maximum) in-line strainer system to prevent heat exchanger fouling and accommodate 100% flow filtration with a minimum surface area of 475 sq. inches per module. Condenser-side strainer system shall incorporate an automatic debris blow-down system for self-cleaning of the strainer system that is controlled and powered by the chiller.

H. Provide single point power connection. Chiller shall be equipped with a pre-engineered genuine bus bar electrical system for single point power at a 22,000 amp SCCR. Where the equipment size exceeds the amp rating of the electrical system, multiple power connections may be applied. Pre-engineered system shall also incorporate individual module isolation circuit breakers for full redundancy and ability of a module to be taken off-line for repair while the rest of the modules continue to operate. Individual power feeds to each module shall be unacceptable.

I. Modules shall mount on 6” I-beam (W6x15) painted steel frame.

2.5 SAFETIES, CONTROLS, AND OPERATION

A. Chiller safety controls system shall be provided with the unit (minimum) as follows: 1. Low evaporator refrigerant pressure 2. Loss of flow through the evaporator 3. Loss of flow through the condenser 4. High condenser refrigerant pressure 5. High compressor motor temperature 6. Low suction gas temperature 7. Low leaving evaporator water temperature

B. Failure of chiller to start or chiller shutdown due to any of the above safety cutouts shall be annunciated by display of the appropriate diagnostic description at the unit control panel. This annunciation will be in plain English. Alphanumeric codes shall be unacceptable.

C. The chiller shall be furnished with a Master Controller as an integral portion of the chiller control circuitry to provide the following functions:

1. Provide automatic chiller shutdown during periods when the load level decreases below

the normal operating requirements of the chiller. Upon an increase in load, the chiller shall automatically restart.



2. Provisions for connection to automatically enable the chiller from a remote energy man-agement system.

3. The control panel shall provide alphanumeric display showing all system parameters in the English language with numeric data in English units.

4. Each module shall contain a slave controller that will allow any module to run in the event of a master controller failure or loss of communication with the master controller via an on/off/manual toggle switch.

D. Normal Chiller Operation

1. When chiller is enabled, the factory supplied Master Controller stages the chiller capacity from minimum to maximum as required by building load.

2. The Chiller control system shall respond to Entering Water Temperature (constant primary flow) or to Leaving Water Temperature (variable primary flow) and will have an integral re-set based on entering water temperature to provide for efficient operation at part-load con-ditions.

E. Power Phase Monitor (PPM)

1. Provide a Power Phase Monitor on the incoming power supply to the chiller. This device shall prevent the chiller from operating during periods when the incoming power is unsuita-ble for proper operation.

2. The Power Phase Monitor shall provide protection against the following conditions: a. Low Voltage (Brown-Out) b. Phase Rotation c. Loss of Phase d. Phase Imbalance

2.6 FACTORY FINISH

A. Provide manufacturer's standard factory-finish.

2.7 SOURCE QUALITY CONTROL

A. Performance Verification:

1. All modules shall be factory run tested prior to shipment on an AHRI certified or 3rd party verified test stand. Provide test results of factory at full load and 3 part load points performance testing. Engineer to confirm part load points during submittal process and format for utility rebate if pursued.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Provide and install as shown on the plans a factory assembled, charged, and run tested, water-cooled packaged modular chiller.

B. Coordinate the size and location of concrete equipment pads.



C. Install chillers in accordance with manufacturers installation instructions.

D. Install chillers plumb and level, firmly anchored, and maintain manufacturer's recommended clearances for servicing and maintenance.

E. Install vibration isolators to concrete pad with anchor bolts and secure chiller to vibration isolators.

3.2 PIPING CONNECTIONS

A. Piping installation requirements are specified in other sections of Division 23. The Drawings indicate the general arrangement of piping, fittings, and specialties. The following are specific connection requirements:

1. Install piping in manner to allow servicing and maintenance. 2. Chilled Water Piping: Connect inlet to evaporator with controller bulb well, shutoff valve,

thermometer, flow switch, pressure gage, and union or flange. Connect outlet to evaporator with shutoff valve, thermometer, pressure gage, and flange.

3. Condenser Water Piping: Provide flanged connections to condenser, arranged piping to allow removal of condenser heads. Connect inlet to condenser with shutoff valve, thermometer, plugged tee, and pressure gage. Connect outlet to condenser with thermometer, drain line and shutoff valve, and plugged tee. Provide easily accessible basket strainer filtration before the module.

4. Install (4) temperature sensors and sensor wells are furnished by the manufacturer: a. entering chilled water, b. leaving chilled water, c. entering condenser water, and d. leaving condenser water.

5. Vent Piping: Provide drain piping as indicated from rupture disc to suitable drain.

3.3 PIPING SYSTEM FLUSHING PROCEDURE

A. Prior to connecting the chiller to the condenser and chilled water loop, the piping loops shall be flushed with a detergent and hot water (110-130° F) mixture to remove previously accumulated dirt and other organics. In old piping systems with heavy encrustation of inorganic materials consult a water treatment specialist for proper passivation and/or removal of these contaminants.

B. During the flushing, a 30 mesh (max.) Y-strainers (or acceptable Equivalent) shall be in place in the system piping and examined periodically as necessary to remove collected residue. The use of on board chiller strainers shall not be acceptable.

C. Existing piping systems with heavy encrustation shall be flushed for a minimum of 24 hours and may take as long as 48 hours before the filters run clean. Detergent and acid concentrations shall be used in strict accordance with the respective chemical manufacturer’s instructions. After flushing with the detergent and/or dilute acid concentrations the system loop shall be purged with clean water for at least one hour to ensure that all residual cleaning chemicals have been flushed out.

D. Prior to supplying water to the chiller the Water Treatment Specification shall be consulted for requirements regarding the water quality during chiller operation. The appropriate chiller manufacturer’s service literature shall be available to the operator and/or service contractor and consulted for guidelines concerning preventative maintenance and off-season shutdown procedures.



3.4 WATER TREATMENT REQUIREMENT

A. Supply water for both the chilled water and condenser water circuits shall be analyzed and treated by a professional water treatment specialist who is familiar with the operating conditions and materials of construction specified for the chiller’s heat exchangers, headers and associated piping. Cycles of concentration shall be controlled such that recirculated water quality for modular chillers using 316 stainless steel brazed plate heat exchangers and carbon steel headers is maintained within the following parameters:

1. pH Greater than 7 and less than 9 2. Total Dissolved Solids (TDS) Less than 1000 ppm 3. Hardness as CaCO3 30 to 500 ppm 4. Alkalinity as Ca CO3 30 to 500 ppm 5. Chlorides Less than 200 ppm 6. Sulfates Less than 200 ppm

3.5 FIELD QUALITY CONTROL

A. Provide the services, to include a written report, of a factory authorized service representative to supervise the field assembly of the components, installation, and piping and electrical connections.

3.6 DEMONSTRATION

A. Provide the services of a factory authorized service representative to provide start-up service and to demonstrate and train the Owner's maintenance personnel as specified below.

B. Start-up Service:

1. Evacuate, dehydrate, vacuum pump and charge with specified refrigerant, and leak test in accordance with manufacturer's instructions if not factory charged. Test and adjust controls and safeties. Replace damaged or malfunctioning controls and equipment.

2. Perform lubrication service, including filling of reservoirs, and confirming that lubricant is of quantity and type recommended by manufacturer.

3. Do not place chillers in sustained operation prior to initial balancing of mechanical systems for interface with chillers.

C. Training:

1. Train the Owner's maintenance personnel on start-up and shut-down procedures, troubleshooting procedures, and servicing and preventative maintenance schedules and procedures. Review with the Owner's personnel, the data contained in the Operating and Maintenance Manuals specified in this Section and in Division 1.

2. Schedule training with Owner through the Architect/Engineer with at least 7 days prior notice.

3.7 WARRANTY

A. General: Provide written special project warranty on chiller work, agreeing to replace/repair inadequate and defective materials and workmanship, including leakage, breakage, improper assembly and failure to perform as required. Include separate product warranties as indicated (if



any) for specific parts or products in the work. Provide warranty signed by both the Installer and Contractor.

B. Manufacturer’s Warranty: Manufacturer shall provide full parts and labor warranty coverage for entire chiller for a period of one year. All parts shall be warranted against defects in material and workmanship. Similar parts-only coverage shall be provided for the chiller compressors for a period of five years. The warranty period shall commence either on the equipment start-up date or six months after shipment, whichever is earlier. Warranty service shall occur during normal business hours and commence within 24 hours of Owner's warranty service request.

C. Under add alternate bid, provide extended 5 year comprehensive chiller parts and labor.

END OF SECTION 23 64 20



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Engineering and Applied Science Building 2019-050 M19 Replace Chillers University of Colorado Colorado Springs

REFRIGERANT MONITORING SYSTEM 23 64 90-1 (19162)

SECTION 23 64 90 - REFRIGERANT MONITORING SYSTEM

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

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

1.2 SUMMARY

A. This Section includes refrigerant monitors, alarms, and audio/visual signaling devices.

1.3 DEFINITIONS

A. CMOS: Ceramic metal-oxide semiconductor.

B. HFC: Hydrofluorocarbon.

C. HCFC: Hydrochlorofluorocarbon.

D. IR: Infrared.

E. LED: Light-emitting diode.

F. ppm: Parts per million.

1.4 SUBMITTALS

A. Product Data: For SCBA; include mounting details and service requirements and compliance with authorized Federal agency.

B. Shop Drawings: For each type of refrigerant monitor; include refrigerant ppm range, temperature range, alarm outputs, readout range, furnished specialties, installation requirements, and power consumption.

1. Wiring Diagrams: Power, signal, and control wiring.

C. Coordination Drawings: Include machinery room layout showing location of monitoring devices in relation to refrigerant equipment.

D. Product Certificates: For monitoring devices and SCBA, signed by product manufacturer.

E. Operation and Maintenance Data: For refrigerant monitoring equipment and SCBA to include in emergency, operation, and maintenance manuals.




A. ASHRAE: Monitoring system shall comply with ASHRAE 15.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Refrigerant Monitoring Equipment:

a. Bacharach HGM-MZ. b. Mine Safety Appliance Company (MSA). c. Trane RMWG.

2.2 FUNCTIONAL DESCRIPTION OF REFRIGERANT MONITORING SYSTEM

A. On leak detection by refrigerant sensor(s), the system shall perform the following:

1. Activate machinery room ventilation. 2. Activate audio and visual alarm inside and outside machinery room. 3. Notify Building Automation System of alarm condition.

2.3 REFRIGERANT MONITOR

A. Description: Photoacoustic Infrared sensor shall continuously measure and display the specific gas concentration and shall be capable of indicating, alarming, and automatically activating ventilation system.

B. Performance Requirements:

1. Refrigerant to Be Monitored: HFC-134a and R-410A as required for new chillers. 2. Refrigerant Concentration: 0 to 1000 ppm. 3. Accuracy: 0 to 50 ppm; 1 ppm, 50 to 1000 ppm; plus or minus 10 percent of reading. 4. Linearity: 0 to 50 ppm; 1ppm, 50 to 1000 ppm; plus or minus 10 percent of reading. 5. Sensitivity: 1 ppm. 6. Resolution: 1 ppm. 7. Operating Temperature: 32 to 122 deg F. 8. Temperature Effect: ±.3% per ˚C of reading. 9. Response Time: 50 percent of a step change in 1 minute. 10. Relatively Humidity: 0 to 95 percent, non-condensing over the operating temperature

range. 11. Sample Flow Rate: .75 liters/Minute. 12. Maximum Tubing Length: 150ft.

C. Operating Requirements:

1. Maximum Power Input: 120-V ac; 60 Hz, .56A. 2. Alarm Relays: SPDT alarm contacts rated at 2A at 250VAC inductive or 5A at 250VAC

resistive:



a. Three (3) assigned to PPM level alarms. b. One (1) assigned to system faults.

3. Alarm Set Points: Displayed on front of meter. 4. Audible Output: Sonic alert at 75 dB at. 5. Analog Output: 0- to 10-V dc or 4- to 20-mA current sourcing. 6. Serial Output Type: RS 232. 7. Building Automation System (BAS) Communications Interface: provide BACnet® Protocol

Converter Kit to convert Modbus RTU via RS 485 signaling.

D. Sensor Configuration: Photoacoustic IR sensor.

1. Four (4) sensing channels. 2. Expandable to eight channels.

E. User interface: Large Graphics LCD, vacuum-fluorescent indicating lights for each alarm set point; standard alarm; acknowledge switch and test switch mounted on front panel; and alarm status LEDs and service fault LEDs.

1. Enclosure: NEMA 4, type as required for ambient condition. 2. Remote Display

F. Alarm Output: Indicating light flashes and siren sounds.

1. Unit-mounted audio/visual signal devices and alarm silence pushbutton. Alarm silence pushbutton shall silence both local and remote audio signal devices.

2. Field-adjustable alarm set points.

G. Calibration: Factory calibrated.

2.4 REMOTE AUDIO/VISUAL SIGNAL DEVICES

A. Non-Hazardous Locations: Audio/visual devices shall be designed for general duty type applications. The following audio/visual signal devices shall be provided in the maintenance offices, and the west entrance to the chiller plant:

1. Audio Devices: NEMA 3R, IP54 enclosure molded from impact resistant acrylic-styrene-acrylonitrile plastic. Unit shall have internal amplifier, swivel mounting and 4” electrical wall mounting box. Multi-tone device shall produce a wail, yelp, or horn tone that is user selectable by reconfiguring the internal jumpers and shall produce a sound level of 108dB at 10 feet.

a. Power Requirements: 120V @ 0.21A. b. Basis of Design: Federal Signal model SST-MV.

2. Visual: NEMA 3R, IP41 enclosure with. Device shall have a base for wall mounting or ½ inch pipe mount, removable strobe mechanism, outer dome, and strobe tube rated for 4,000 hours of operation. Provide amber lens for warning and red lens for alarm signaling. Device shall provide a 100,000 candlepower strobe light effect with a flash rate of 80 flashes/minute.

a. Power Requirements: 120V @ 0.06A. b. Basis of Design: Federal Signal model 141ST.



B. Hazardous Locations: Audio/visual indicating devices shall be explosion-proof when mounted in a refrigeration machinery room or in a room with chillers. The following audio/visual signal devices shall be provided:

1. Audio Devices: NEMA 3R, IP44 enclosure listed for Class 1, Division 1, Groups B, C, & D constructed of die-cast aluminum with internal amplifier, spun aluminum projector, and adjustable mounting bracket. Multi-tone device shall produce a wail, yelp, or horn tone that is user selectable by reconfiguring the internal jumpers and shall produce a sound level of 108dB at 10 feet.

a. Power Requirements: 120V @ 0.21A. b. Basis of Design: Federal Signal model SSTX-MV.

2. Visual: NEMA 4X, IP66 enclosure listed for Class 1, Division 1, Groups C & D with self-contained power supply. Device shall have an aluminum finned base for wall mounting, tempered glass outer dome, polycarbonate inner lens and strobe tube rated for 10,000 hours of operation. Provide amber lens for warning and red lens for alarm signaling. Device shall provide a lightning bolt flash of light with a flash rate of 80 flashes/minute.

a. Power Requirements: 120V @ 0.25A. b. Basis of Design: Federal Signal model FB2PSTX.

2.5 CONTROL CABLE

A. Electronic and fiber-optic cable for control wiring shall be as specified in Division 26.

2.6 SOURCE QUALITY CONTROL

A. Refrigerant Monitor: Factory tested and certified.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine chiller layout for proper location of monitoring device.

B. Verify refrigerant contained in chiller(s) to ensure compatibility of refrigerant monitor.

C. Examine machinery room ventilation system to verify its operation with refrigerant monitor(s).

3.2 INSTALLATION

A. Install refrigerant monitoring equipment level and plumb.

B. Install labels and nameplates to identify monitoring devices and SCBA components according to Division 23 Section "Mechanical Identification."

C. Install building wire and cable according to Division 26.



D. Install signal and communication cable according to Division 26 Section.

E. Provide two (2) sampling points per chiller between 6” and 16” above floor.

F. Install tubing with line end filters in accordance with manufacturer’s instructions.

G. Install purge line to provide clean air for resetting the infrared zero baseline.

H. Install an exhaust line to vent gas samples away from the instrument.

I. Install charcoal purge filter in accordance with manufacturer’s instructions.

3.3 FIELD QUALITY CONTROL

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

1. Inspect field-assembled components, equipment installation, and electrical connections for compliance with requirements.

2. Program unit. 3. Connect to the Building Management System via optional BACnet® Protocol Converter. 4. Test and adjust controls and safeties. 5. Test Reports: Prepare a written report to record the following:

a. Test procedures used. b. Test results that comply with requirements. c. Test results that do not comply with requirements and corrective action taken to

achieve compliance with requirements.

B. Repair or replace malfunctioning units. Retest as specified above after repairs or replacements are made.

3.4 ADJUSTING

A. Adjust alarm set points.

3.5 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain refrigerant monitoring devices.

B. Include training materials and test results in O & M Manual.




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CLOSED CIRCUIT FLUID COOLERS 23 65 50 - 1 (19162)

SECTION 23 65 50 – CLOSED CIRCUIT FLUID COOLERS

PART 1 - GENERAL

1.1 WORK INCLUDED

A. New FC-2 under Add Alternate Bid.

B. Extent of factory-fabricated closed circuit fluid cooler work required by this section is indicated on drawings and schedules and by requirements of this section.

C. Types of factory-fabricated closed circuit fluid coolers specified in this section include the following:

1. Induced-draft, counter-flow closed circuit fluid cooler.

1.2 RELATED SECTIONS

A. Refer to other Division 23 sections for remote closed circuit fluid cooler sump, not work of this section.

B. Refer to other Division-23 sections for automatic temperature controls required in conjunction with factory-fabricated closed circuit fluid coolers.

C. Refer to Division-23 section "Water Treatment System" for water treatment system.

D. Refer to Division-23 section “Hydronic Piping” for water piping to factory-fabricated closed circuit fluid coolers.

E. Refer to Division-23 section "Vibration Isolation" for vibration control work required in conjunction with factory-fabricated closed circuit fluid coolers.

F. Refer to Division-26 sections for the following work:

1. Power supply wiring from power source to power connection on closed circuit fluid cooler. Include starters, disconnects, and required electrical devices, except where specified as furnished, or factory-installed, by manufacturer.

G. Provide the following electrical work as work of this section, complying with requirements of Division-26 sections:

1. Control and interlock wiring between operating controls, indicating devices, and closed circuit fluid cooler temperature control panels.

2. Provide variable frequency drives for closed circuit fluid cooler motors in accordance with Division 23 “Variable Frequency Drives”.




A. Manufacturer's Qualifications: Firms regularly engaged in manufacture of factory-fabricated closed circuit fluid coolers, of types and sizes required, whose products have been in satisfactory use in similar service for not less than 5 years.

B. Provide manufacturer's certification of closed circuit fluid cooler cooling capacity, based on factory performance tests, and provide performance curve plotting Leaving-Water Temperature (LWT) against Wet-Bulb Temperature (WBT).

C. Certify closed circuit fluid cooler wind resistance to withstand pressure indicated, in any direction.

D. Certify earthquake resistance against loading as indicated.

E. Codes and Standards:

1. UL and NEMA Compliance: Provide electric motors and electrical components required as part of factory-fabricated closed circuit fluid cooler, which have been listed and labeled by UL and comply with NEMA Standards.

2. NEC Compliance: Install closed circuit fluid coolers in accordance with NFPA 70 "National Electrical Code".

1.4 SUBMITTALS

A. Product Data: Submit manufacturer's technical product data, including rated capacities, pressure drop, fan performance data, weights (shipping, installed, and operating), installation and start-up instructions, and rating curves with selected points clearly indicated.

B. Shop Drawings: Submit assembly-type shop drawings indicating dimensions, weight loadings, required clearances, and methods of assembly of all components.

C. Wiring Diagrams: Submit manufacturer's electrical requirements for power supply wiring to closed circuit fluid coolers. Submit manufacturer's ladder-type wiring diagrams for interlock and control wiring. Clearly differentiate between portions of wiring that are factory- installed and portions to be field-installed.

D. Maintenance Data: Submit maintenance data and parts list for each closed circuit fluid cooler, control, and accessory; including "troubleshooting" maintenance guide. Include this data, product data, shop drawings, and wiring diagrams, in maintenance manual; in accordance with requirements of Section 23 00 00.

E. Certifications: Submit required certifications and written tests results for required testing.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Handle closed circuit fluid coolers and components carefully to prevent damage, breaking, denting and scoring. Do not install damaged closed circuit fluid cooler or components; replace with new.

B. Store closed circuit fluid coolers and components in clean place. Protect from dirt, fumes, construction debris, and physical damage.



C. Comply with Manufacturer's rigging and installation instructions for unloading closed circuit fluid coolers and moving them to final location.

PART 2 - PRODUCTS

2.1 FACTORY-FABRICATED CLOSED CIRCUIT FLUID COOLER CONSTRUCTION

A. General: Fabricate closed circuit fluid coolers using manufacturer's standard design, materials, and construction in accordance with published product information, except as otherwise indicated.

B. Design structural system for the following live loading in addition to closed circuit fluid cooler dead-loads and operating-loads:

1. Wind Loading: 30 psf on exposed vertical surfaces. 2. Earthquake Resistance: Acceleration of 1.0 G horizontally through center of gravity.

C. Fabricate structural system including assembly of collecting basin and steel casings by the following methods:

1. Bolt connections with fasteners having equal or better corrosion-resistance than materials fastened; seal joints to make watertight enclosure.

2. Weld connections and weld metal seams continuously to make watertight. 3. Provide rigging supports on structure for final rigging.

D. Provide stainless steel casings, fabricated and installed by manufacturer to make cooler watertight.

E. Collecting Basin and Sump: Designed and installed to support water and to ensure water tightness:

1. Provide stainless steel. 2. Provide integral type collecting basin and sump with lift-out strainer with openings smaller

than nozzle orifices, and with connections for drain, overflow and water make-up.

F. Drift Eliminators: Fabricated by manufacturer into three-pass configuration to limit drift-loss to .001 percent of the maximum circulating-water flow-rate:

1. Provide inert polyvinyl chloride plastic, having flame spread rating of 5 per ASTM E 84.

G. Louvers: Designed and installed by manufacturer, and of sufficient thickness and rigidity to prevent visible sagging:

1. Provide stainless steel.

H. Water Distribution System: Distribution system shall consist of schedule 40 PVC pipe and precision molded ABS spray nozzles. All spray branches shall be removable for cleaning. Nozzles shall be threaded into the header for easy removal and shall have internal sludge ring to eliminate clogging. System shall provide a water flow rate of 6 GPM over each square foot of unit face area to ensure proper flooding of the coil.



I. Heat Transfer Coil: The coil shall be all prime surface steel, encased in a steel framework and hot-dip galvanized after fabrication as a complete assembly. The tubes shall be arranged in a self-spacing, staggered pattern in the direction of air-flow for maximum heat transfer efficiency and minimum pressure drop, without the use of additional spacers between the coil tubes. The coil shall be designed with sloping tubes for free drainage of liquid and shall be pneumatically tested at 350 P.S.I.G., under water.

J. Water Recirculation Pump: The pump shall be a close - coupled, centrifugal type with mechanical seals, installed vertically at the factory to allow free drainage on shut down. Pump motor shall be totally enclosed fan cooled (T.E.F.C.) suitable for outdoor service. Pump shall be selected by the manufacturer to provide the required flow based on the system pressure drop including the pressure drop of the centrifugal separator.

1. The centrifugal separator shall be sized for 50% of the distribution system flow.

K. Discharge Dampers: Provide airfoil capacity control dampers and linkage for cells as indicated, formed of galvanized steel sheets, designed and installed by manufacturer to control air flow and to provide linear control of fluid cooler capacity.

L. Discharge Hoods: One of the following materials, including access doors, fabricated and installed by manufacturer to prevent recirculation of discharge air:

1. Provide galvanized steel.

M. Basin Heaters: Provide electric immersion heaters including thermostat and low-water cutout, in weatherproof enclosure, for field wiring. Provide basin heaters sized by manufacturer to maintain basin water at 40°F at an ambient temperature of -20°F and wind velocity of 15 mph.

N. Water Level Control: Provide electric float switch and solenoid makeup valve.

O. Flow Control Valves: Provide one of the following flow control valves for balancing flow to the distribution system, and for shut-off during servicing:

1. Provide butterfly valves.

2.2 FACTORY FABRICATED CLOSED CIRCUIT FLUID COOLER FANS, MOTORS, AND DRIVES

A. Fans: Aluminum alloy axial propeller-fan of fixed-pitch type statically balanced.

1. Fan shall be fitted in a cowl with a venturi air inlet and galvanized steel mesh screen bolted to the outlet.

2. Fan Bearings: One of the following types installed by manufacturer.

a. Provide self-aligning ball bearings rated for and L-10 life of 75,000 hours; include external extended grease lines, and fittings.

B. Drive: Provide direct driven type.

C. Motor Type: Provide totally enclosed, air over, (TEAO) energy efficient type motor. Motors shall be suitable for outdoor service and shall have a 1.25 service factor.

2.3 FACTORY FABRICATED COOLING TOWER ACCESSORIES



A. Vibration Cutout Switch: Provide switch to de-energize fan motors if excessive vibration occurs due to fan imbalance.

B. Discharge Damper Controls: Provide electric damper operator, with end switches.

C. Assemble Components by one of the following methods:

1. Use galvanized or stainless fasteners and accessories to assemble components.

D. Apply phosphatized pretreatment on zinc coated surfaces which have not been mill-phosphatized or polymer-coated. Apply gasoline- soluble rust preventative compound on ferrous parts which cannot be galvanized, including shafts and machined parts.

1. Finish components with zinc-coated metal surfaces by one of the following methods:

a. Coat abraded areas and welded areas with 95% pure zinc rich compound.

E. Maximum Permissable Sound Pressure Level: Use 0.0002 microbar as reference. Measure at 50’ in several directions, uniformly covering 360 deg. Do not exceed maximum permissible dB level in each of the following octave bands:

1. 63 HZ - dB 2. 125 HZ - dB 3. 250 HZ - dB 4. 500 HZ - dB 5. 1000 HZ - dB 6. 2000 HZ - dB 7. 4000 HZ - dB 8. 8000 HZ - dB

F. Vibration Control: Provide as scheduled, one of the following types of vibration isolators, with number and size of isolators selected by manufacturer.

1. Isolator Type 2: Rubber floor isolator.

G. WATER FILTRATION SYSTEM (CENTRIFUGAL SEPARATOR):

1. The centrifugal vortex separator shall be furnished for installation in the liquid supply/circulation system to remove separable solids from the system. The Separator shall remove 98% by weight, or separable solids 200 mesh (74 microns) and larger.

2. A centrifugal vortex separator shall be furnished for installation in the liquid supply/circulation system to remove separable solids from the system. The Separator shall remove 98%, by weight, of separable solids 200 mesh (74 microns) and larger.

3. The separator shall be designed with tangential entry into the acceptance chamber. Upon tangential slots and accelerated into the reduced diameter separation cylinder. The solids heaver than the carrying liquid are centrifugally spiralled down the perimeter of the separation cylinder past the deflector stool and allowed to accumulate in the separator's collection chamber. The liquid (free of separable solids) will follow the vortex created and entered on the deflector stool up through the interior of the separation cylinder and into the vortex finder which becomes the separator outlet.

4. Quiescent solids accumulation shall be facilitated by the baffle spin arrestor below the deflector stool in the collection chamber. Separation and collection of solids shall not promote excessive wear nor require a continuous "involuntary" underflow.

5. Separator Construction:



a. The separator shall be fabricated of carbon steel (or stainless steel) with shell material and head material equivalent to schedule 40 thickness or better.

b. Paint coating shall be Mactek M-Line Enamel (Stainless steel shall be unpainted).

6. Separated Solids Purging Operation:

a. Automatic: A full port, straight-through motorized ball valve may be installed on the standard purge opening and operated as determined by the building automation system.

7. Manufacturer: Subject to compliance with requirements, provide condenser water filtration system of one of the following:

a. Lakos Separators, A Claude Laval Corporation.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas and conditions under which factory-fabricated closed circuit fluid coolers are to be installed. Do not proceed with work until unsatisfactory conditions have been corrected in manner acceptable to Installer.

3.2 INSTALLATION

A. General: Install closed circuit fluid coolers where indicated, in accordance with equipment manufacturer's written instructions and with recognized industry practices, to ensure that closed circuit fluid coolers comply with requirements and serve intended purposes.

B. Access: Provide access and service space around and over closed circuit fluid cooler as indicated, but in no case less than that recommended by manufacturer.

C. Support: Install floor-mounted units on 8" high reinforced concrete pad, 4" larger on each side than closed circuit fluid cooler base. Cast anchor bolt inserts into pad.

D. Placement: Mount unit on vibration isolators. Level units to tolerance of 1/8" in 10'-0", in both directions.

E. Water Piping: Refer to Division-23 section "Hydronic Piping". Provide flanged or union connections to closed circuit fluid cooler, with flexible pipe connections if equipment is mounted on vibration isolators. Pitch lines so water will drain into sump. Connect inlets to closed circuit fluid cooler with shutoff valve, and balancing valve. Connect outlets with shutoff valves.

F. Make-up and Water Piping: Refer to Division-23 section "Water Distribution Piping". Provide flanged or union connections to closed circuit fluid coolers, with flexible pipe connections if cooler is mounted on vibration isolators. Pitch lines so water will drain into sump. Connect to automatic fill valve with 3-valve bypass, and backflow preventer.

G. Drain Piping: Refer to Division-23 section "Storm Water Systems". Connect drain, overflow, and bleed lines to closed circuit fluid cooler as indicated, full size of connection on cooler.



H. Electrical Wiring: Install electrical devices furnished by manufacturer but not specified to be factory-mounted. Furnish copy of manufacturer's wiring diagram submittal to Electrical Installer.

1. Verify that electrical wiring installation is in accordance with manufacturer's submittal and installation requirements of Division-26 sections. Do not proceed with equipment start-up until wiring installation is acceptable to equipment installer.

3.3 ADJUSTING AND CLEANING

A. Cleaning: Clean inside of closed circuit fluid cooler thoroughly before filling for start-up. Clean factory-finished surfaces. Repair any marred or scratched surfaces with manufacturer's touch-up paint.

B. Start-up: Comply with manufacturer's instructions for filling and start-up of operation, but not less than the following:

1. Verify lubrication of rotating parts; lubricate as needed. 2. Verify fan rotation direction. 3. Verify that motor amperage is in accordance with manufacturer's data. 4. Adjust water level control for proper operating level. 5. Adjust bleed valve for indicated percentage of circulated water volume. 6. Adjust temperature controls and verify operation.

C. Operation Test: Test each closed circuit fluid cooler to show that it will operate in accordance with indicated requirements.

3.4 CLOSEOUT PROCEDURES

A. Provide services of manufacturer's technical representative for one 8-hour day to instruct Owner's personnel in operation and maintenance of factory-fabricated closed circuit fluid coolers.

1. Schedule training with Owner, provide at least 7-day notice to Contractor and Engineer of training date.




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