SECTION 15622

PACKAGE WATER CHILLERS - CENTRIFUGAL AND SCREW

PART 1 GENERAL

1.1 SUMMARY

A. Section includes chiller package, charge of refrigerant and oil, controls and
control connections, chilled water connections, condenser water connections, auxiliary
water connections, starters, electrical power connections.

B. Related Sections:
1. Cast-In-Place Concrete: Execution requirements for concrete
housekeeping pads specified by this section.
2. Mechanical Sound, Vibration, and Seismic Control: Product
requirements for Vibration Isolators for placement by this section.
3. Mechanical Identification: Product requirements for chiller insulation for
placement by this section.
4. Heating and Cooling Piping: Execution requirements for chilled water
condenser water and refrigerant piping specified by this section.
5. Testing, adjusting, and Balancing: Execution requirements for testing
chillers specified by this section.
6. Wiring Connections: Execution requirements for connection to chillers
specified by this section.
7. Motors: Product requirements for electric motors for placement by this
section.

1.2 REFERENCES

A. ARI 550 (Air-Conditioning and Refrigeration Institute) - Centrifugal or Rotary

Water-Chilling Packages.

B. ASHRAE 15 (American Society of Heating, Refrigerating and Air-Conditioning

Engineers) - Safety Code for Mechanical Refrigeration.

C. ASHRAE 90A (American Society of Heating, Refrigerating and Air-

Conditioning Engineers) - Energy Conservation in new Building Design.

D. ASME SEC VIII (American Society of Mechanical Engineers) - Boiler and

Pressure Vessel Code.

E. UL 1995 (Underwriters Laboratories, Inc.) – Heating and Cooling Equipment.

1.3 SUBMITTALS

A. Submittal Procedures: Submittal procedures.

B. Shop Drawings: Indicate components, assembly, dimensions, weights and loads,

required clearances, and location and size of field connections. Indicate equipment,

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 piping and connections, valves, strainers, and thermostatic valves required for complete
system.

C. Product Data: Submit rated capacities, specialties and accessories, electrical

requirements and wiring diagrams.

D. Design Data: Indicate energy input versus cooling load output from 25 to 100
percent of full load at specified and minimum condenser water temperature.

E. Test Reports: Indicate results of factory performance test.

F. Manufacturer's Installation Instructions: Submit assembly, support details,

connection requirements, and include start-up instructions.

G. Manufacturer's Certificate: Certify products meet or exceed specified

requirements including components not produced by manufacturer.

1.4 CLOSEOUT SUBMITTALS

A. Execution Requirements: Closeout procedures.

B. Operation and Maintenance Data: Submit start-up instructions, maintenance data,

parts lists, controls, and accessories. Include trouble- shooting guide.

1.5 QUALITY ASSURANCE

A. Perform Work in accordance with standard.

B. Constriction and rating in accordance with ARI 550.

C. Maintain one copy of each document on site.

1.6 QUALIFICATIONS

A. Manufacturer: Company specializing in manufacturing products specified in this

section with minimum three years experience and with service facilities within 100 miles
of Project.

B. Installer: Company specializing in performing Work of this section with

minimum three years experience

1.7 PRE-INSTALLATION MEETING

A. Administrative Requirements: Pre-installation meeting.

B. Convene minimum one week prior to commencing Work of this section.

1.8 DELIVERY, STORAGE, AND HANDLING

A. Product Requirements: Product storage and handling requirements.

B. Comply with manufacturer's installation instructions for rigging, unloading, and

transporting units.

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 C. Protect units from physical damage. Leave factory covers in place until
installation.

1.9 FIELD MEASUREMENTS

A. Verify field measurements prior to fabrication.

1.10 WARRANTY

A. Execution Requirements: Product warranties and product bonds.

B. Furnish two five year manufacturer warranty to include coverage for compressor
motor evaporator condenser complete chiller package as manufactured and delivered to
site including materials only

1.11 MAINTENANCE SERVICE

A. Execution Requirements: Maintenance service.

B. Furnish service and maintenance of chillers for period of two years from Date of
Substantial Completion.

1.12 MAINTENANCE MATERIALS

A. Execution Requirements: Spare parts and maintenance products.

B. Furnish two containers of lubricating oil

PART 2 PRODUCTS

2.1 WATER CHILLERS

A. Manufacturers:
1. Baltimore Air coil Company
2. Carrier Corp.
3. Frick Co.
4. The Trane Company
Or approved equal

B. Furnish materials in accordance with standards.

C. Factory assembled and tested, packaged, water cooled, liquid chillers consisting
of centrifugal or screw compressors, compressor motor, condenser [s], evaporator,
refrigeration accessories, instrument and control panel including gages and indicating
lights, auxiliary components and accessories, and motor starters.

D. Use Energy Efficiency Ratings not less than prescribed by ASHRAE 90A.

E. Conform to ASHRAE 15 code for construction and operation of chillers.

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 2.2 CENTRIFUGAL COMPRESSORS

A. Compressor Casing: Cast iron, horizontally or vertically split with machined

passages. Leak test with refrigerant trace gas to pressure suitable for refrigerant used.
Furnish sight glass for monitoring compressor rotation.

B. Impellers: Single or multi-stage, in-line design, statically and dynamically

balanced, tested to 20 percent over operating speed, mounted on heat treated forged or
rolled steel shaft, nonferrous, labyrinth seals between stages.

C. Guide Vanes: Modulating or fixed dampers, with externally mounted electric,

suitable for capacity reduction to 10 percent of specified load without hot gas bypass.
Minimum capacity when supplied with design entering water flow rate and 55 degree F
design temperature entering condenser water.

D. Gear Box: Helical design, center supported by spherically seated, self-aligning

bearing, arranged for inspection without disassembly.

E. Motor: Hermetically sealed, singled speed, low slip induction type. Refer to
Section 16225.

F. Lubrication: Direct drive, positive displacement oil pump, with oil cooler,
pressure regulator, oil filters, thermostatically controlled oil heater, and motor controls.
Interlock to start before chiller motor and run after motor is shut down. Furnish sight
glass for monitoring oil level.

G. Refrigerant: Pre-charge unit with HFC-134a Site-charge unit with HCFC-123

2.3 Screw Compressors:

A. Unit: Direct drive, semi-hermetic 3600 RPM, fixed compression, rotary screw
compressor with control panel.

B. Features: Differential refrigerant pressure oil pump, oil heater, oil separator and
filter and oil charging valve.

C. Motor: Suction gas-cooled, hermetically sealed, squirrel cage induction.

D. Control panel: Factory mounted NEMA 4 panel with starter and refrigeration
controls including:
1. Non-fused molded case, disconnect switch.
2. Single point power connection and grounding lug.
3. Anti-recycle timer.
4. Solid state overload relay for each compressor.
5. Phase loss/reversal monitor.
6. Cycle counter and hour meter for each compressor.
7. Low and high, pressure control.
8. Automatic shutdown compressor overload and low and high refrigerant
pressure.

E. Automatic Capacity Reduction: Continuously variable slide valve with control to

25 percent of full load.

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 2.4 EVAPORATOR

A. Shell and tube type, seamless or welded steel construction with cast iron or
fabricated steel, heads, seamless copper tubes with integral fins, rolled or silver brazed
into tube sheets. Space tube support sheets approximately 3 feet

B. Design, test, and stamp for working pressure suitable to refrigerant used, in
accordance with ASME SEC 8.

C. Furnish marine type water boxes, with tapped drain and vent connections, and
flanged or mechanical joint connections arranged to permit inspection of tubes from
either end without disturbing refrigerant.

D. Insulate evaporator and cold surfaces with 0.75 inchminimum thick flexible
expanded polyvinyl chloride insulation with maximum K factor of 0.28.

E. Furnish thermometer wells for temperature controller and low temperature

cutout.

F. Furnish refrigerant chambers with baffles to distribute entering liquid and

separate liquid from leaving gas.

G. Furnish carbon rupture disc on shell or settable pressure relief valves in

accordance with ASHRAE 15.

H. Furnish construction and materials in accordance with ASME SEC VIII.

2.5 CONDENSERS

A. Shell and tube type, seamless or welded steel construction with cast iron or
fabricated steel heads, seamless copper tubes or red brass tubes with integral fins, rolled
or silver brazed into tube sheets. Space tube support sheets approximately 2.5 ftFurnish
additional condensers on heat recovery units.

B. Design and stamp for working pressures suitable to refrigerant used in

accordance with ASME SEC VIII.

C. Furnish marine type water boxes, with tapped drain and vent connections, and
flanged or mechanical joint connections arranged to permit inspection of tubes from
either end without disturbing refrigerant.

D. Furnish carbon rupture disc on shell in accordance with ASHRAE 15.

E. Furnish baffles for even distribution of incoming gas and to concentrate non-
condensing gases.

F. Furnish construction and materials in accordance with ASME SEC VIII.

2.6 PURGE SYSTEM

A. Furnish purge system when water chiller uses refrigerant with less than
atmospheric pressure on suction side of compressor at any point in its operation.

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 B. Furnish low temperature refrigeration purge system to automatically remove
non-condensing gases, water and air independent of chiller operation.

C. Use system discharge with maximum 0.10 poundof refrigerant for each poundof
air discharged.

2.7 CONTROLS

A. On or near chiller, mount steel control panel containing solid state, fully
automatic operating and safety controls.

B. Furnish the following safety controls arranged so operating any one shuts down
machine and requires manual reset:
1. High condenser refrigerant pressure.
2. Low oil pressure.
3. High oil temperature.
4. High motor current.
5. High motor temperature.
6. Low refrigerant (evaporator) pressure.
7. High bearing temperature.

C. Furnish the following safety controls arranged so operating any control shuts
down machine:
1. Low chilled water temperature.
2. Chilled water flow switch.
3. Condenser water flow switch.

D. Furnish manual machine off-auto switch on control panel and the following
manual or software and menu driven devices.
1. Oil pump switch.
2. [Purge pump switch].
3. Machine selector switch to allow load, unload and hold or automatic
operation.
4. Manual Set Point Adjustments:
a. Leaving chilled water temperature.
b. Current demand limit.
5. Status display:
a. Chilled water flow proven.
b. Cooling required.
1) Unit running.
2) Unit loading.
3) Unit unloading.
4) Manual reset required.
5) Remote chilled water set point active.
6) Remote current water set point active.
6. Set point and Temperature Display:
a. Chilled water set point.
b. Current limit set point.
c. Entering evaporator water temperature.
d. Leaving evaporator water temperature.
e. Entering condenser water temperature.
f. Leaving condenser water temperature.

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 7. Dial or Electronic Type Pressure Indicators.
a. Evaporator refrigerant pressure.
b. Condenser refrigerant pressure.
c. Low oil pressure (oil sump).
d. High oil pressure (oil supply).

E. Furnish the following operating controls:

1. Solid state chilled water temperature controller controlling electronic
guide vane operator [and hot gas bypass. Locate temperature sensor in entering
and leaving chilled water.
2. Adjustable thirty-minute off timer prevents compressor from short
cycling.
3. Demand limit device to manually set maximum current infinitely
between 40 percent and 100 percent of full load amperes.
4. Automatic start, determining demand for chilled water from proof of
chilled water flow and temperature differential between chilled water set point
and supply temperature.
5. Solenoid valve between heat recovery condenser and receiver to limit
refrigerant level in condenser.

2.8 ELECTRICAL CHARACTERISTICS AND COMPONENTS

A. Wiring Connections: Requirements for electrical characteristics.

B. Motors: Requirements for motors.

C. Disconnect Switch: Factory mount in control panel

2.9 MOTOR STARTER

A. On or near chiller, mount steel NEMA type 1 enclosure, containing Star-Delta

closed transition full voltage auto-transformer, closed transition starter, manufactured in
accordance with chiller manufacturer's specifications and factory tested.

B. Design enclosure for top or bottom cable entry with front access. Furnish door,
interlocked with circuit breaker, to accommodate padlock.

C. Mount the following devices within enclosure:

1. Disconnect switch on line side with fuses or circuit breaker with ground
fault protection.
2. Pilot relays to start and stop compressor on signal from chiller control
panel.
3. Electronic overload provides overload protection, protects compressor
motor from distribution system irregularities, and provides motor current signal
to chiller capacity control module.
4. Control power transformer.
5. Fused control circuits for control circuit, oil pump motor, oil heater, and
purge control unit.
6. Contactor interlocks for communication between starter and control
panel.
7. Capacitors, one for each phase, to correct power factor to minimum
percent.

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 8. Fused disconnect and starter for oil pump.
9. Relay for remote mounted emergency shutdown switch.

D. Furnish the following devices on starter door or equivalent on unit control panel:
1. Starter fault trip indicator and reset.
2. Overload trip indicator and reset.
3. Distribution fault trip indicator and reset.
4. Ground fault trip indicator and reset.
5. Ammeters, one for each phase.
6. Voltmeters, one for each phase.

2.10 SOURCE QUALITY CONTROL (AND TESTS)

A. Furnish shop inspection and testing of completed chiller.

B. Conform to ARI 550 code for testing of chillers. Furnish report of factory full
performance test.

C. Conform to UL 1995 code for construction of chillers [and furnish UL label].

D. Conform to ASME SEC VIII for construction and testing of chillers.

E. Make completed chiller available for inspection at manufacturer’s factory prior

to packaging for shipment. Furnish seven days notice before packaging is scheduled.

F. Allow witnessing of factory inspections and tests at manufacturers test facility.

Furnish seven days notice before inspections and tests are scheduled.

PART 3 EXECUTION

3.1 INSTALLATION

A. Install Work in accordance with standards.

B. Provide for connection of electrical wiring between starter and chiller control
panel, oil pump, and purge unit.

C. Install chiller on concrete housekeeping pad minimum 3-1/2 incheshigh and 6

incheswider than chiller base on each side.

D. Install units on vibration isolation. Refer to Section 15070.

E. Install the following piping accessories on evaporator chilled water piping

connections.
1. On inlet:
a. Thermometer well for temperature controller.
b. Thermometer well and thermometer.
c. Strainer.
d. Nipple and flow switch.
e. Flexible pipe connector.

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 f. Pressure gage.
g. Shut-off valve.

2. On outlet:
a. Thermometer well and thermometer.
b. Flexible pipe connector.
c. Pressure gage.
d. Balancing valve.

F. Provide auxiliary water piping for oil cooling units and purge condensers.

G. Insulate evaporator and cold surfaces.

H. Install the following piping accessories on condenser water piping connections.

1. On inlet:
a. Thermometer well for temperature controller.
b. Thermometer well and thermometer.
c. Strainer.
d. Nipple and flow switch.
e. Flexible pipe connector.
f. Pressure gage.
g. Shut-off valve.
2. On outlet:
a. Thermometer well and thermometer.
b. Flexible pipe connector.
c. Pressure gage.
d. Balancing valve.

I. Arrange piping for easy dismantling to permit tube cleaning.

J. Install piping from chiller rupture disc to outdoors. Size as recommended by

manufacturer.

3.2 MANUFACTURER'S FIELD SERVICES

A. Quality Requirements: Manufacturers’ field services.

B. Furnish services of factory trained representative for minimum one day to leak
test, refrigerant pressure test, evacuate, dehydrate, charge, start-up, calibrate controls, and
instruct Owner on operation and maintenance.

C. Furnish initial charge of refrigerant and oil.

3.3 DEMONSTRATION AND TRAINING

A. Demonstrate operation and verify unit delivers specified chilled water

temperature.

END OF SECTION 15622

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