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SECTION 15785 – PCA AIR HANDLING UNITS

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 the following types of Preconditioned Air (PCA) air handling units:

1. Point-of-Use, Water Cooled Air Handling Units.

B. Work of this section, including selection and procurement of equipment and materials,
installation, and testing for PCA systems, shall be performed by prequalified manufacturer
and Installer.

C. The chilled water/DX air handling units shall be capable of operating with all temperature
ranges. Unit designs shall achieve the scheduled cooling capacity.

1. All air handling units shall be capable of a one hour “pull down” time for their
respective heat “soaked” aircraft.

D. Related Sections include the following:

1. Division 15 Section "Mechanical Vibration Controls and Seismic Restraints".

2. Division 15 Section "Duct Insulation".
3. Division 15 Section "Equipment Insulation".
4. Division 15 Section "Piping Insulation".
5. Division 15 Section "Hydronic Piping".
6. Division 15 Section "Refrigerant Piping".
7. Division 15 Section "HVAC Water Treatment".
8. Division 15 Section "HVAC Instrumentation and Controls".
9. Division 15 Section "Sequence of Operation".

0.3 REFERENCES

A. Materials and workmanship shall conform to the latest issue of all industry standards,
publications, or regulations referenced in this section and with the following references as
applicable.

1. Air-Conditioning and Refrigeration Institute (ARI).

a. 410 – Standard for Forced-Circulation Air-Cooling and Air Heating Coils.

b. 850 – Commercial and Industrial Filter Equipment.

2. American Society of Heating, Refrigerating and Air-Conditioning Engineers

(ASHRAE):

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a. 15 – Safety Code for Mechanical Refrigeration.

b. 34 – Number Designation and Safety Classification of Refrigerants.
c. 52 – Method of Testing Air-Cleaning Device Used in General Ventilation for
Removing Particulate Matter.
3. ASME Section 8 – Boilers and Pressure Vessels Code.

0.4 SUBMITTALS

A. Shop Drawings: Indicate assembly, unit dimensions, weight loading, required clearances,
construction details, field connection details, and electrical characteristics and connection
requirements.

B. Product Data:

1. Provide literature which indicates dimensions, weights, capacities, ratings, fan

performance, gages and finishes of materials, and electrical characteristics and
connection requirements.
2. Provide fan curves with specified operating point clearly plotted.
3. Submit sound power level data for both fan outlet and casing radiation at rated
capacity.
4. Submit electrical requirements for power supply wiring including wiring diagrams for
interlock and control wiring, clearly indicating factory-installed and field-installed
wiring.

C. Manufacturer’s Installation Instructions.

D. General: Comply with all requirements of Division 1 Specifications as applicable to quality

control and required submittal of inspection records, test reports, and certifications.

E. Working Procedures: Submit proposed working procedures for the installation / erection of
work of this Section to the Engineer for his approval sufficiently in advance of commencing
any work affected by the working procedures.

0.5 OPERATION AND MAINTENANCE DATA

A. Maintenance Data: Include instructions for lubrication, filter replacement, motor and drive
replacement, spare parts lists, and wiring diagrams.

0.6 QUALITY ASSURANCE

A. ARI Compliance: Coils shall comply with ARI 410; air filter equipment shall comply with
ARI 850.

B. ASHRAE Compliance: Air filters shall comply with ASHRAE Standard 52 for method of
testing, and for recording and calculating air flow rates; and Standard 15 Safety Code for
Mechanical Refrigeration.

C. Codes and Regulations: Comply with applicable codes and regulations for components and
installation of air handling units.

D. Listing and Labeling: Provide electrically operated components specified in this Section
that are listed and labeled.

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E. Comply with listed and labeled as defined in latest and relevant IEC standard, by a testing
agency acceptable to the Engineer.

0.7 DELIVERY, STORAGE, AND HANDLING

A. Lift and support units with the manufacturer’s designated lifting or supporting points.

B. Disassemble and reassemble units as required for movement into the final location,
following manufacturer’s written instructions.

C. Deliver fan units as factory-assembled units to the extent allowable by shipping limitations,
with protective crating and covering.

D. Store all equipment and material in suitable facilities until delivery and acceptance by the
Engineer.

E. Each air handling unit shall be easily mounted and removed from the aircraft bridge without
permanent damage to the bridge or its operation.

0.8 PERFORMANCE TESTING

A. Contractor or Named Subcontractor, as applicable, is responsible for making preparatory

arrangements for testing and scheduling activities with the testing agency and the Engineer.

B. Advise Engineer 14 days in advance of all testing so Engineer may be present for
witnessing. Manufacturer shall also be present for all testing.

C. Performance testing of the PCA air handling units shall be conducted in accordance with
ASHRAE Test Procedure 37-88. The Named Subcontractor shall provide a 65-foot hose and
aircraft adapter nozzle for the test.

D. Factory Tests: Named Subcontractor is to arrange and pay for attendance of two DCA
engineers and The Engineer for witnessing performance of PCA units in tests conducted at
the factory. One fully assembled unit of each type and size of units required for the project
shall be tested at design conditions, with output to be recorded and approved by the
Engineer before equipment is dispatched from the factory.

0.9 GUARANTEE

A. Compressors with horsepower ratings up to and including 15 HP shall be guaranteed for a

period of 5 years from the date of Substantial Completion.

0.10 EXTRA MATERIALS

A. Deliver to the Government, before final acceptance of the project, the following spare parts
and system materials, in containers or packaging approved by the Engineer:

1. One spare set of air filters for each PCA unit.

2. Refrigerant and compressor oil, in approved containers, sufficient to recharge two of
the largest compressors provided for the units.
3. One spare refrigerant compressor of each type and capacity installed.

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4. One spare fan motor of each type and capacity installed.

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 GENERAL DESCRIPTION

A. Provide preconditioned air PCA chilled water / DX air handling units for interior installation
in equipment rooms as shown on the drawings.

B. Units shall be free of vibration transmission and installed with vibration isolators as
necessary.

C. The PCA air handling unit at each gate shall contain evaporator coil(s), high pressure
evaporator fan with variable frequency drive to cater for different types of aircraft cabins,
compressor(s), chilled water coil, heat exchanger and circulation pump, refrigeration and
temperature controls, smoke detector, filters, complete motor starting equipment (including
disconnect switch), condensate drain pan, and condensate discharge pump (where gravity
drain to drainage system cannot be accomplished) to provide the required cooled or
ventilated air to maintain the aircraft cabin temperature specified.

D. The air handling unit(s) shall have the capacity required to sufficiently cool the largest
designated aircraft parked at a gate, considering quantity of air to be delivered and static
pressures. All PCA units, including components and accessory devices, shall be specifically
designed to provide reliable operation at ambient temperature of 50 degrees C without any
mechanical or electrical damage, degradation of operating characteristics, or loss of normal
life expectancy.

1. Units serving wide-body and B-747 gates shall also operate properly when serving a
narrow-body aircraft at the same gate.

E. The supply air blower shall be centrifugal type and sized for the appropriate variable
volume airflow requirements to cater for different types of aircraft cabins. The unit size
shall be selected so that the fan brake horsepower does not exceed the maximum required
over the design operating range of the unit at the total static pressure.

F. Unit external static pressure shall be defined as the gauge pressure measured at the outlet of
the air handling unit.

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1. The Named Subcontractor shall submit, for approval, information presenting the
gauge pressure whish his proposed air handling unit can produce at the outlet of the
air handling unit and at the aircraft connection through supply ductwork and 19.8 m
(65 feet) of hose with an aircraft adapter nozzle.

G. Motor kW (horsepower) shall be selected based on the Named Subcontractor’s choice of

equipment which affects the external resistance of the system.

1. However, the minimum motor kW rating for narrow-body air handling unit shall be
11.2 (15 hp), a wide-body air handling unit shall be 22.4 (30 hp); and a B-747 air
handling unit shall be 37.3 (50 hp).
2. Named Subcontractor shall furnish the fan motor and unit size adequate for final total
static pressure and maximum brake horsepower requirements.

H. Return air, from aircraft to the PCA unit shall not be utilized.

I. The construction of the units shall be:

1. of a material sufficient to provide adequate structural rigidity of frame and enclosure;

2. of a non corrosive nature; and,
3. provided with thermal insulation for conditions encountered in normal usage.

J. Equipment exterior shall be primed and painted to match bridge color. Equipment interior
color shall be manufacturer’s standard. Enclosure finish shall be as follows, or approved
substitute having equivalent resistance to corrosion:

1. All steel parts, except internal galvanized surfaces (if used), shall be cleaned and a
zinc-phosphate pre-treatment applied prior to paint application.
2. Painting system shall be specially formulated and applied to ensure protection of
surfaces from saline dust and high humidity conditions. The average thickness of the
paint film shall be 0.05 mm. Paint film shall be uniform in color and free from
blisters, sags, flaking and peeling.
3. Adequacy of paint finish to inhibit the buildup of rust on ferrous metal materials shall
be tested and evaluated per paragraphs 5.2.8.1-7 of ANSI C37.20.2-1987. Salt spray
withstand tests in accordance with ASTM D1654 and B117 shall be performed on a
periodic basis to provide conformance with the corrosion resistance standard of at
least 2500 hours minimum.

K. The maximum sound level for the chilled water/DX air handling units at maximum cooling
shall not exceed 85 dBA at a distance of 4.6 m from the unit. Sound power level radiated by
the unit outlet and at the unit inlet when the unit is operated at the designated capacity shall
be furnished with the submittal.

L. Provide “dirty filter” indicator gauge for each air handling unit.

M. Capacity control and defrost control shall be identified and fully described in submittal.

N. Provide access doors of the hinge type. Locate as required for proper access to the
following:

1. Compressors.
2. Blower/damper.
3. Circulation Pump and Heat Exchanger.
4. Filters.
5. Coils.
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O. A condensate pump and drain pan shall be provided for each chilled water/DX air handling
unit where gravity drain to the ramp drains is not possible.

1. The condensate pump shall be lightweight, self-priming, and capable of running

without damage under no-flow conditions.
2. Minimum pump rating shall be 0.2 L/sec (3 gpm), 120 kPa (40-foot) head, 250 W
(1/3 hp) motor. Position the drain pan under the coil selection.
3. Drain pan shall be stainless steel.

P. Control system shall be factory equipped with all necessary interface communication to
BMS on BACN protocol. Controls panel shall include, but are not limited to:

1. A remote “start/stop” push-button station shall be provided, accessible from the

ground level for each AHU.
2. “ON” light.
3. “Ready” light.
4. Cool/ventilate/heat push-button.
5. Other push-button as applicable.

Q. Internal ductwork of air handler shall be stainless steel construction.

R. Variable Frequency Fan Motor Drive (VFD):

1. VFD shall consist of a 3-phase converter for 50 Hz line to variable frequency,

variable voltage output, suitable for a Standard NEMA Design B motor.
2. Torque characteristics shall match drive load.
3. Provide with disconnect, current limiting fuses, rated 200, 000 A/C.
4. Control shall allow for 4-20 ma speed control signal, “Hand/Off/Auto” selector
switch motors, indicating lights and auxiliary contacts. Protective features include
power surge, over voltage, over current, random short circuit and extend load
disconnect.

0.3 COMPONENTS

A. Casing:

1. Double-wall casing construction with insulation between wall panels, having

corrosion protection coating, and exterior finish. Casings shall have removable panels
or access doors for inspection and access to internal parts, knockouts for electrical, a
minimum of 38 mm thick thermal insulation of type specified in Section 15854,
knockouts for electrical and exterior condensate drain connection, and lifting lugs.
2. Where the fan is located upstream of the cooling coils, the casing shall be reinforced
and sealed as appropriate for the unit’s operating pressure, but in no case less than
6.97 kPa. The fan compartment in all cases shall meet this criteria.

B. Fans:

1. General: Provide fans that are factory fabricated and assembled, factory tested, and
factory finished, with required capacities and characteristics.
2. Fans and Shafts: Statically and dynamically balanced and designed for continuous
operation at the maximum rated fan speed and motor horsepower.

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a. Fan Shaft: Turned, ground, and polished steel designed to operated at no more
than 70% of the first critical speed at the top of the speed range of the fan’s
class.
b. Shaft Bearings: Provide bearings having a median life “Rating Life” (AFBMA
L50) of 200, 000, calculated in accordance with AFBMA 9 for ball bearings of
AFBMA 11 for roller bearings.

3. Factory Finish: Finish shall be as follows, or approved substitute having equivalent

resistance to corrosion:

a. All steel parts, except internal galvanized surfaces (if used), shall be cleaned
and a zinc phosphate pre-treatment applied prior to paint application.
b. Exterior paint color shall match loading bridge color, and painting system shall
be specially formulated and applied to ensure protection of surfaces from saline
dust and high humidity conditions. The average thickness of the paint film
shall be 0.05 mm. Paint film shall be uniform in color and free from blisters,
sags, flaking and peeling.
c. Adequacy of paint finish to inhibit the buildup of rust on ferrous metal
materials shall be tested and evaluated per paragraphs 5.2.8.1-7 of ANSI
C37.20.2-1987. Salt spray withstand tests in accordance with ASTM D1654
and B117 shall be performed on a periodic basis to provide conformance with
the corrosion resistance standard of at least 2500 hours minimum.

4. Fans: Forward-curved, centrifugal, direct-drive fans; and permanently lubricated

motor bearings.

C. Coils:

1. Copper plate fins or spiral wound fins and seamless copper tube type.
2. Coils shall have a galvanized steel casing.
3. Coils shall be mounted in the coil casing with same end connections accessible for
service.
4. Coils shall be removable from the unit.
5. Coil section shall be completely insulated.
6. The number of tubes and fin spacing shall be submitted on coil selections made.
7. DX coils shall be proof tested at 2760 kPa (400 psig) and leak tested at 1724 kPa (250
psig) with air pressure under water, then cleaned, dehydrated, and sealed with a
holding charge of nitrogen.
8. Chilled water coils shall be proof tested at 1375 kPa (200 psig).
9. Provide, for each DX coil, expansion valve, solenoid valve and distributor.

D. Compressors:

1. Serviceable, semi-hermetic, or hermetic scroll compressors with vibration isolators.

a. Describe capacity control method in submittal, (i.e. cylinder unloaders, hot-gas

bypass).
b. Thermal expansion valves, filter dryers, permanently mounted or portable
electronic sight glasses, compressor service valves (if required by
manufacturer), liquid line service valves (if required by manufacturer) ;and
minimum of two refrigerant circuits for units having two or more compressors.

2. Safety Controls:

a. Low pressure cutout, automatic reset;

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b. High pressure cutout, automatic reset;

c. Compressor motor overload protection, manual reset;
d. Anti-recycling timing device;
e. Oil pressure switch, if required by manufacturer.

3. Refrigerant: Refrigerant used shall be a Hydrochlorofluorocarbon (HCFC) or

Hydrofluorocarbon (HFC) product as referenced by ASHRAE Standard 34, and shall
conform to applicable local environmental regulations.

E. Airflow Control: Airflow control may be by inlet damper, variable air volume control or
other proven method. Describe proposed airflow control in submittal.

F. Air filters:

1. Provide factory fabricated, viscous-coated, flat panel type replaceable air filters with
holding frames; with 50 mm thick UL Class 2 washable media material; construct
media of interlaced glass fibers, spray with nonflammable adhesive, frame in
throwaway fiberboard casings, and sandwich between perforated metal grills.
2. Construct holding frames of galvanized steel, capable of holding media and media
frame in place, and gasketed to prevent unfiltered air by-passing between media
frames and holding members.
3. Provide filters with rated face velocity of 2.5 m/sec, initial resistance of not greater
than 75 Pa (0.30 inches water gauge), final rated resistance of 125 Pa (0.50 inches
water gauge) and average arrestance of 80 percent.

G. Shell and Tube Type Heat Exchanger:

1. Tubes shall be U-tube with 20 mm (3/4 inch) O.D. min. seamless cupro-nickel tubes
suitable for 862 kPa (125 psi) working pressure.
2. Shell shall be steel with threaded pipe connections and necessary tappings.
3. Heads shall be Fabricated Steel with threaded pipe connections.
4. Design shall be for refrigerant condenser application.

H. Circulation Pump:

1. Type: Horizontal shaft, single stage, direct connected, with resiliently mounted motor
for in-line mounting, oil lubricated, for 862 kPa maximum working pressure.
2. Casing: Cast iron, with flanged pump connections.
3. Impeller: Cadmium plated steel, stamped brass or cast bronze, keyed to shaft.
4. Bearings: Two, oil lubricated bronze sleeves.
5. Shaft: Alloy or stainless steel with copper or bronze sleeve, integral thrust collar.
6. Seal: Carbon rotating against a stationary ceramic seat, 100 degrees C maximum
continuous operating temperature.
7. Drive: Flexible coupling.
8. Performance: As shown on the Drawings.
9. Wiring Terminations: Provide terminal lugs to match branch circuit conductor
quantities, sizes, and materials indicated. Enclose terminal lugs in terminal box sized
to NFPA 70.

I. Motors: Provide motors in accordance with Section 15170.

J. Temperature Control:

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1. Factory-installed, demand-oriented solid-state control system with minimum of two

cooling steps. Controls include solid-state thermostats with dead-band, and subbase
with system and fan switches. Other control features include:
a. Discharge temperature reset capability with space temperature override.

K. Accessories: Units shall include the following accessories:

1. Control Panel: Furnish panel for mounting on air handling unit which contains
control of cooling, evaporator fan, and volume control; and indicator lights for up to
six unit functions.
2. Anti-recycling control to automatically prevent compressor restart for 3 minutes after
shutdown.
3. Thermostat: Assembly shall provide for staged cooling with manual or automatic
changeover on standard subbase.
4. Energy Usage Metering: Systems shall include:

a. Solid state electronic metering of electrical input to units, providing for digital
analog readout of kilowatt hours expended during each gate occupancy by an
aircraft.
b. Metering of thermal energy expended in supporting PCA cooling load
(kolojoules extracted by the building chilled water system supplying cooling
service to PCA units), totalized for each gate occupancy by an aircraft.

PART 3 - EXECUTION

0.1 EXAMINATION

A. Examine areas and conditions, with Installer present, for compliance with requirements for
installation tolerances and other conditions affecting performance of air handling units.

B. Do not proceed until unsatisfactory conditions have been corrected.

0.2 INSTALLATION, GENERAL

A. PCA air handling units shall be mounted in the designated PC air mechanical room located
at the end of the fixed portion of the bridge. All units shall be supported from the floor.
Where there is only one unit, it shall be mounted low.

B. Arrange installation of units to provide access space around air handling units for service
and maintenance.

C. Furnish all necessary supports, brackets, guard posts, safety hooks, etc., for properly
installing all air handling units.

D. All air handling units shall be properly aligned, adjusted and lubricated before final
acceptance.

0.3 CONNECTIONS

A. Make final duct connections with flexible connections.

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B. Electrical Connections: The following requirements apply:

1. Electrical power wiring shall be as shown on the drawings and specified.

C. Piping Connections: Final connections between unit and building chilled water system shall
be made with steel piping and flexible connections matching connections for building
HVAC system air handling units.

0.4 FIELD QUALITY CONTROL

A. Manufacturer’s Field Inspection: Arrange for and pay for a factory authorized service
representative to perform the following:

1. Inspect the field assembly of components and installation of air handling units
including ductwork and electrical connections.
2. Prepare a written report on findings and recommended corrective actions.

0.5 DEMONSTRATION

A. Start-up Services:

1. Provide the services of a factory-authorized service representative to start-up PCA

chilled water/DX air handling units, in accordance with manufacturer’s written start-
up instructions.
2. Test controls and demonstrate compliance with requirements.
3. Replace damaged or malfunctioning controls and equipment.
4. Provide training sessions for the employers' maintenance personnel.

0.6 ADJUSTING, CLEANING, AND PROTECTING

A. Check variable inlet damper for proper damper operation.

B. Clean unit cabinet interiors to remove foreign material and construction dirt and dust.

C. Vacuum clean fan wheel and cabinet.

END OF SECTION 15785

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