Volume 3 – Technical Specification CD REV 00

SECTION 23 60 00

CENTRAL COOLING EQUIPMENT

PART 1 – GENERAL .................................................................................................................................. 3

1.1 SUMMARY ............................................................................................................................... 3

1.2 QUALITY ASSURANCE .............................................................................................................. 3

1.3 SUBMITTALS ............................................................................................................................ 3

PART 2 – PRODUCT ................................................................................................................................. 3

2.1 REFRIGERATION MACHINE...................................................................................................... 3

2.2 REFRIGERANT MONITOR ......................................................................................................... 9

2.3 SELF-CONTAINED BREATHING APPARATUS .......................................................................... 11

PART 3 – EXECUTION ............................................................................................................................ 12

3.1 INSTALLATION OF REFRIGERATION MACHINE ...................................................................... 12

3.2 INSTALLATION OF REFRIGERANT CONCENTRATION MONITOR ........................................... 13

3.3 INSTALLATION OF SELF-CONTAINED BREATHING APPARATUS ............................................ 13

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Volume 3 – Technical Specification CD REV 00

PART 1 – GENERAL

1.1 SUMMARY

A. General: Provide central cooling equipment in accordance with requirements of

Contract Documents.

1.2 QUALITY ASSURANCE

A. Statement of Method: Contractor to submit the statement of method for the execution
of each item stating the installation activities, repairing, protection, and the finishing
process.
B. Unit shall be manufactured to withstand and meet the project specified seismic
requirement.
C. Unit shall be installed to withstand and meet the project specified seismic requirement.

1.3 SUBMITTALS

A. Submit shop drawings for all refrigeration equipment specified in Part 2 of this Section.

PART 2 – PRODUCT

2.1 REFRIGERATION MACHINE

A. Air-Cooled screw chillers with performance as indicated on the drawings. Supply and
install where shown in the B.O.Q packaged type air cooled screw water chillers with at
least two refrigerant circuits note each compressor must have its own circuit. Chillers
shall be AHRI or Euro-vent certified and shall comply with EC requirements for
machinery, electromagnetic and pressure equipment directives.Chillers shall be
especially designed for operation on HFC-134a. Refrigerants containing CFC’s or
refrigerant blends shall not be acceptable.

The air-cooled screw chiller will be designed and manufactured in accordance with
following European directives:
Rating of chillers EN 12055
Construction of pressure vessel 97/23/EC (PED)
Machinery Directive 98/37/EC as modified
Low Voltage 2006/95/EC
Electromagnetic Compatibility 2004/108/EC
Electrical & Safety codes EN 60204–1 / EN 60335-2-40
Manufacturing Quality Stds. UNI – EN ISO 9001:2000

Unit footprint shall not exceed than those mentioned in the schedule of equipment.

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Chiller shall include as standard not less than: two independent refrigerant circuits,
semi-hermetic type rotary single or twin screw compressors, electronic expansion device
(EEXV), refrigerant direct expansion shell & tube heat exchanger, air-cooled condenser
section, R134a refrigerant, lubrication system, motor starting components, discharge line
shut-off valve, control system and all components necessary for safe and stable unit
operation.

Chillers shall be factory assembled on a robust base-frame made of galvanized steel,

protected by epoxy paint. The cabinet shall be made of galvanized steel sheet and
painted to provide a high resistance to corrosion. Full load capacity of chiller shall be
provided at 60 Hz.

Contractor to ensure chiller dimensions should not exceed than those specified on the
schedule.

B. Units are leak and pressure tested at 390 psig (2689 kPa) high side, 250 psig (1724
kPa) low side, then evacuated and charged. All Air-cooled chillers are factory tested to
confirm operation prior to shipment. Packaged units Chiller will be delivered to the job
site completely assembled and charged with right refrigerant and oil quantity. Comply
with the manufacturer instructions for rigging and handling equipment.

C. Unit panels, structural elements and control boxes are constructed of galvanized steel
and mounted on a welded structural steel base. Unit panels and control boxes are
finished with a baked-on powder paint, and the structural base with an air dry paint. All
paint meets the requirement for outdoor saline environment equipment of the U.S.
Navy and other Federal Government Agencies and meets ASTM B117 1000 Hours salt
spray.

D. Anytime water only is present in the evaporator, the chiller must have flow control of the
chilled water system. Flow control can be done either directly or through an input to a
building automation system to conduct an action resulting in minimum flow through the
chiller evaporator barrel to avoid potentially catastrophic damage to the evaporator due
to freezing. If the system has sufficient glycol to protect down to the lowest expected
ambient, flow control is optional.

E. Evaporator

1. The evaporator is a tube-in-shell heat exchanger design with internally and

externally finned copper tubes roller expanded into the tube sheet. The
evaporator shall be single-pass on both the refrigerant and water sides for pure
counter-flow heat exchange and low refrigerant pressure drops. The evaporator is
designed, tested and stamped in accordance with ASME Pressure Vessel Code
Section VIII for a refrigerant side working pressure of 200 psig (1379 kPa) or
equivalent PED approval. . The evaporator is designed for a water side working
pressure of 150 psig (1034 kPa). Water connections are grooved pipe. Each shell
includes a vent, a drain and fittings for temperature control sensors and is

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insulated with UV resistant 1.25 inch Armaflex II or equal insulation (K=0.28).

Insulation also covers the suction line and evaporator heads. Heaters, with
thermostat, are provided to help protect the evaporator from freezing at ambient
temperatures down to -20 F (-29 C) controlled by a thermostat and shall be
insulated with flexible, closed cell polyurethane insulation material of minimum 20
mm thick, depending on application.

2. A separate field supplied low voltage power source is required to power the
freeze protection.

3. The evaporator shall have 2 circuits, one for each compressor and shall be single
refrigerant pass. The water connections shall be VICTAULIC type connections as
standard to ensure quick mechanical disconnection between the unit and the
hydronic network.

F. Operating Temperature

1. The chiller shall be able to operate at 50 C ambient without trip.

2. The units shall be provided with an automatic control for condensing pressure
which ensures the working at low external temperatures down to 10°C, to
maintain condensing pressure. Compressor automatically unloads when
abnormal high condensing pressure is detected to prevent the shutdown of the
refrigerant circuit (shutdown of the unit) due to a high-pressure fault.

G. Chilled Water Reset

1. Provides the control logic and factory-installed sensors to reset leaving chilled
water temperature. The set point can be reset based on ambient temperature or
return evaporator water temperature.

H. Pressure Vessel Code

1. Chiller complies with ASME Pressure Vessel Code Section VIII. ASME
nameplates are attached to applicable pressure vessels including oil separators.

I. Condenser and Fans

1. The condenser coils shall be constructed with internally finned seamless copper
tubes and arranged in a staggered row pattern and mechanically expanded into
lanced and rippled aluminium fins with full fin collars for higher efficiencies. Fins
per inch should be optimized to 14. The condenser coil has an integral sub
cooling circuit. Condensers are factory proof and leak tested at 506 psig (3489
kPa). The space between the fins shall be given by a collar that will increase the
surface area in connection with the tubes, protecting them from ambient corrosion.
Coils shall be protected against corrosion by here-site factory coating and a
warranty of 10 years shall be provided on the coating.
2. Direct drive vertical discharge condenser fans are dynamically balanced. Three
phase condenser fan motors with permanently lubricated ball bearing and internal

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thermal protection are provided.

3. Totally Enclosed Air-Over (TEAO) motors completely seal motor windings,
preventing exposure to weather conditions. TEAO fan motor insulation class F.
4. The coils shall have an integral sub-cooler circuit that provides enough
sub-cooling to effectively eliminate the possibility of liquid flashing and increase
the unit's efficiency of 5-7% without increasing in energy consumption.

J. Compressor Starter - Y Delta

1. Starter is a wye-delta closed transition configuration. The wye-delta closed

transition starter reduces inrush current (Locked Rotor Amps) by 66%. The starter
is factory mounted and completely prewired to the compressor motor. Starters
are housed in a weather tight enclosure per UL 1995.

K. Compressor and Lube Oil System

1. The rotary screw compressor is semi-hermetic, direct drive, 3000 rpm, with step
and variable load and unloader valves for capacity control, rolling element
bearings, differential refrigerant pressure oil pump and oil heater. The motor is a
suction gas cooled, hermetically sealed, two pole squirrel cage induction motor.
2. Oil separation is provided separate from the compressor. Automatically controlled
valves are provided on the compressor discharge and lube oil system. A solenoid
valve in the lube oil return system is also provided. Oil filtration is accomplished
by an integral oil filter located within the compressor.
3. Compressor shall be fully field serviceable. Compressor that must be removed
and returned to the factory for service shall be unacceptable.

L. Refrigerant Circuits

1. Each unit has two refrigerant circuits, with one or two rotary screw compressor
per circuit. Each refrigerant circuit includes compressor suction and discharge
service valves, liquid line shutoff valve (except remote evap), removable core
filter, liquid line sight glass, charging port and one electronic expansion valve per
circuit. Fully modulating compressors and electronic expansion valves provide
variable capacity modulation over the entire operating range.

M. Unit Controls
1. All unit controls are housed in an outdoor rated enclosure per UL 1995 with
removable plates to allow for customer connection of power wiring and remote
interlocks. All controls, including sensors, are factory mounted and tested prior to
shipment.

2. Microcomputer controls provide all control functions including start up and

shutdown, leaving chilled water temperature control, compressor and electronic
expansion valve modulation, fan sequencing, anti-recycle logic, automatic
lead/lag compressor starting, load limiting and chilled water pump control.

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3. The unit control module with Rapid Restart (TM), utilizing Adaptive Control (TM)
microprocessor automatically takes action to avoid unit shut down due to
abnormal operating conditions associated with low refrigerant pressure, high
condensing pressure and motor current overload. Should the abnormal operating
condition continue until a protective limit is violated, the unit will be shut down.

4. A control power transformer is factory installed and wired.

N. Controls Function Data

1. Unit protective functions include loss of chilled water flow, evaporator freezing,
loss of refrigerant, low refrigerant pressure, high refrigerant pressure, compressor
starting and running over current, phase loss, phase imbalance, phase reversal,
under/over voltage protection and loss of oil flow.

2. A menu driven digital display indicates over 20 operating data points including
chilled water set point, current limit set point, entering and leaving chilled water
temperature, evaporator and condenser refrigerant pressures and temperatures.
Over 60 diagnostic checks are made and displayed when a problem is detected.
The digital display can be read and advanced on the unit without opening any
control panel doors. Touch screen LCD allows for easy access of all important
chiller operating information.

O. Short Circuit Current Rating (SCCR)

1. A short circuit current rating offers a measure of safety for what the starter panel
enclosure is able to withstand in the event of an explosion caused by a short
circuit.
P. Power Disconnect Switch

1. A non-fused molded case disconnect switch with through-the-door lockable

handle is provided to disconnect the main power and comes pre-wired from the
factory with terminal block power connections.

Q. Power Connection

1. Unit is provided with dual-point electrical power connection. Field wiring

connection point will be on the bottom right corner of each electrical panel at each
end of the chiller.

R. Compressor Sound Enhancement

1. Provide a weatherproof compressor enclosure to reduce compressor sound
levels.

S. Flow Switch
1. There is a factory installed flow switch with a velocity set point of 35 cm/sec

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included on this chiller.

T. Seismic Anchoring

1. Suitable anchoring connection hardware factory installed to suit requirements of

Section entitled Seismic Control and Restraint.

U. Start-up and Operator Training

1. The services of a factory trained, field service representative will be provided to
supervise the final leak testing, charging and the initial start-up and conduct
concurrent operator instruction.

V. NOISE LEVEL AND VIBRATIONS

Sound pressure level at 1-meter distance in free field, semi-spherical conditions, shall
not Proposed chiller shall be sound enclosure to further reduce the sound levels. The
sound pressure levels must be rated in accordance to ISO 3744.Proposed chiller shall
with Factory installed Vibration Isolators and seismic restraint device and manufacturer
to provide point loadings for correct selection of vibration isolators.

W. Warranty:
1. Provide a five (5) year total service (“flange to flange”) service contract for the
refrigeration machines which includes the following:
a. All required emergency service, including all parts and labor required for
emergency service, 24 hours a day, 7 days a week with a response time
of 2 hours;

b. All required parts and labor, including refrigerant for all maintenance
work;

c. Seasonal operational inspections (minimum of 5 including fall shut-down

and spring start-up);

d. Annual complete maintenance inspection including condenser tube

cleaning and oil analysis;

e. Evaporator tube cleaning in the 3rd year of contract;

f. Vibration analysis of refrigeration machine in the 3 rd year of service
contract;

g. Eddy current testing in 5th year of contract;

h. Thermography scan in the 2nd and 4th years of service contract.

W. Acceptable manufacturers as follows:

1. Trane

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2. YORK
3. Mcquay / Diakin
4. Carrier

2.2 REFRIGERANT MONITOR

A. Honeywell Analytics/Vulcain, or approved equal, refrigerant leak detection system, as

shown on the drawings and specified herein, providing continuous gas concentration
display, UL Certified, with the following:

B. VA301EM-RFSA-EMBG Expansion Module:

1. The expansion module shall be capable of communicating digitally with the

networked sensors through RS-485 Modbus communication. Up to four infrared
sensors can be connected at a maximum distance of 200 feet (61m). One power
supply will be sufficient to power the entire gas detection network.

2. The expansion module will manage four internal DPDT relays at fully
programmable alarm levels.

3. The expansion module shall comply with ASHRAE/B-52 Mechanical Codes.

This includes a key for manual fan start/ stop operation, a silence key to
acknowledge RFSA 105db horn (audible alarm operation), a RED strobe on top
of the unit as a visual alarm and (2) inputs for the ‘’EMBG’’ break glass switch for
EMERGENCY shutdown.

4. The expansion module shall indicate the exact concentration of gas and the gas
detected. The LCD display will indicate multiple alarm levels for each sensing
point. The LED will also provide visual feedback in the following manner:

a. Normal Operation: Green LED

b. Alarm Level A: Red LED

c. Alarm Level B: Red LED

d. Alarm Level C: Red LED

e. Failure: Yellow LED

f. TX: Yellow LED

5. The standard three high/low alarm levels will be complemented with a fault relay.
6. The expansion module shall provide an individual 4-20mA output per refrigerant
sensor (up to four) for BAS compatibility.

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C. VA301EMRP-RFSA-EMBG Remote Panel:

1. The expansion module shall be capable of communicating digitally with the

Expansion module. Remote Panels shall be capable of being connected at a
maximum distance of 1000ft (304.8m).
2. The Remote Panel shall manage four internal DPDT relays at fully programmable
alarm levels.

3. The remote panel shall comply with ASHRAE or B-52 Mechanical Codes. This
includes a key for manual ‘’fan start’’ only operation, a silence key to
acknowledge the internal 65 dB audible alarm and a RED strobe on top of the unit
as a visual alarm.

4. The Remote panel will indicate the exact concentration of gas and the gas
detected. The LCD display will indicate multiple alarm levels for each sensing
point. The LED will also provide visual feedback in the following manner:

a. Normal Operation: Green LED

b. Alarm Level A: Red LED

c. Alarm Level B: Red LED

d. Alarm Level C: Red LED

e. Failure: Yellow LED

f. TX: Yellow LED

5. The unit shall be equipped with a NEMA 4X polycarbonate ABS impact resistant,
weather proof housing.

6. The standard three high/low alarm levels will be complemented with a fault relay.
7. The expansion module must provide an individual 4-20mA output per refrigerant
sensor (up to four) for BAS compatibility.

D. VA301IRFSR Refrigerant Gas Sensor

1. The sensor will be powered by the expansion module. Refrigerant gas will enter
the infrared gas detection chamber according to the diffusion principle. The ABC
logic infrared sensing technology will detect the refrigerant gas by sensing the
absorption rate of a specific bandwidth of light. The gas sensor will have
resolution levels of 1 ppm with a standard range of 0-1000 ppm. Temperature
and relative humidity variations will have no effect on the unit’s accuracy.

2. The sensor will be capable of operating within relative humidity ranges of 5-95%

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and temperature ranges of 32°F-100°F (0°C-40°C).

3. The Unit will be equipped with a Nema 4X Polycarbonate-ABS impact-resistant

housing.

4. The sensor alarm levels and unit are to be installed in accordance with the
following parameters:

GAS FIRST ALARM SECOND TRANSMITTER RADIUS OF

SET POINT ALARM SET LOCATION COVERAGE
POINT
R-134A 250 PPM 500 PPM 1’-6” (450mm) 20 ft. (6 m)
above the floor

E. Site Services:

1. Conduct site review of installed refrigeration plant and determine (finalize) most
suitable location(s) for refrigerant sampling point locations.

2. Manufacturer shall calibrate monitor and certify satisfactory system installation

and operation in writing to Engineer.

F. Operating and Maintenance Manual:

1. Supply three (3) bound operating and maintenance manuals each complete with:

a. a complete explanation of operation principles and sequences;

b. complete parts list with numbers;

c. recommended maintenance practices and precautions.

G. Acceptable manufacturers are Vulcain (USA), MSA Inc. (USA), or approved equal.

2.3 SELF-CONTAINED BREATHING APPARATUS

A. Survivair "Mark 2", or approved equal, open-circuit, positive pressure, self-contained

breathing apparatus to MSHA/NIOSH TC-13F-108 and NFPA 1981, with thirty (30)
minute duration Certified to MSHA/NIOSH 30-CFR-11; 15.3 MPa low pressure hoop
wrapped fiberglass tank; hypoallergenic silicone rubber face piece with memory, single
curved, wide-view lens with brow guard and inside anti-fog and outside surface scratch
resistant coatings, clear speaking diaphragm, large sealing area, raised lens guard,
four (4) point neck strap; redundant first stage regulator with distinctly different audible
alarm on first stage failure and end of service; second stage regulator with large control
ring and quick-connect; non-collapsing silicone rubber low pressure hose with

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fittings; strap mounted over shoulder tank status dial type indicator; alpine style
backpack with hinged support plate, "NOMEX"/"KEVLAR" straps, 1-piece stainless
steel cylinder band, lower cylinder support, buckles, loops, etc., and designed such
that equipment weight is
distributed over the hips.

B. The unit shall be equipped with a weatherproof housing clearly labeled with
“SELF-CONTAINED BREATHING APPARATUS”.

C. Site Services:

1. Manufacturer shall include for a minimum of six (6) hours of instruction to

Employer's staff by qualified personnel to demonstrate all facets of equipment
fitting, operation, maintenance, etc.
D. Operating and Maintenance Manual:

1. Supply three (3) bound, operating and maintenance manuals each complete with:

a. a complete explanation of operation principles and sequences;

b. complete parts list with numbers;

c. recommended maintenance practices and precautions.

PART 3 – EXECUTION

3.1 INSTALLATION OF REFRIGERATION MACHINE

A. Provide refrigeration machine where shown.

B. Secure each machine in place on vibration isolation on a concrete housekeeping pad.
Ensure that the machine is level to within 0.16” (4 mm).

C. Anchor the frame and concrete base in accordance with requirements specified in
Section entitled Seismic Control and Restraint. Provide flexible connections in all
piping connections.

D. Provide two (2) flow switches for each machine and install a flow switch in the chilled
water piping connection to the machine. Connect each flow switch to the machine control
panel to shut down the machine on a no flow condition. Provide all required sensors and
piping wells.

E. Provide a drain valve and vent cock for the water box of the machine. Pipe the pressure
relief rupture disc of the evaporator to atmosphere in accordance ASHRAE 15
requirements.

F. Provide all required refrigerant and oil.

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G. For low pressure refrigeration machines, provide valved chilled water supply piping
with strainer and valved chilled water return piping connections to the purge unit and oil
cooler on the machine. Piping shall be in accordance with the machine
manufacturer’s recommendations. In the chilled water piping to the purge condenser,
leave a piping tee for connection of domestic cold water piping as part of the plumbing
work specified in Division 22 “Plumbing”.

H. Insulate the cooler or evaporator water-box covers, compressor suction housing,

cooler relief valves and float chamber in accordance with the requirements of Division
20.

I. Supply a minimum of four (4) copies of complete wiring and piping connection
diagrams and details for proper execution and completion of the control circuits and
cooling water requirements.
J. Provide all required control wiring in conduit in accordance with requirements of
Electrical Division and in accordance with control wiring schematics and the machine
manufacturer's instructions.

K. Arrange for the refrigeration machine supplier to check machine installation prior to
start-up, to start-up the machine and to check out the machine through a performance
and acceptance test in the presence of and to the satisfaction of the Engineer, and to
completely instruct the Employer's designated operating personnel on proper machine
operation and maintenance. Supply and turn over to the Engineer, a minimum of four (4)
typewritten copies of machine start-up reports indicating all operating capacities and
performance, and a letter from the machine supplier stating that he (the supplier), has
checked the machine installation and found it to be in accordance with the
manufacturer's recommendations and instructions.

3.2 INSTALLATION OF REFRIGERANT CONCENTRATION MONITOR

A. Provide a complete refrigerant concentration monitor system where shown.

B. Exact location of sampling points and other components shall be determined on site by
the manufacturer upon review of completed refrigeration systems. Calibration of system
shall be on site by manufacturer.

C. Confirm location of monitor panels with Engineer prior to roughing in.

D. Install components in strict accordance with manufacturer's instructions and wiring
diagrams. Provide low voltage wiring in conduit per the requirements of Electrical
Division.

E. Forward four (4) copies of letter from manufacturer certifying satisfactory installation
and operation of system.

3.3 INSTALLATION OF SELF-CONTAINED BREATHING APPARATUS

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A. Provide two (2) self-contained breathing apparatuses and install as indicated by the
Engineer on site.

B. Arrange and coordinate instructions to Employer’s staff by manufacturer, at the

convenience of the Employer.

C. Provide two (2) spare tanks. Leave all tanks full.

END OF SECTION

23 60 00

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