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Water Cooled Centrifugal Chillers ME- Building Group

SECTION 15685 - WATER-COOLED CENTRIFUGAL CHILLERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Requirements of the Contract Documents, including Division 1 Specifications, apply to work of this section.

1.2 SUMMARY

A. This Section is to provide skid-mounted, water-cooled centrifugal chillers, starters, and controls as described herein.

1.3 SUBMITTALS

A. General: Submit each item in this Article according to Conditions of the Contract and Division 1 Specification Sections.

B. Product data for each chiller, including the following:1. Chiller refrigerant and quantity.2. Chiller capacity at design conditions.3. Condenser pressure drop.4. Cooler pressure drop.5. Weights (shipping, installed, and operating).6. Furnished accessories.7. Installation and start-up instructions.8. Chiller APLV in accordance with ARI rating procedures.9. Test report conducted at 100% full load, part loads at 50 and 25% loads.9. Chiller power consumption per ton at design conditions.

C. Shop drawings detailing fabrication and installation of chiller, including plans, elevations, sections, component details, attachments, and other construction elements. Include the following:1. Dimensions.2. Weight loadings and distribution.3. Clearances for maintenance and operation on all sides and on top of chiller.4. Size and location of field connections.

D. Coordination drawings indicating the following:1. Structural supports.2. Piping rough-in requirements.3. Wiring rough-in requirements. Determine spaces reserved for electrical equipment.4. Access requirements around other work, including working clearances to mechanical

controls and electrical equipment.

E. Electrical and Control Wiring Drawings1. General Requirements: A complete set of control wiring drawings and physical layout of

the multi-chiller system (P & ID drawing) and associated control and sensing devices

of 30Revision Date: 01/21/14 Project & Bid Package File name: document.doc


(temperature, pressure, flow sensors, end switches, etc. on the chiller unit and/or in the field piping) shall be submitted to the Owner and engineer prior to start of fabrication. Drawings shall include:a. Schematic and interconnection diagrams shall have each point numbered including

the schematic of the starter and annunciator panel and internal wiring of relays. Wire sizes to be indicated.

b. Bill of material showing the manufacturer, rating, catalog number and identification symbol of each component, including relays, meters, fuses, timers, contactors, resistors, capacitors, all control and sensing devices, etc. Supplier to include in the bill of materials whether the control and sensing devices are "furnished and installed", or "furnished by chiller manufacturer and installed by others", or "furnished by others and installed by others".

c. A complete sequence of operation.d. All electrical and control drawings are to be done in ladder logic format to JIC and

Chrysler standards.e. All electrical and control drawings are to be done by Chrysler’s preferred control

subcontractor including reproduction of the chiller manufacturer’s drawings into a format acceptable to Chrysler. Drawings are to be done with a Chrysler approved title block and numbering sequence.

f. The electrical and control drawings shall incorporate all aspects of the chiller plant including the chiller, all field devices (pressure temperature and flow transmitters and level controls, etc.), pumps (primary, secondary, and condenser water), cooling towers, MCC’s plus monitoring of certain aspects of the compressed air and hot water boiler systems including interface to the plant DIS system.

g. The electrical and control drawings shall include both power wiring, 4160 and 480 Volts, and control wiring 115, and 24 Volt etc., AC and DC.

h. A motor starter analysis will need to be provided indicating the Full load amps and the rush current.

2. Drawings Required:a. Chiller unit electrical and control drawings.b. Master control panel, field wiring, and starter (MCC) drawings.c. Medium voltage (4160 V) starter drawings.d. Electrical/control riser diagrams.e. Sequence of operation.f. Input/output list and addresses.

F. Software: Manufacturer shall provide the following software packages:1. System Graphics - Panelview2. System Graphics - PC (Intellution)3. Program for PLC

G. Certification of performance from the factory.

H. Certification letter from manufacturer stating that the chiller has been through start-up procedures and that it is functioning properly.

1.4 ELECTRICAL



A. The unit manufacturer shall provide all unit package power, wiring, including terminal box, maindrive motor, oil pump separator, oil pump, oil heater, control devices and auxiliaries, together with all protective and operating control wiring.

B. All wiring for external connections shall be brought to readily accessible terminal strips for connection thereto.

C. Electrical work excluded.1. Motor control centers for cooling towers, cooling water pumps, chilled water, and hot

water pumps. Pumps will be furnished and installed by the installation Contractor.2. All power wiring to compressor motors and motor control centers associated motors (as

explained above) will be furnished and installed by the installation Contractor.3. All interlock and interface wiring from the chiller master system control panel to the chiller

unit microprocess control panels, to energy center PC, and to the motor control centers will be furnished and installed by the installation Contractor. Design of all electrical and control wiring 4160 V, 480 V, 115 V, etc., however is part of the chiller prepurchase.

1.5 QUALITY ASSURANCE

A. Manufacturer's Qualifications: Firm experienced in manufacturing water-cooled centrifugal chillers similar to those indicated for this Project and that have a record of successful in-service performance.

B. Air Conditioning and Refrigeration Institute Compliance: Conform to ARI 590 for chiller performance ratings.

C. ASHRAE Compliance: Conform to ASHRAE 15 for chiller design, construction, leak testing, and installation.

D. ASME Compliance: Comply with ASME "Boiler and Pressure Vessel Code," Section VIII "Pressure Vessels," Division 1 "Basic Coverage" for constructing and testing cooler and condenser pressure vessels. Stamp cooler and condenser with ASME mark.

E. NEC Compliance: Comply with applicable NEC requirements pertaining to electrical power and control wiring.

F. Chillers shall be designed and constructed to meet UL requirements and have labels appropriately affixed.

G. Compressor impellers shall be over-speed tested by manufacturer to a minimum of 20 percent above operating conditions.

H. Controls will meet all limitations on radiated and conducted radio-frequency emissions for Class "A" devices, defined in FCC rules and regulations, part 15, sub-part J.

I. Test centrifugal compressors at a minimum speed of 15 percent above the design. Peak-to-peak vibration displacement not to exceed 0.01 inch.

J. Motor testing as per MG1200. Indicate type of test previously performed on motors and provide all standard routine tests.



K. JIC Compliance: The chiller mounted microprocess control panel and all field wiring and the chiller itself need not comply to JIC standards. The master system control panel and all field wiring must comply.

L. Basic Electrical Installation Guidelines for Equipment (BEIGE) December 1, 1996 version Compliance: The chiller mounted control panel and the chiller itself need not comply to “BEIGE” standards. The master system control panel and all field wiring must comply.

M. Allen Bradley Book of Implementation Guidelines (BIG Book) Compliance: The chiller mounted control panel and the chiller itself need not comply to “BIG Book” standards. The master system control panel and all field wiring must comply.

1.6 SCHEDULING AND SEQUENCING

A. Notify Owner and Installing Contractor one week in advance of each shipping date.

1.7 OPERATION AND MAINTENANCE MANUALS

A. Ninety days prior to start-up of equipment, furnish Owner with six (6) copies of operating and maintenance instruction manuals bound in durable stiff covers.

B. Instruction manuals shall contain the following:1. Index on book form of all component and diagram data sheets.2. Description and assembly drawings of each item of equipment.3. Parts nomenclature.4. Wiring and piping drawings.5. Procedures for start-up and operation of unit.6. Instructions for disassembly and reassembly of all items of equipment furnished, as

required for normal operation and maintenance.7. Sequence of operation for the equipment.8. Normal set points and limits for all controls.9. Final settings and adjustments established for start-up tests.10. Preventative maintenance schedule and checklist including daily, weekly, monthly, and

annual schedules.11. Operating checklists.12. Spare parts list.13. Special tools list.

C. In addition to the folded insert drawings (11” X 17”) and data sheets incorporated in the five (5) copies of the manual, all large diagrams and schematics shall be furnished in as-built condition on mylar reproducible sheets and electronically on disc.

1.8 SERVICE ORGANIZATION

A. Furnish the name, address and telephone number of nearest field service headquarters actually staffed with Engineers engaged in such work.

B. Bidders are invited to supply factual engineering information of special design features which are intended to increase efficiency. Reduce maintenance costs and improve reliability.



1.9 SPARE PARTS LISTS

A. Contractor shall furnish a list of parts recommended to maintain units in full operation under normal operating conditions, including long lead time items in excess of one (1) week delivery such as vacuum contractors, spare motors and spare compressors. List should include expected life and recommended replacement schedule for furnished equipment. Selection shall take into account vulnerability to normal wear, availability and expected shelf life. Contractor shall also advise special devices and tools required for maintenance and calibration of all equipment furnished. Lists shall indicate current total prices of recommended and optional parts and materials.

1.10 REFRIGERANT AND LUBRICATING OIL CHARGE

A. Refrigerant and lubricating oils needed to satisfy the initial start-up and testing needs of the equipment shall be provided.

PART 2 - PRODUCTS

2.1 WATER-COOLED CENTRIFUGAL CHILLERS

A. General: Factory assembled, single piece, liquid chillers shall consist of compressor and motor, lubrication system, cooler, condenser, interstage flash economizer/storage vessel, vibration isolation assembly, electrical microprocessor control system, and documentation required prior to start-up. Motor starter, initial oil, and refrigerant charges shall be supplied by the chiller manufacturer for field installation, by the installing Contractor.

B. Centrifugal Compressor: Include the following features:1. One centrifugal compressor of the high performance open drive. Minimum efficiency at

full load shall be 0.60 kw per ton at condensing EWT of 85°F, LWT of 95°F and evaporator EWT of 62°F, LWT of 42°F.

2. Compressor Pipe Connections: Flanged for easy disassembly.3. Cast iron casing.4. High-strength, cast-aluminum-alloy impeller.

a. Statically and dynamically balanced.b. Keyed to the shafts.

5. Carbon- or forged-steel shaft.

C. Compressor Capacity Control: Variable inlet guide vanes to maintain chilled-water set point, without overshoot or hunting, with stable operation free of surge, cavitation, or vibration throughout the throttling range of full load to 10 percent of full load without hot gas bypass. Hot gas bypass for further capacity reduction shall be provided on each chiller.

D. Lubrication System: Compressor shall be provided with a factory installed lubrication system to deliver oil under pressure to bearings and transmission gears. Positive lubrication shall be provided at all operating speeds, on start-up or shutdown, and during power failure coast down conditions. System shall be completely factory mounted, piped, and wired, including all cooling water pipe.1. Motor driven, positive displacement oil pump.



2. Refrigerant-cooled oil cooler.3. Oil pressure regulator.4. Twenty-micron oil filter with isolation valves, oil relief valve.5. Oil pump starter factory mounted on the chiller and factory wired to pump motor and

control circuit.6. Oil sump heater (115 V 60 Hz) controlled from unit microprocessor.7. Oil reservoir temperature sensor with main control panel digital readout.8. Sight ports, non-mercury thermometers, and pressure gauges.

E. Refrigerant: Chiller shall be delivered with a nitrogen charge. Any leaks identified shall be repaired prior to refrigerant charge. HFC-134a full operating charge of refrigerant and oil shall be furnished with each chiller. Charging of chillers by Manufacturer.

F. Insulation: Factory-insulate cooler, suction lines, marine water boxes, and other surfaces where condensation might occur with flexible elastomeric insulation of the following thickness:1. Thickness: 3/4 inch, conductivity not exceeding 0.28 BTU-inch/hour-foot-F and shall

conform to UL Standard 94, Classification 94HBF.2. Performance: Insulation shall prevent condensate drip to floor in all weather conditions

from all chiller surfaces.

G. Mist Eliminators: Metal screen-mesh eliminators to prevent carryover into the compressor.

H. Evaporator and Condenser: Shell and tube design with the following features:1. Construction: Conform to ASME code for unfired vessel, bear ASME stamp on shell and

conform to ANSI B9.1.2. Water enclosed in the tubes; refrigerant enclosed by the shell.3. Shell and Tube Support Material: Carbon steel plate.4. Cooler Tubes: Seamless, integrally finned, individually replaceable copper tubes rolled

into tube sheets.a. Wall Thickness: 0.035 inch.b. Maximum Tube Velocity: 8 feet per second.c. Tube area based on a fouling factor of 0.00025.d. Water Boxes: Marine type, removable covers, carbon steel, valved vent, 2 inch

valved drain connection.

5. Pipe Connections: 150 pound flanges.6. Refrigerant Working Pressure: 300 psig.7. Water-Side Working Pressure: 150 psig.8. Pressure-relief safety valve.9. Vessels to be ported for hot gas bypass.10. Automatic Tube Brushing system.

I. Refrigerant Receiver Unit: Floor-mounted, stand alone receiver unit designed, tested, and stamped according to ASME "Boiler and Pressure Vessel Code" and with the following features:1. Manually controlled compressor to deliver refrigerant to storage receiver.2. Minimum Receiver Capacity: Full operating charge of refrigerant.3. Isolation valve that separates storage receiver and compressor from the chiller.4. Receiver's pressure-relief safety valve vented to exterior of building.5. Level gauge.



6. Oil separator.7. Filter/dryer.8. Necessary controls for stand alone operation.

J. Motor:1. The motor shall be of sufficient size to satisfy efficiently the compressor power input

requirements and shall be induction open type, with a service factor of 1.15.2. The motor shall be suitable for reduced voltage auto transformer starting. Motors shall

be supplied with insulated bearings lubricated from main lubrication system. The power factor shall be corrected to 0.95 under work conditions of loading.

3. A permanently attached stainless steel nameplate shall be provided stating the motor horsepower, speed, voltage and current phase, NEMA torque design, temperature ratings, full load and locked rotor amps, together with a metal direction arrow to indicate proper direction of rotation, when applicable.

4. Chiller electric drive motor includes the following:a. High motor bearing RTD temperature sensors with control modules to provide an

alert and a motor shutdown signal. Sensors shall suit the manufacturer's motor and bearing design. Base temperature limits on manufacturer's recommendations with respect to lubrication, bearing materials and other temperature related factors.

b. Provide motor winding with 6 RTDs, 2 per phase. Temperature settings shall be as determined by the motor manufacturer for trip and alarm.

c. Connect 3 RTDs to starter motor protection system and 3 to control modules located within chiller unit control panel, for alarm only. Provide separate terminal box for RTDs.

d. Terminal box-run motor leads into a large NEMA-12, JIC terminal box having a gasketed cover, brass or stainless steel fastening hardware and mounted at the refrigeration machine. Oversize the terminal box to accommodate the following accessories to be furnished and mounted by the motor manufacturer and to permit easy training and termination of the motor leads.

e. Surge protective equipment consisting of capacitors and lightning arresters. Ensure quick disconnect for testings. Provide provisions for meggering motor easily.

f. Ground bus.g. Current transformer(s) for the compressor manufacturer's load control scheme

with the secondary leads connected to suitable terminal strips. Provide a minimum of three (3) current transformers for differential protection to be connected with CTs at starter and to differential relay.

h. Six (6) leads in motor terminal box for CTs.i. Provisions for connection of the 4160 volt service with adequate space for stress

cones. Coordinate with 5 KV motor starter manufacturer.

5. Insulate motor leads for the voltage class utilized and maintain proper air clearances between phase conductors, phase to neutral conductors, phase to ground, and neutral conductors to ground. Provide double indent type lugs, design terminal box for top, entry of cable.

6. D-Flange, Design "B", squirrel cage, ODP, induction, non-reversing type designed for use with 3 phase, 60 hertz, 4160 volt service and capable of producing rated output continuously at a voltage of 10 percent above and 10 percent below the rated voltage without decrease in its life expectancy. Maximum allowable temperature rise shall not exceed 90 deg. C., over 40 deg. C. ambient. Insulation shall be NEMA Class F.



7. Acceptable motor manufacturers: U.S. Electric, Reliance, Westinghouse, Siemens.

K. Supports and Vibration Isolator Base: The machine shall be provided with integral steel supports and anchor bolts, complete with ribbed 1/4 inch thick neoprene vibration isolator pads, sandwiched between 2 steel plates and sized for a surface loading of from 40 to 50 pounds per square inch. Jack screws and leveling pads shall be provided.

L. Noise:1. Sound pressure level, resulting from centrifugal refrigeration machine operation, shall not

exceed 80 DBA. When measured in accordance with ARI standard 575 and the National Machine Tool Builders Association NMTBA Noise Measurement Techniques latest edition. Data shall comply with the requirements of Chrysler Corporation's sound level specification for industrial machinery and equipment.

2. Bids shall clearly state exceptions regarding the ability of the proposed vendor in complying with this requirement.

3. If bidders cannot meet the specified noise level and the manufacturer of the proposed equipment is capable of demonstrating that all engineering solutions have been fully explored without positive results, the bidder shall furnish with the bid, the minimum sound level that can be achieved (not to exceed 85 dBA), manufacturer's complete octave-band analysis, together with his identification of probable noise sources. Data shall include readings at each test point from each load condition in sufficient detail to permit calculation of associated noise exposure. Furnish manufacturer's information as to nature, construction type, and expected noise reduction for corrective schemes such as enclosures and include cost of such corrective schemes in bid.

M. Chiller Unit Microprocessor Control Panel:1. General:

a. Furnish and install a unit mounted automatic operating and automatic warning, protective and continuous monitoring system enclosed in a NEMA 12 panel for each chiller. The unit control panel shall be mounted at eye level on the machine. The system shall be micro-computer based on real time, multi-variable, multi-level function unit, designed for operation as a stand-alone processor capable of implementing the control sequences, communications network, alarm and monitoring functions listed. The unit shall contain not less than 2 kilobytes of 16 bit words on Random Access Memory with the addition of 2 kilobytes of on-board EPROM. A battery back-up shall be provided capable of retaining the on-board memory for up to one (1) year. The unit shall have the capacity to handle not less than 12 discrete digital inputs, 6 discrete digital outputs, 32 analog inputs. (4 to 20 mA 2-wire type), and 2 analog outputs (4 to 20 mA). The system shall incorporate a communication port for interfacing.

2. Operational Functions and Displays:a. The microprocessor shall have operational function keys with integral LCD

program display memory and alpha-numeric display. System shall provide for time, lube oil function, and motor power functions with capacity to scan, set operating mode, reset, calibrate and monitor all functions, including provision of alarm and control outputs. Temperature sensors shall be 100 OHM RTDs. Pressure sensors shall be strain gauge type with 4 to 20 mA output signal.

b. The chiller unit microprocessor control panel shall incorporate as a minimum the following operational devices, functions, and display and set-up capabilities.



1) Local/manual/auto start/stop.2) Remote stop and remote alarm annunciation.3) Solid state malfunction trip contacts.4) Solid state latch seal in contacts.5) Auxiliary trip contacts.6) Run hour meter.7) Unload/modulate control mode.8) Chilled water temperature reset.9) Motor current transducer.10) Pressure level - oil supply.11) Pressure level - evaporator refrigerant.12) Pressure level - condenser refrigerant.13) Temperature indicating - entering chilled water.14) Temperature indication - leaving chilled water.15) Temperature indication - entering condenser water.16) Temperature indicating - leaving condenser water.17) Temperature indicating - evaporator refrigerant.18) Temperature indicating - condenser refrigerant.19) Running - normal operation.20) Oil pump control - auto/on.21) Provide NEMA-1 type pushbuttons.22) Date and time of day.23) Chiller operating hours.24) Oil differential pressure.25) Oil sump temperature.26) Percentage of motor full load amps (FLA).27) Evaporator pressure.28) Condenser pressure.29) Bearing oil supply temperature.30) Compressor bearing temperature.31) Quantity of compressor starts.32) Control point setting (high, low, present).33) Discrete output status of devices.34) Schedule function:

a) Start-up and shutdown shall be manual or automatic.b) The chiller can be started and stopped remotely by the chilled water

system master system control panel.

35) Demand limit set-point.36) Alarm history file containing up to 25 alarm/alert messages with time and

date stamp.37) Capacity control - load modulation shall be from 10% to 100% of full load

without hot gas bypass. The guide vanes shall be precisely positioned by the P.I.D. (proportional, integral and derivative) control algorithm to ensure precise control (± .5o F or .3oC) of desired chilled water temperature.

38) Microprocessor shall be capable of accepting remote maximum load set point from the master system control panel.

39) Accept start/stop command from the master system control panel.40) Motor winding temperatures41) Sensor faults



42) Evaporator freeze protection and low limit control. Design this control to be used to avoid low evaporator refrigerant temperature trip-outs during critical periods of chiller operation.

N. The system shall incorporate as a minimum the following indicating, warning and shut-down protective devices and shall include all wiring:

Sensor Warning Shutdown

Oil pressure X XHigh lube oil temperature X XLow lube oil temperature X XHigh condenser head pressure X XHigh evaporator head pressure X XLow evaporator temperature X XVibration X XCondenser water differential pressure X -High electrical motor current X -Hours run totalizing meter - -Compressor bearing temperature sensor X XEvaporator water differential pressure X XSurge X X

O. Master Chilled Water Control System:1. General: The chiller manufacturer shall provide a master control panel and overall

system control design to monitor and control the following:a. Chilled Water System

1) Chillers2) Cooling towers3) Condensing water pumps4) Primary water pumps5) Secondary water pumps

b. Other Systems: The chiller manufacturer’s master control panel shall also monitor and transmit the following to the DIS system through an Allen Bradley PLC included in the master control panel:1) Status of each of five (5) air compressors.2) General alarm on each of five (5) air compressors.3) Status of each of three (3) desiccant dryers.4) General alarm on each of three (3) desiccant dryers.5) Compressed air system delivery dew point temperature, pressure, and flow

rate.6) Status of each of three (3) hot water generators.7) General alarm of each of three (3) hot water generators.8) Hot water system delivery temperature, pressure, and flow rate.

c. Motor Control Center1) The chiller manufacturer’s master control panel shall also monitor the chilled

water, compressed air and boiler systems pumps and cooling tower fan



motors through the master control panel Allen Bradley PLC and remote IO provided with the MCC by others.

2) All monitored points shall be transmitted through to the facility DIS system.3) Monitored points associated with the chilled water system, pumps, and

cooling tower for starters shall also be displayed on the master control panel “Panelview” and the PC operators station.

4) The following points shall be monitored on each starter:a) Currentb) Field device open (field and MCC disconnect)c) Overload trippedd) Motor run mode - both high and low speed on tower fanse) Up to speed for SMC starters (all but VFD’s are SMC’s)f) VFD fault - on VFD drivers (secondary chilled water pumps)

2. System Integration - The electrical controls Contractor shall:a. Incorporate chiller manufacturers chiller unit controls into the overall system design

and present in a format acceptable to Chrysler (JIC/ladder logic).b. Design all power wiring (4160 V and 480 V) through to and including motor starters

(less the 4160 V starter but including incorporation of the 4160 V starter in the design package and interconnection).

c. Design all control wiring (115 V, 24 V, etc.) digital and analog as described herein including the master system control panel and field wiring.

d. Fabricate the master control panel.e. Provide field mounted sensors (pressure, temperature, and flow) and transmitters

as indicated on the system P&IDs.f. Design 480 V starter controls including MCC remote IO.g. Design integration of compressed air system (compressor and dryer) and hot

water generator monitoring points as described herein.h. Design PC monitoring system and interconnection.i. Provide all PLC software and programming.j. Integrate PC software in conjunction with chiller manufacturer.k. Design interconnect to FIS/DIS.l. Integrate all systems design into a single design drawing package.

3. Approved Control Contractors are as follows:a. Commerce Controls Inc.b. The Aarell Companyc. Automation Solutions of America (ASA)d. Tekworx

4. Master System Control Panela. Control Panel Components: Master system control panel shall be provided for

overall system control and monitoring. The panel shall contain the following:1) The control panel shall house all associated equipment (I/O modules,

analog modules, control relays, main disconnect, Allen Bradley Panelview, terminal strips, fuses, pilot lights, pushbuttons, alarm horn and rotating beacon, etc.).

2) The control panel shall house all required controls necessary for a safe and completely functional chilled water system along with monitoring of air compressor, compressed air dryer and hot water generating systems.



3) Sufficient space to accommodate controls for eight chillers (6 plus 2 future) chillers and their auxiliary equipment (pumps, fans, sensors, etc.) including program memory, shall be furnished.

4) All safeties for shutdown shall be hard wired.5) Manufacturer shall provide a network drawing showing all components and

location. Manufacturer shall provide all software for a functional system.6) The control panel and programming logic shall have provision for interfacing

to the Chrysler Factory Information System (F.I.S.) and Data Information System (DIS). The master system control panel shall be wired to J.I.C. standards.

7) The control panel shall include a modem for remote monitoring and trouble-shooting by the manufacturer.

b. Control functions shall include:1) Sequence control of chillers based on flow demand and chilled water

temperatures.2) Primary chilled water pump control.3) Condenser water pump control.4) Secondary chilled water pump variable frequency drive control.5) Cooling tower fan control. Fans motors will be double winding two speed.6) Cooling tower level control and alarm.7) System pressure, temperature and flow monitoring.8) Interface with all chiller microprocessor control panels to accept all chiller

parameters (temperature, pressure, flow, status, alarms, etc.).9) Transmit all data to the plant DIS system via the plant ethernet system.10) Transmit status and alarms to the plant FIS system via the plant ethernet.11) Sequence automatic valves.12) Provide common current load reset for all chillers.13) Automatic/manual operation.14) Lead/lag selection and sequencing to equalize equipment wear.15) Select and adjust assignment of primary pumps and cooling tower to each

chiller.

c. PLC: The master control panel shall include an Allen Bradley PLC5 40 (minimum size) processor of sufficient size and capability for current and future chiller systems, i.e. up to eight (8) chillers with associated pumps, fans and controls. The PLC shall act as a data collection and interface device to the plant DIS and FIS systems. All software and drivers to enable chiller system, air compressor and dryer system, and hot water system, communication to the plant DIS and FIS system is to be included.

d. Operator Interface1) The master control panel shall incorporate an Allen Bradley Panelview

1400E color monitor for operator interface. Operator interfaces are to be capable of independently invoking password protection of the entire display and keypad, operator settings (e.g. chilled water set point, machine configuration settings, and service start-up settings).

2) This operator interface shall include graphics for control and monitoring of:a) Chilled water system.b) Condenser water system.



c) Cooling towers.d) Primary and secondary chilled water pumps.e) Condenser water pumps.f) Hot water generating system.

3) At least one page of graphics shall be devoted to each of the above.

4) The graphics shall provide:a) Ready/start/run/stop/fault status of chillers.b) Run/stop status of pumps. The MCCs will have off/run/start selection

for each starter with auxiliary contacts for status indication back to the master system control panel, through the MCC remote I/O and master control panel PLC.

c) Slow/fast/stop status of cooling tower fans. The MCCs will have slow/fast/auto/off selection for each starter with auxiliary contacts for status indication back to the master control panel.

d) Temperature, pressure, flow and level indication for all system parameters.

e) Alarm display e.g. chiller fault, system chilled water temperature low and high, tower high and low level.

f) Valve status with limit switch verification for all actuated valves.g) Control, monitoring and alarm of any other system parameters

required to provide reliable, efficient and safe chilled water plant operation.

h) Individual chiller operating parameters must also be displayed at this panel.

i) Boiler status and alarms, hot water system temperature, pressure, and flow rate.

j) Compressed air status and alarms for compressors and dryers; compressed air system pressure, temperature, dewpoint, and flowrate.

e. Manual Control1) Each automatic valve shall have manual selector switch control to permit

system operation without the system controller and/or PC interface. Valve open and close position shall be indicated on the PC display. A single open/close/auto selector switch shall be provided for each valves function control.

2) The panel is to have sufficient space for manual control of future chillers valves.

3) Chillers must be capable of running in manual and independently on their unit microprocessor control panels only.

4) Pumps and cooling tower fans will be capable of running in manual from the MCCs.

f. Automatic Control1) The master system control panel will provide fully automatic control with all

systems being automatically started and stopped by program logic after the master start button is depressed and until a master stop button is depressed.



2) Air house coil control will be through two-way valves (by others) in which case flow rate to the system loads will vary. Remote pressure sensors will be provided as part of the installation contract with 4 to 20 mA analog input to the Master Control Panel. This pressure indication shall be used to vary the speed of secondary pumps to maintain pressure setpoint, +2 psi.

3) Flow through the primary secondary system crossover orifice plate shall be monitored for direction and volume.

4) Chiller lead/lag sequence shall be controlled by any of the following control strategies:a) Secondary chilled water supply temperature only.b) Secondary chilled water return temperature only.c) A combination of the above along with bypass temperature.d) Monitoring of flow direction in bypass.

5) After enabled, chillers will only start if system chilled water supply temperature is above minimum shut down set point and only stop if system chilled water supply temperature is below minimum shutdown setpoint.

6) Primary chilled water and condenser pumps will start and stop in conjunction with their assigned chiller. Manual reassignment will be accomplished at the systems MCC.

7) Cooling towers (one double cell tower for each chiller) shall be enabled when that chiller is started.

8) Cooling tower on/off and speed shall be controlled by tower discharge temperature.

9) Cooling tower level shall be controlled by two capacitance level probes with tower mounted relay panels provided by cooling tower manufacturer. These panels will provide relay outputs to the master control panel for high and low level indication and make up valve opening and closing.

10) Condenser water pumps will start and stop in conjunction with their assigned chiller.

11) Chiller chilled and condenser water inlet valves and tower supply valves shall be opened and closed in conjunction with their assigned chiller.

12) If a chiller trips on fault, an alarm will be indicated and the next chiller in sequence will automatically start. Chiller lead/lag sequence shall be automatically changed based on Chiller run time or by operator input. When multiple chillers are running chillers shall be load balanced.

13) Primary chilled water flow rate and temperatures shall be used to calculate and display a running tonnage for the system.

5. Input/Output Summary: The master control panel shall contain the following inputs and outputs as a minimum (see P&ID bid drawing):a. Analog Inputs (minimum) to Master Control Panel DDC- Primary chilled water flow GPM.- Secondary chilled water flow GPM.- Bypass chilled water flow GPM.- Secondary chilled water supply temperature.- Secondary chilled water return temperature.- Primary chilled water supply temperature.- Primary chilled water return temperature.- Primary chilled water supply pressure.



- Primary chilled water return pressure.- Secondary chilled water supply pressure.- Secondary chilled water return pressure.- Cooling tower supply temperature.- Cooling tower return temperature.- Cooling tower supply pressure.- Secondary loop differential pressure.- Secondary loop remote temperature.- Compressor motor winding temperature.- Outdoor air temperature.- Outdoor air humidity.

b. Analog Inputs (minimum) to Master Control Panel PLC- Hot water system temperature.- Hot water system pressure- Hot water system flow rate.- Compressed air system dew point.- Compressed air system pressure.- Compressed air system flow rate.- Compressed air system temperature.

c. Discrete Inputs (minimum) to Master Control Panel DDC- Condenser water isolation valves at cooling towers open/close (12 each).- Chiller chilled water primary pump run status (6).- Chiller condenser water pumps run status (6).- Cooling tower fan vibration switch typical for all cooling tower fans (12).- Chiller on/off (6).- Chilled water chiller isolation valve open/close (6 each).- Condenser water isolation valve open/close (6 each).- Alarm acknowledge pushbutton.- Cooling tower sump low/high level (2 each).- Cooling tower make-up valve open/close (1 each).- Chiller operating mode (6).- Equipment room refrigerant monitor (3 alarm levels, plus fault status, seven

sensing points plus two future).- Chilled water secondary pump run status (5).

d. Discrete Inputs (minimum) to Master Control Panel PLC through Remote IO in MCC (MCC with remote IO is by others)

Chiller Pumps Air Compressor Hot Water

Primary

Secondary

Condenser

Chiller Tower Fans Pump

s

Tower Fans Pumps

- Current 6 5 6 12 3 2 3- Field device open 6 5 6 12 3 2 3



- Overload tripped 6 5 6 12 3 2 3- Motor running 6 5 6 3 2 3- Motor running

high12

- Motor running low

12

- Run mode 6 5 6 12 3 2 3- Up to speed 6 6 12 3 2 3- VFD Fault 5

e. Discrete Inputs (minimum) to Master Control Panel PLC direct (IO is to be provided with Master Control Panel PLC)

- Air compressor status (5).- Air compressor general alarm (5).- Boiler status (3).- Boiler general alarm (3).

f. Analog Outputs (minimum) from Master Control Panel DDC- Chilled water supply temp set-point (6).- Chiller demand load limit set-point (6).- Secondary pump VFD control (5).

g. Discrete Output (minimum) from Master Control Panel DDC- Chiller start/stop (6).- Cooling tower low speed start/stop (12).- Cooling tower high speed start/stop (12).- Condenser water pumps start/stop (6).- Chilled water pumps primary pumps start/stop (6).- Chilled water isolation valve open/close (6 each).- Condenser water isolation valve open/close (6 each).- Cooling tower isolation valve open/close (12 each).- Chilled water secondary pumps start/stop (5 each).- Global alarm output.

6. Personal Computer (PC) Operator Interface: In addition to the master control panel Allen Bradley Panelview, the supplier shall furnish one (1) personal computer operator interface display with printer, and interface boards, in the Energy Center. All with a printer, keyboard, and interface card to master control panel, as listed below. PC shall be for monitoring set point change and remote operation.

a) The PC shall contain a series of screens that monitor status alarm conditions, process variables, adjustable setpoints, etc. It is the only means by which the operators can maintain the parameters of the system through set point adjustments. All stored variables associated with compared analog signals or limit comparative values shall be indicated on the PC and changed where appropriate.

b) All the monitoring parameter capabilities on the chiller unit microprocessor control panel, master system control panel DDC and PLC controllers, and motor starter chiller microprocessor based protection system shall be observable at the PC. It is a means in which one (1) operator can monitor any of the chillers he desires at



the PC (see "Unit Microprocessor Control Panel," "Motor Starter Microprocessor Based Protection System" section, and “Master Chilled Water Control System”).

c) The PC operator interface shall contain screens showing the overall chilled water process (chillers, primary and secondary water pumps condenser water pumps, and cooling towers) and all their associated points of monitoring (temperature, pressure, GPM, flow, pump, current power and fans status), in graphic format.

d) The overall screen shall be broken down into smaller sections or subsystems. There shall be a screen for each chiller and all their associated points of measurement (pressure, GPM, condenser water in/out temperature, chilled water in/out temperature, lube oil temp., evaporator temp., compressor motor current, voltage, fault, etc.).

e) There shall be a separate screen for each set of pump and fan motors (primary and secondary chilled water pumps, condenser water pumps, air compressor pumps, hot water pumps, air compressor cooling tower fans, and chilled water, and cooling tower fans) and all their associated monitoring points, such as motor running, field device open, motor overload, vibration fault (for cooling tower fans), auto/manual, hilo speed, up to speed, current, run mode, VFD fault, etc.

f) There shall be separate screen for hot water generator/hot water system.g) As a minimum, the PC shall monitor all functions as indicated in input/output

summary and all functions of the individual chiller unit Microprocessor Control Panel. The Energy Center PC shall also be capable of logging alarms and faults. Alarms are to automatically printed at the PC printer. The Energy Center PC is to be capable of historical trending and logging of operator inputs, status, and system variables, and print out. Provide a daily log of the list of points recommended in ASHRAE Guideline 3.

7. Miscellaneous Control Devices and Subsystemsa. Switches for preventing compressor starting with IGV valves open and for closing

IGV upon unit shutdown and upon power failure.b. Pressure sensors and gauges for condenser, evaporator inlets and outlets, and

lubricating oil.c. Thermometers and temperature sensors for condenser, and evaporator inlet and

outlet and lubricating oil.

2.2 MAIN MOTOR STARTERS

A. 4160 Volt motor starter shall consist of NEMA Class E2 medium voltage vacuum contactor motor starters all in a dead front line-up with all interconnecting power and control buses.

B. Provide termination lugs to accommodate cables per phase for incoming line power. All incoming line and load cable shall be top entry. Supplier to coordinate lug type with the contractor furnishing and installing the primary (4160 volt) power feeds.

C. All starters shall be designed and tested to meet the latest applicable NEMA, IEEE, and ANSI published industrial control standards. Starters shall be fused type NEMA Class E2 for industrial control ICS2-324. Upon request, certified test reports shall be provided on all published interrupting, fault capacity and BIL ratings. Short circuit level is 50 KA symmetrically.



D. The starter shall be a class to accommodate motors of the size and type as specified with a safety factor of 1.15. The type of starting shall be reduced voltage auto transformer with 80 percent and 65 percent voltage taps. Auto transformer shall be 3 winding rated locked rotor current and starting time. Motor and starter shall be capable of starting at either 80% or 65% of rated line voltage.

E. Isolating switch and vacuum contactor assemblies, including current limiting fuses, shall be easily removed from the front of the enclosure. Line and load cable terminations shall be completely accessible from the rear and front.

F. The motor starter is to be remote free-standing type and will be installed by the installation contractor.

G. The compressor shall be equipped with a capacitor for power factor correction, sized as recommended by the motor manufacturer to provide not less than 0.95 connected power factor at full load.

H. The capacitor shall be of the enclosed, dust-tight type, rated 4160 volts, 3 phase, 60 Hz, nonflammable, non-PCB, oil type complete with 5 minute discharge resistors and internal fuses. Capacitors shall be mounted inside the individual motor starters enclosure.

I. Acceptable manufacturers shall be General Electric, Cutler-Hammer/Westinghouse, Square-D, Allen Bradley.

J. Starter and motor supplier shall suggest the best ways of connection and actuation, guarantee no harmonics and start-up problems.

K. Pushbutton stations and controls - pushbutton stations shall be start/stop, with pilot light were required, or momentary contact, heavy-duty, oil-tight construction. Pilot lights shall be heavy-duty, oil-tight design, press-to-test type with built-in 120 to 6 volt transformer. Pushbuttons stations and pilot lights shall be Allen Bradley bulletin 800T. Selector switches shall be of similar manufacturer as pushbuttons.

L. The isolating switch shall be externally operated manual 3-pole draw-out and isolates the starter from the line connectors with a mechanically driven isolating non-metallic shutter leaving no exposed high voltage. Integral mechanical interlocks shall prevent entry into the high voltage areas while the starter is energized and shall block accidental opening or closing of isolating switch when door is open or contactor is closed. Isolating switch handle shall have provisions for 3 padlocks.

M. Current limiting power fuses shall be of the self-protecting type with visible fuse condition indicators and with special time/current characteristics for motor service allowing proper coordination with contactor and overload relay for maximum motor protection. The power fuses shall be vertically mounted permitting an easy inspection and replacement without starter disassembly.

N. Fusing must withstand full load and starting inrush and provide contactor and motor short circuit protection.



O. Vacuum contactor shall be drawout, main contacts single-break high pressure type with weld resistant silver alloy contact faces.

P. A built-in test circuit shall be included to permit checking of the starter control circuit and pilot circuits with high voltage de-energized and isolated either with the contactor in its normal position or in the draw-out inspection position. Allow for normal or auxiliary power switch for remote start bypass switch.

Q. Low voltage control shall be isolated and barriered from the high voltage area and provided with a separate low voltage access door.

R. Enclosures for the high voltage starters shall be freestanding and completely front accessible.

S. Provide power factor correction capacitors to maintain a power factor of 0.95.

T. Provide differential relay CTs inputs to MPR and ensure interface with 3 Cts or corebalance CT at motor terminal.

U. The motor protection relay shall be a Multlin-269 plus with metering function for power, voltage, current, etc.

V. All medium voltage starters shall be provided with a microprocessor based, definite purpose mini-computer in each individual starter to protect and monitor.1. The mini-computer shall be capable of monitoring electrical power, voltage and current;

communicate by alphanumeric display with the operator and by digital signals with other equipment. Provide control power transformers and metering PTs and CTs.

2. The mini-computer shall provide both stalled rotor and stator protection with RTDs in the starter windings during starting and running. True RMS current shall be constantly monitored, separated into positive and negative sequence components and the heating effects caused by both, automatically combined and processed to provide close motor protection.

3. The mini-computer shall be mounted in the low voltage section of the starter enclosure. The MPR shall be mounted on the door of the low voltage compartment. A software program, designed to cover the features required in large motor starters, shall be stored in permanent memory.

4. The MPR shall receive its power from a separate SOLA constant voltage transformer.5. Motor starter power doors shall include start/stop pushbutton, pilot lights, and selector

switches (auto/manual).6. Specific data entry to suit the actual motor application shall be accomplished by means

of the MPR.7. The relay shall have a broad range of motor terminal time characteristics ready for use or

be custom built.8. The following monitoring, protection and functions shall be provided:

a. Monitoring Functions1) Line-to-line voltage in RMS volts.2) Line amperage in each phase in RMS amperes.3) Line amperage in each phase in percent of motor full load current.4) Ground current in amperes.5) Winding temperature in degrees C. (hottest of 6 RTDs).6) Motor bearing temperature in degrees C.



7) Instantaneous power in KW.8) Instantaneous reactive power in KVARs.9) Power factor in percent.10) Energy consumption in megawatt hours.11) Running time (cumulative) in hours.12) Operation count.13) Frequency in hertz.14) Percentage unbalanced.15) Alarm only.16) Motor bearing temperature.

b. Protection Functions1) Phase loss2) Time overcurrent.3) Zero-sequence ground fault.4) Stator protection with 6 RTDs.5) Adjustable instantaneous overcurrent.6) Rotor protection starting/stalled rotor current7) Long acceleration.8) Under load.9) One shot lockout.10) Current unbalance.11) Over and under voltage.12) Voltage unbalance.13) Phase reversal and loss of phase reversal protection.14) Locked rotor.15) Short circuit.16) Motor overload.17) Motor overload protection incorrectly set.18) Momentary power loss protection with auto restart consisting of three-phase

current sensing devices that monitor the status of the current.19) Starter contractor fault protection.20) Starter transition failure.

2.3 GENERAL ELECTRICAL REQUIREMENTS

A. Master Control Panel: The manufacturer shall conform to the Chrysler Basic Electrical Guidelines for Equipment and Chrysler Corporation Book of Implementation Guidelines: Paintshop.1. Each processor control panel shall have permanent legend tags identifying the names of

all remote I/O sequence panels, and control consoles controlled by the programmable controller.

2. Each control panel shall have a swing out shelf for an Allen Bradley 6160-T53 terminal. The shelf shall be located on the interior side of the control panel.

3. Each control panel shall have a collapsible drawing shelf.4. Each control panel shall have two (2) control panel door pockets. One (1) door pocket

shall be sized to accept one (1) 24" x 36" set of Electrical "as-built" blueline drawings. One (1) door pocket shall be sized to accept one (1) complete bound "as-built" ladder logic printout.



5. The manufacturer shall provide and insert one (1) full-size set of "as-built" blueline drawings on a drawing stick into each control panel door pocket, and one (1) complete bound ladder logic printout shall be provided in each control panel.

6. As a minimum, each control panel shall require the following door mounted devices:

Process running (pilot lights)Process start (pushbuttons)Process stop (pushbuttons)Ground fault (pilot lights)Panel alarm hornFault reset (pushbutton)Silence alarmControl panel power on (pilot light)Rotating beacon

7. Surge suppressors are required for contactors, solenoids, and relays.8. Any device or signal (hardware or software) that causes the process system to stop shall

have a separate pilot light located on the control panel door.9. Each control panel shall contain a properly sized control transformer. The minimum size

control transformer is 3 KVA.10. Control panels containing programmable controller PLC or DDC processors shall have a

Psytronics P-1301 surge suppressor mounted across the secondary side of the transformer, 120 volt power lines.

11. Door mounted lexan windows shall be provided to view the programmable controller, programmable controller I/O rack.

12. The control power on 120 volt power relay(s) must be monitored by the programmable controller.

13. The Contractor shall supply a minimum of ten (10) or 30 percent spare holes, whichever is greater, complete with hole plugs on the control panel door. The hole plugs shall be painted to match the control panel enclosure.

14. All transformers larger than 5KVA shall be mounted on the exterior roof of the control panel in a properly rated NEMA enclosure. The enclosure shall be designed and sized to provide for maximum transformer heat dissipation.

15. Lighting transformers shall be mounted on the exterior top of the control panel. Each lighting transformer shall be a minimum 2 KVA size.

16. All control panels shall be mounted on a 4" "C" channel. The "C" channel pad shall be painted to match the control panel exterior paint color.

17. The manufacturer shall provide touch-up painting for each control panel control enclosure damaged during shipment, storage, or installation. The paint colors used for touch-up painting shall match the original paint color and finish.

18. The Contractor shall paint all control panel enclosures:

Exterior Chrysler Blue (#NPVP-2.5PB/3/10)Interior Machine White (#NPVP-5Y9/1)

Interior of Door Safety Orange (#NPVP-3.75XY6/14)

19. All solenoids shall be separately fused.20. All control panel internal backplate or internal/external enclosure mounted equipment

shall be labeled with white lamacoid nameplates with engraved black letters to identify each device, or piece of equipment.



21. All control panel door mounted devices (pilot lights, pushbuttons, selector switches, etc.) shall be identified with white lamacoid nameplates with engraved black letters. The nameplates shall be square with a hole located in the center to allow the nameplate to be mounted behind and held in place by the door mounted device.

The function of the door mounted device shall be engraved in the nameplate above the device (ex: BXX thermal O/L fault) and the device line number of PLC I/O number will be engraved below the device (ex: 167PL).

22. Each control panel containing interlock wiring powered from another source shall have the following yellow lamacoid tag with black engraved letters. The tag shall read:

“WARNING”

“Disconnect does not DE-ENERGIZE all equipment in this enclosure.”“Yellow interlock wiring is hot with system off.”

23. Each control panel shall have a legend tag identifying the following information:a. Control panel numberb. Process descriptionc. Bus plug sized. Bus plug locatione. Control panel primary voltage.

24. Outputs to motor starters and solenoid valves are to be through Allen Bradley relays.

B. Hardwire Circuits1. Devices monitoring or controlling the safe operation of the system (emergency stop,

motor overload, motor disconnect, motor thermal overload, etc.) shall be "hardwired" and not controlled by the programmable controller. The programmable controller shall individually monitor the status of these devices, and control illuminating indicator lights.

2. Control circuits shall be designed for the "fail-safe" condition. Logic decisions should be based upon inputs turning on as opposed to loss of an input.

3. Safety circuits shall be designed for safety "fail-safe" condition. If a safety mat, light screen, or safety limit switch, etc. should fail, the system will stop as though a safety fault has occurred.

4. Each device monitoring or controlling the safe operation of the system (motor overload, motor disconnect, motor thermal overload, etc.) shall be individually wired to relays. All faults will be reset using a fault reset pushbutton through a hardwired "seal in" circuit.

C. Programmable Controllers1. General Items

a. Manufacturer shall provide Allen Bradley PLC5 enhanced family programmable controllers (ex.: PLC 5/40, 5/60) and associated hardware for all new process systems, as required for data collection and interface to the plant DIS and FIS system.

b. The manufacturer shall follow the guidelines established by Allen Bradley for the proper installation, and grounding of all programmable controller equipment when designing the programmable controller controls system.



c. The programmable controller and I/O rack power supplies only within the PLC enclosures shall be powered by a separate ground connected isolation transformer. The isolation transformer shall be powered from the line side of the control panel disconnect.

d. Circulation fans of 120 CFM or larger shall be furnished for the programmable controller.

e. A separate two (2) pole circuit breaker shall be provided to function as separate disconnect for the programmable controller isolation transformers. A (keyed) selector switch shall be mounted on the control panel backplate for processor power off/on.

f. All programmable controller card and rack switch settings shall be shown on the electrical drawings. Each switch setting shall have a description giving all switch position functions.

g. All programmable controller rack and card jumper positions shall be shown on the electrical drawings. Each jumper position shall have a description giving all jumper position functions.

h. Multiplexing of I/O devices to the programmable controller is not acceptable.i. Electrical components (limit switches, pushbuttons, solenoids, field lights, etc.)

shall be identified according to the corresponding I/O address.j. The manufacturer shall provide electromatic ER8-1A resistors for all solid state

programmable controller inputs (proximity switches, etc.).k. The electrical/controls Contractor shall load the FIS/DIS software.l. The programmable controller shall have continuous unused memory for F.I.S.m. The manufacturer shall not run Rack I/O, remote programming, DCM module, or

data highway (+) communication cable in panel wire duct with control or power wires.

n. Manufacturer shall use high density 16-point input and output modules. The programmable controller and I/O racks shall be configure for single slot addressing.

o. All programmable controller solenoid and relay outputs shall be separately fused. The manufacturer shall use Allen Bradley 1492-H4 fuse holders or Owner approved equal.

p. The manufacturer shall receive a listing of data highway (+) station numbers from Chrysler F.I.S. The manufacturer shall configure each programmable controller dip switch settings to match the Chrysler F.I.S. supplied data highway (+) station numbers.

q. Programmable controllers shall be adequately sized to perform all functions properly while achieving the Chrysler standard spare space and memory requirements. Programmable controllers which do not meet spare space, memory requirements, and have excessive scan times shall not be accepted by the Owner or representative. If a programmable controller is not accepted by the Owner or representative, the manufacturer shall install an additional processor to split the system to relieve the burden of the original processor.

r. All peripheral devices shall have the proper NEMA rated enclosure to withstand the plant environment where they are located.

s. The manufacturer shall provide all programmable controller equipment, (programmable controllers, I/O cards, power supplies, racks, communication cards, station connectors, etc.) required for all equipment under this contract.

t. All conditions that cause the process to stop (processes, safety equipment, faults, etc.) shall be individually monitored by the programmable controller.



u. The manufacturer shall provide and install a McNaughton/McKay Programming Port Catalog #McMc-NPDH+-CPD at each programmable controller console panel.

v. The manufacturer shall provide and install batteries inside each PLC5 family programmable controller. The batteries will allow the PLC5 programmable controller to retain its memory in the event of a power failure.

w. The processor power isolation transformer shall be a minimum size of 1.5 KVA and mounted on the exterior wall of the process control panel. A psytronics surge suppressor P-1301 shall be provided across the 120 VAC transformer secondary lines.

x. Where more than one (1) programmable controller is used to control a system, the area which each processor controls shall be split to minimize interlocking between the programmable controllers.

y. The processor power isolation transformer shall also provide the power for:1) Rack I/O power supplies.2) McNaughton and McKay programming ports.

2. Communications Networka. Communications networks shall be designed to assure the network will function

properly.b. The manufacturer shall clearly identify all communications equipment, software,

and associated costs in the bid submittal.c. The manufacturer shall specify:

1) The pin wiring and size of all connectors.2) The communications wiring, type (RS-232, RS-423, etc.).3) The type of data transmission coding (BCD, ASCII, etc.)

d. The manufacturer shall not exceed the maximum recommended distance when connecting equipment to all peripheral devices.

e. The programmable controllers and associated hardware shall be configured for the communication networks.

f. No information, safety, motion controlling, or interlocks shall be implemented with the Data Highway (+) communications hardware. The data highway (+) network is for data communications for the monitoring of equipment status.

3. Logic Designa. The manufacturer shall fully comply with all guidelines and specifications

established by the Owner or representative for the programming techniques to be used when designing the programmable controller system.

b. The programmable controller logic shall sequentially start the system, control and monitor the status of all process devices, equipment, and motors, and sequentially stop the system.

c. The manufacturer shall be responsible for all programming required for a complete and workable system. All programs shall be developed off-site. The Owner or representative shall not furnish program facilities, program loading, or program storage.

d. Programmable controller programs must accomplish the fundamental goals for software design.1) Reliability - Reliability must prevent failure as well as provide fast recovery

from those failures which will occur.



2) Clarity - The program must be clearly written and documented such that skilled trades and engineering personnel can easily understand them.

3) Efficiency - The manufacturer shall make proper and efficient use of processor memory.

e. Control logic shall be designed so that decisions are based on field inputs rather than the memory of a previous decision or movement.

f. The programs shall be designed in a modular fashion. A control module may be defined as sequential lines of logic that define the control functions for a distinct portion of the process system.

g. Programmable controller programs shall be written to follow the "flow" of the process system. Logic written for a specific control area will be confined to a specific area of the program and not spread throughout the program. PLC memory shall consist of as a minimum:1) Process control logic - D.I.S. logic2) Diagnostic logic - D.I.S. driver logic3) Fault recovery logic - Square memory

4. Diagnosticsa. Diagnostic rungs shall be provided at the beginning of each programmable

controller program. These diagnostic rungs shall be organized by function. Motion output monitoring (solenoids, relays, contactors, etc.), fault monitoring, counter monitoring, and other useful diagnostics shall be required.

b. The contractor shall provide PLC logic in accordance with approved Chrysler Standards. Logic standards to be provided by Chrysler.

c. The process control system will automatically maintain diagnostic data in a central PLC memory area. Precise formats to be developed together with Chrysler engineering staff.

d. Diagnostics must be to the component level; e.g. limit switch, solenoid, motor, etc.).

e. Diagnostics must include all process faults, as well as faults and interlock status for any cells or process equipment that is interfaced.

5. Fault Detectiona. All fault recovery and start-up/shutdown procedures shall be tested with plant

personnel and the procedural techniques documented as they are worked out. This document will become part of the "as-built" documentation.

6. Memory Organizationa. The programmable controller memory table shall be organized and documented to

provide ease of maintenance. Internal addresses should be grouped together for specific control areas. In addition, common internal bits should be used for common functions which occur throughout the system.

7. Logic Documentationa. Programmable controller programs shall be documented with the same

terminology as labeled on control devices and operator stations. The program shall be documented thoroughly to assure quick look-up of specific control areas and ease of maintenance.



b. Titles shall be provided to divide and identify specific areas within the programmable controller program.

c. Programmable controller inputs and outputs shall be documented to identify the device (selector switch, pushbutton, solenoid, relay, field light, pilot light, limit switch, etc.).

d. All programmable controller programs shall contain as a minimum, the following:1) All outputs completely cross-referenced.2) Memory map.3) Title index with pages.4) Title and I/O description listing.5) Input contacts shall have the output rung listed for each contact.

D. Interfacing Process to Chrysler D.I.S.1. The manufacturer shall provide and install end of line resistors in the process and FIS

data highway network, once the networks are defined.2. The manufacturer shall provide the following documentation to Chrysler D.I.S. prior to

commissioning.a. Sequence of operation.b. Process layout drawings.c. Complete control panel schematics.d. Ladder logic program, bound in book form, complete with address descriptions,

memory map, cross-referencing, and ladder logic.

Should any of the items listed above be changed, a revised set of documentation shall be provided to Chrysler D.I.S. no later than one (1) week after the revisions occur.

3. The manufacturer shall engineer and install software and documentation in the programmable controllers to provide process system faults and diagnostics in the bit level format required for use by Chrysler D.I.S.

4. Chrysler D.I.S. shall terminate the plant data highway plus (+) cabling to the D.I.S. system.

E. Approval Documentation1. The manufacturer shall submit complete process design information for approval. The

design information shall include a complete sequence of operation, fully detailed and dimensioned electrical equipment location layouts, start-up and shutdown procedures document, and complete control panel design information, (title page with index of drawings, electrical equipment location layouts, riser diagrams, interconnection diagrams, electrical schematics, control panel interior and exterior layouts, operator station layouts, programmable controller I/O schematics, programmable controller communications diagrams, programmable controller equipment dip switch settings, a complete control panel, operator station, programmable controller, and electrical field equipment material listing).

2. Any sequence of operations, electrical equipment location layouts, start-up shutdown procedures document, and control panel/operator station approval documentation submitted to the Owner or representative without complete design information shall be rejected by the Owner or representative.

3. The manufacturer shall comply in full with all Owner or representative approval comments or changes in the approval documentation. Any approval comments not complied with by the manufacturer shall be reworked, redesigned, and revised.



4. No material fabrication or installation shall occur until the manufacturer receives the Owner's or representative's full approval on all approval documentation.

5. Drawing numbers shall be assigned by the manufacturer according to the Owner's or representative's standard numbering scheme. All electrical drawings shall be done in a neat, clean, concise, legible, and professional manner.

6. The manufacturer shall, when submitting revised existing design documentation (title page with index of drawings, electrical equipment location layouts, control panel schematics, riser diagrams, interconnect diagrams, and programmable controller programs), for Owner or representative approval shall send two (2) different sets of documentation. The first set shall be marked to show items removed or changed in the original documentation. The second set shall be the actual design documentation as it will be installed for all processes covered under this contract. All changes in both sets of design documentation submitted for approval shall be highlighted and marked to make them easily identified to the Owner or representative, and returned to the manufacturer. The manufacturer shall make the appropriate changes to the design documentation and resubmit it to the Owner or representative for approval.

7. The manufacturer shall provide to the Owner or representative two (2) separate sets of "B" size field device layouts, and control panel drawings bound in book form with hardcover one (1) week after full Owner or representative approval is received. The drawings shall be revised to show all Owner or representative approval changes. The control panel drawings shall show the actual "as-built" control panel prior to shipment, or rework in the Toledo Assembly Plant. The drawings shall be separated by conveyor and control panel with labeled divider tags.

8. The manufacturer shall provide all logic design for the process systems covered under this contract. The manufacturer shall submit ladder logic program printouts for approval three (3) weeks prior to system debug. Each ladder logic program printout shall have inputs and outputs numbered and labeled complete with mnemonics. Each ladder logic printout shall be separately bound in booklet form.

9. The manufacturer shall submit to the Owner or representative for approval two (2) sequences of operation, two (2) start-up, shutdown procedures documents, two (2) complete sets of electrical equipment location layouts, and complete control panel schematic drawings, one (1) full-size sepia set 24" x 36", one (1) full-size blueline sets, and two (2) complete sets of bound ladder logic documentation.

10. The sequence of operation shall be written describing the operation of the process system. This document shall include a description of each separate control area. The document should be written to follow the "flow" of the process system. A description of specific limit switch functions, operator, controls, and methods of control shall be provided. This document shall be submitted to the Owner or representative and approved prior to proceeding with the design phase of the project.



F. "As-Built" Documentation1. The final "as-built" documentation is required, one (1) set of 24" x 36" mylar drawings,

one (1) set of 24" x 36" blueline drawings separately bound for insertion into the control panel enclosures, and seven (7) sets of B-size 11" x 17" drawings to be included with the system manuals. Additionally, three (3) sets of AutoCad version 13 drawing file disks (3-1/2" size high density type) shall be provided. All drawing files shall be stored on the disks in .dwg format. Files shall not be compressed unless a single file will not fit on one disk. If compression is used, the file must be self-exacting. All drawings shall have the menu set to "ACAD.mnx". Any required shapes files, font files, or symbol files shall be included. Each disk shall have the text format "read.me" DOS text file that lists the files contained with manufacturer a description of the files. The manufacturer shall also provide seven (7) sets of complete process programmable controller and panelview program printouts bound in book form and three (3) sets of ICOM and panelview program file disks (3-1/2" size high density type) shall be provided. The program disks shall contain all ladder logic and documentation files in the Chrysler program approved format.

2. The Owner or representative shall approve the "as-built" electrical drawings, PlC programs, and software documentation prior to final system acceptance. The Owner or representative will verify, during the "as-built" approval process, the final "as-built" documentation represents actual system conditions. Any discrepancies the Owner or representative finds between the "as-built" documentation and the actual system conditions will cause the "as-built" documentation to be returned to the manufacturer. The manufacturer shall revise the "as-built" documentation to show the actual system conditions and resubmit them to the Owner or representative for approval. Final system acceptance will not occur until all "as-built" documentation is approved and accepted by the Owner or representative.

G. Manuals1. Electrical Maintenance Manuals

a. The manufacturer shall provide five (5) sets of electrical maintenance manuals containing, as a minimum, operation and maintenance manuals of purchased equipment, source list for purchased equipment, spare parts list, sequence of operations, start-up/shutdown procedures document, complete 11" x 17" drawings (or Owner or representative approved equal), PLC program documented, annotated printout, and panelview (MMI) documented, annotated printout. The purpose of the maintenance manual is to fully describe all components used in the system, and provide complete system documentation. This will be bound and indexed in 3" D-ring binders.

2. Electrical Log Booka. The manufacturer shall provide five (5) sets of electrical log books containing as a

minimum, the following items in report format:1) Motor test reports.2) Discrete controller configuration sheets with all parameters.3) Instrumentation calibration and procedure reports.4) Discrete component reports.

(Example: timer setpoints, air conditioner setpoints, ITR setpoints, etc.5) Alarm logic configuration sheets with all parameters.6) Variable frequency drives configuration sheets with all parameters.



NOTE: Formats must be approved by the Owner or representative prior to start-up.

7) These will be bound and indexed in 3" D-ring binders. The purpose of this book is to provide complete system documentation.

PART 3 - EXECUTION

3.1 INSTALLATION:

A. Equipment Installation: Include costs required to furnish technically qualified personnel, who are fully familiar with installing, operating, and servicing the equipment and control systems, for the purpose of supervising of installation of the units, and who shall notify the Owner of any discrepancies of improper conditions noted.

B. Allow six (6) 1-day visits to cover installation.

3.2 START-UP AND COMMISSIONING:

A. Include costs required to furnish technically qualified personnel, who are fully familiar with his equipment and control systems, for the purpose of equipment start-up, including calibration and adjustment of all equipment furnished, setting of instrumentation and controls, initial running and testing of systems for proper operation and performance.

B. All utilities necessary for testing, trial, and start operations including power, air, and water will be furnished without charge by the Owner.

C. Unit start-up operation shall include system evacuation, leak detection tests, charging of refrigerant and oil, adjustments and all other such operations normally associated with the equipment provided.

D. Start and run each unit independently and, where applicable, in combination with other machines for a continuous period of not less than 48 hours. All machines shall be operated in such a manner as to develop full rated tonnage. During the running period, operating data shall be recorded of all pressure, temperature, flow and control settings for each machine, so as to assure and substantiate that the system is in conformance with the scheduled tonnage. Data shall also be recorded to assure proper performance at various part-load conditions.

E. The manufacturer shall provide the services of a factory-trained representative to supervise the testing, evacuation, dehydration, charging, adjusting and initial start-up of the unit including 5 KV motor starters.

F. The system shall be complete and in satisfactory operating condition before turning over to Owner's operating personnel.

G. Should additional trips be required due to equipment malfunction or performance, these shall be provided at no additional cost to the Owner.

H. Adjustments required for balancing shall be made by the manufacturer's representative.



3.3 TEST AFTER INSTALLATION

A. If requested, following completion of the installation and after initial commissioning, testing and balancing work has been completed, an acceptance test to demonstrate the performance of the installed refrigeration machines shall be made by a recognized testing agency, acceptable to the Owner. Costs for this testing service will be paid by the Owner.

B. Testing shall conform to ARI standard 550-90 where applicable with the following exception:1. The net usable tons of water chilling produced by each chiller shall be a minimum of 100

percent of specified capacity while operating at specified design load operating conditions.

C. Should performance test show a deficiency in capacity, the manufacturer shall make alterations to the refrigeration machines to overcome deficiency and pay for the test. Failing in this, the Owner shall be compensated by either, or a combination of both of the following:1. Installation of additional capacity.2. A percentage refund of the refrigeration machine contract price proportional to the

percentage of deficiency established.

D. Should performance test show the manufacturer requires more than his bid KW/Ton or fails to meet specified KW/Ton. The manufacturer shall promptly correct deficiency at no cost to the Owner. Failing in this, the Owner shall be compensated with a one-time payment of $10,000 U.S. for each 0.01 KW/ton per unit tested above manufacturer's bid value, for each refrigeration machine.

E. Field capacity tests if required are to be conducted under full load and part load conditions to verify capacity and turn down capability of each machine. Tests are to be conducted using a computerized data acquisition and processing system with full instrumentation and with all output recorded. Analog and digital inputs and outputs to be obtained shall include motor inlet KW, motor voltage amperage and power factor, inlet and outlet temperatures on evaporator and condenser using RTDs, inlet and outlet pressures on evaporator and condenser using insertion flow probes, ambient temperature conditions, and other data as necessary to verify system performance. The Owner will operate the system so as to provide sufficient constant load necessary during the test period. Output data is to provide readout of all input information, together with processed output for motor amperage, machine tonnage output, total thermal balance into evaporators and from condensers, as well as KW per ton rating.

3.4 TRAINING

A. Instruction of Owner's Personnel - Furnish technically qualified personnel, who are fully familiar with his equipment and control systems, for the purpose of instructing selected personnel employed by the Owner during start-up in the proper techniques for operation and maintenance of the equipment.

B. The instruction includes "hands on" training of Owner's personnel in operation and maintenance of the equipment.

END OF SECTION
