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PROJECT STANDARD SPECIFICATION

SECTION 15684 - ROTARY-SCREW CHILLERS

PART 1 - GENERAL

0.1 RELATED DOCUMENTS

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

0.2 SUMMARY

A. This Section includes packaged, rotary-screw water chillers.

B. Related Sections include the following:

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

chiller vibration isolation requirements.
2. Division 15 Section "Hydronic Piping" for chiller piping requirements.
3. Division 15 Section "Refrigerant Piping" for chiller piping requirements.
4. Division 15 Section "HVAC Water Treatment" for chemically treating chilled and
condenser water.
5. Division 15 Section "HVAC Instrumentation and Controls" for temperature-control
devices for chillers.
6. Division 15 Section "Sequence of Operation" for temperature-control sequences for
chillers.

0.3 SUBMITTALS

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

1. Accessories.
2. Spare Parts.
3. Vibration Isolators.

B. Certificates to standards of manufacturing and testing shall be submitted for following items
showing conformance with the referenced standards contained in this section:

1. Compressor.
2. Motor.
3. Control Panel.
4. Condenser.
5. Evaporator.
6. Refrigerant Circuit.
7. Alarm Systems.
8. Vibration Isolators.
9. Gages.

C. Manufacturer's Instructions shall be submitted for water-cooled screw chiller units including
manufacturer's style or catalog numbers, specification and drawing reference numbers,
warranty information, and fabrication site information.

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D. Operation and Maintenance Data shall be submitted in accordance with paragraph entitled,
"Manufacturer's Field Service," of this section.

E. Product Data: Include refrigerant; rated capacities; shipping, installed, and operating
weights; noise criteria; furnished specialties; and accessories for each model indicated.
Product Data: Equipment and Performance Data shall be submitted for the following items
indicating use life, system functional flows, safety features, and other features such as
electrical system protective device ratings.

1. Chiller Unit.
2. Compressor.
3. Condenser.

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

remedies, limitations, and exclusions.

G. Shop Drawings: Signed and sealed by a qualified professional engineer. Connection

diagrams shall be submitted indicating the relations and connections of the following items.
The drawings shall indicate the general physical layout of all controls, and internal tubing
and wiring details.

1. Compressor.
2. Motor.
3. Control Panel.
4. Condenser.
5. Evaporator.
6. Refrigerant Circuit.
7. Alarm Systems.
8. Vibration Isolators.
9. Gages.
10. Control Diagrams shall be submitted for water-cooled screw chiller units showing the
physical and functional relationship of equipment. Electrical diagrams shall show
size, type, and capacity of the systems.
11. Wiring Diagrams: Detail wiring for power, signal, and control systems and
differentiate between manufacturer-installed and field-installed wiring.

H. Design Calculations: Calculate requirements for selecting vibration isolators and seismic
restraints and for designing vibration isolation bases.

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

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

1. Structural supports.
2. Piping roughing-in requirements.
3. Wiring roughing-in requirements.
4. Determine spaces reserved for electrical equipment.
5. Access requirements around other work, including working clearances to mechanical
controls and electrical equipment.
6. Required clearances for operation and maintenance.

K. Product Certificates: Certification of performance according to ARI 550 and that chillers
have been started and function properly.
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L. Factory Test Reports: Reports shall certify the compliance with performance requirements
and follow the format of the required testing standard for both the Chiller Performance Tests
and the Chiller Sound Tests. Test report shall include certified calibration report of all test
instrumentation. Calibration report shall include certification that all test instrumentation
has been calibrated within 6 months prior to the test date, identification of all
instrumentation, and certification that all instrumentation complies with requirements of the
test standard. Test report shall be submitted one week after completion of the factory test.

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

1. Date and outside weather conditions.

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

a. The refrigerant used in the system.

b. Condensing temperature and pressure.
c. Suction temperature and pressure.
d. Running current, voltage and proper phase sequence for each phase of all
motors.
e. The actual on-site setting of all operating and safety controls.
f. Chilled water pressure, flow and temperature in and out of the chiller.

N. Field Test and Commissioning Reports: As specified in "Field Quality Control" and
"Commissioning" Articles in Part 3 of this Section. Indicate and interpret test results for
compliance with performance requirements.

O. Maintenance Agreement: As specified in this Section.

P. Maintenance Data: For each chiller to include in the operation and maintenance manual
specified in Division 1.

Q. Warranties: Warranties specified in this Section.

R. Certification of performance and factory test results specified in "Factory Tests" Article.

0.4 QUALITY ASSURANCE

A. ARI Compliance: Rate chiller according to ARI 550.

B. ASHRAE Compliance: Conform to ASHRAE 15 for chiller design, construction, leak

testing, and installation.

C. ASME Compliance: Comply with ASME Boiler and Pressure Vessel Code, Section VIII,
Division 1, for construction and testing of evaporator and condenser pressure vessels. Label
evaporator and condenser with ASME mark.

D. UL Compliance: Comply with UL 465.

E. Comply with latest and relevant IEC standard and IEE wiring regulation 16 th edition.

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F. Refrigerant Exposure: Monitor machine room and sound audible alarm and shut-down
chiller if refrigerant concentrations exceed 10 ppm.

0.5 WARRANTY

A. Manufacturer's Warranty: Provide a written warranty signed by the chiller manufacturer

and countersigned by the Contractor, agreeing to furnish parts for compressor and motor
failures within specified warranty period.

1. Warranty Period: 5 years from date of Substantial Completion.

0.6 MAINTENANCE SERVICE

A. Maintenance: Submit four copies of manufacturer's "Agreement for Continued Service and
Maintenance," before Substantial Completion, for the Employer's acceptance. Offer terms
and conditions for furnishing consumables and providing continued testing, maintenance
and servicing to include replacing materials and components. Include one-year term of
agreement, commencing at date of Substantial Completion, with option for one-year
renewal.

PART 2 - PRODUCTS

0.1 STANDARD COMMERCIAL PRODUCTS

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

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

0.2 MANUFACTURED UNIT

A. Description: Factory-assembled and -wired rotary-screw water chiller. Packaged chiller

consists of one or more rotary-screw compressors, an evaporator or cooler, air-cooled
condenser, safety controls, and operational controls.

0.3 REFRIGERANT

A. Material: R-134a (HFC-134a); provide full operating charge of refrigerant and oil.

1. Refrigerant Circuit: Provide refrigerant charging port.

B. Vent Pipe: Provide black steel vent pipe from rupture disk to exterior of building. . Delete
the piping if a purge system is not required for the type of chiller that is to be provided.

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Contractor to provide pipe details and size based upon the chiller manufacturer's
recommendations

0.4 COMPRESSOR

A. Description: Hermetic or semihermetic, rebuildable, single-screw compressor.

B. Description: Hermetic or semihermetic, rebuildable, twin-screw compressor.

0.5 MOTOR

A. Refrigerant-cooled, hermetic or semihermetic motor; or open, dripproof induction motor;

with the following features:

1. Overvoltage protection.
2. Undervoltage protection.
3. Single-phasing protection.
4. Current-overload protection.

0.6 EVAPORATOR

A. Description: Shell and tube cooler with refrigerant totally enclosed by shell; water in tubes.

B. Shell Material: Carbon-steel plate.

C. Cooler Tubes: Seamless copper; expanded into tube sheets; individually replaceable;
externally finned; with standard, removable, carbon-steel, marine type, water boxes.

1. Internal Finish: Internally ribbed or smooth tubes.

D. Refrigerant Working Pressure: 2070 kPa.

E. Water Side Working Pressure: 1035 kPa.

F. Insulation: Factory-applied and painted, 19 mm thick, flexible elastomeric insulation.

Insulate evaporator, suction lines, and other surfaces where condensation might occur.

0.7 AIR-COOLED CONDENSER

A. Description: Factory assembled, wired, and tested; and consisting of casing, air-cooled
condenser coils, fans, and controls integrated with compressor operation.

B. Casing: Weatherproof, constructed of hot-dip galvanized steel with factory-painted finish.

C. Fans: Propeller type, statically and dynamically balanced.

D. Fan Discharge Arrangement: Vertical.

E. Fan Motor: Direct drive, weatherproof, with bearings permanently lubricated, and having
built-in current- and thermal-overload protection.

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F. Condenser Coil: Copper tubes with mechanically bonded aluminum fins coated with
weatherproof coating suitable for local temperature and humidity conditions.

G. Safety and Operating Options: Low-ambient operational controls.

0.8 CHILLER OPTIONS

A. Furnish chillers with the following features:

1. Remote time clock.

2. Control transformer.
3. Indicating lights for chiller status.
4. Pressure gages.
5. Audible alarm.
6. Sound blanketing.
7. Sound enclosure.

0.9 CONTROLS, GENERAL

A. Manufacturer's standard, microprocessor-based DDC chiller controls to include BMS

interface with Chiller Sequencing Controls.

B. Chiller Plant Manager System: Factory supplied chiller plant manager system including
gateways for BMS connections supplied by chiller manufacturer shall be provided to
sequence, control, monitor chillers, and interface with BMS.

C. Chiller Interface Panel: Factory supplied interface panel to communicate and transmit data
between the chillers, chillers plant manager and BMS. All required data from chillers as
specified shall be transmitted to BMS.

0.10 TEMPERATURE CONTROLS

A. Compressor Capacity Control: Modulating slide valve to maintain chilled water

temperature set point without hunting within throttling range. Include the following
features:

1. Throttling Range: Full load to 10 percent of full load.

2. Chilled water temperature control.
3. Chilled water temperature setback.
4. Load limit controller.

0.11 SAFETY CONTROLS

A. Manually reset controls to perform the following functions:

1. Low evaporator pressure cutout.

2. Low evaporator temperature cutout.
3. Low oil sump temperature cutout.
4. Low oil pressure cutout.
5. High oil temperature cutout.
6. High condenser pressure cutout.

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7. Water-Flow Interlock: Vapor proof water-flow switch to prevent starting of

compressor without chilled and condenser water flow.

B. Automatically reset controls to perform the following functions:

1. Low evaporator pressure cutout.

2. Low evaporator temperature cutout.
3. Low oil sump temperature cutout.
4. Low oil pressure cutout.
5. High oil temperature cutout.
6. High condenser pressure cutout.
7. Water-Flow Interlock: Vapor proof water-flow switch to prevent starting of
compressor without chilled and condenser water flow.

0.12 FACTORY TESTS

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

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

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

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

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

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

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

F. Test Instrumentation: The factory test instrumentation shall be per ARI 550/590 and the
calibration shall be traceable to the National Institute of Standards and Technology.

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

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

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

0.13 POWER CONTROLS

A. Control Panel: Manufacturer's standard, unit mounted, factory wired with a single-point
connection, with the following power-control options:

1. External-overload protection.
2. Control circuit fuse.
3. Power terminal block.
4. Lockout restart timer.

B. Combination controller and disconnect with star-delta (wye-delta) start.

C. Combination controller and disconnect with solid-state start.

D. Combination controller and disconnect with across-the-line start.

1. Controller listed by Underwriters Laboratories (UL), classified as suitable for

installed use and environmental conditions.

0.14 VIBRATION CONTROL

A. Direct isolation (no base) and vibration isolators recommended by the manufacturer.

B. Direct isolation and the following vibration isolators specified in Division 15 Section "
Mechanical Vibration Controls and Seismic Restraints ":

1. Molded-rubber mounts with a minimum deflection of 6 mm.

2. Seismically restrained spring isolators with a minimum deflection of 25 mm.

PART 3 - EXECUTION

0.1 EXAMINATION

A. Examine areas to receive chillers for compliance with installation tolerances and other
conditions affecting performance and maintenance of chillers.

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B. Examine proposed route of moving chillers into place and verify that it is free of
interferences.

C. Verify piping roughing-in locations.

D. Verify branch circuit wiring suitability. Do not proceed with installation until unsatisfactory
conditions have been corrected.

0.2 INSTALLATION

A. Install chillers according to manufacturer's written instructions.

B. Install chillers plumb and level, and anchor. Anchor housekeeping pads to building floor.
Anchor chiller and vibration isolators to housekeeping pad.

C. Install vibration isolators according to isolator manufacturer's written instructions.

D. Maintain manufacturer's recommended clearances for service and maintenance.

E. Install piping connections maintaining clearances for service and maintenance of chillers.

F. Install flange or union connections at chillers.

G. Install flexible pipe connections for chillers mounted on vibration isolators.

H. Install shutoff valves at chiller inlet and outlet connections.

0.3 FIELD REFRIGERANT CHARGING

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

B. Refrigerant Leakage: If a refrigerant leak is discovered after the system has been charged,
the leaking portion of the system shall immediately be isolated from the remainder of the
system and the refrigerant shall be pumped into the system receiver or other suitable
container. The refrigerant shall not be discharged into the atmosphere.

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

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0.4 ELECTRICAL CONNECTIONS

A. Refer to Division 16 Sections for wiring devices, wires and cables, and electrical installation
requirements.

B. Install and connect remote flow switches and remote chiller control panel.

C. Ground equipment.

1. Tighten electrical connectors and terminals, including grounding connections,

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

0.5 FIELD QUALITY CONTROL

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

supervise field assembly of components and installation of chillers, including piping and
electrical connections, and to report results in writing.

1. Test and adjust controls and safeties. Replace damaged and malfunctioning controls
and equipment.

0.6 CLEANING

A. Clean finishes to remove dust and dirt.

B. Touch up scratches in unfinished surfaces to restore corrosion resistance.

C. Touch up scratches in finished surfaces to restore finish.

0.7 COMMISSIONING

A. Verify that installation complies with Contract requirements.

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

and check for the following items:

1. No physical damage to unit.

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

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C. Start-up:

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

following services.

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

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

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

a. One complete set of installation drawings.

b. Wiring diagrams.
c. Installation instructions.
d. Start-up instructions.
e. Operation and maintenance instructions.

D. Guarantee the main electric motor starters shall be furnished and guaranteed by the rotary-
screw chiller manufacturer who will be responsible for the refrigeration system performance
and its control.

0.8 DEMONSTRATION

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

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

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

END OF SECTION 15684

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