CCPEOC – Central Chiller Plant Energy Optimization Controller Guide Specification

1.1 CCPEOC DESCRIPTION A. The Central Chiller Plant Energy Optimization Controller, CCPEOC or EOC, is a chiller installed or remotely installed hardware and software control system consisting of an open-protocol Niagara Framework “Tridium” JACE platform and chiller plant operation software engineered to directly monitor, control, stage and optimize the chiller, its compressors and other connected mechanical equipment and instrumentation such as cooling towers, pumps and valves to produce the required thermal duty at the lowest possible total kW/ton energy consumption.

1.2 APPROVED SUPPLIERS The control contractor shall use only the manufacturers listed below for the Central Chiller Plant Energy Optimization Controller - ArcticJACE EOC

ARCTIC CHILLER GROUP – Arctic Cool Chillers, Ltd. 2100 Steeles Avenue East Brampton, ON Canada L6T 1A7 (905) 789-9988

ArctiChill 200 Park Avenue Newberry, SC 29108 (800) 849-7778

1.3 QUALITY ASSURANCE A. All EOC products and manufacturer supplied connected devices and systems, and the components used therein shall be nationally recognized and readily available brands, new and currently manufactured items. This provision applies to the central controller hardware and the User Interface. The use of proprietary controller hardware or interface screen shall not be acceptable. All EOC hardware must be readily available in local and regional industrial and electrical equipment supply companies. B. Codes and Standards: The Controls Contractor shall meet all applicable local and national standards, practices and codes as well as the requirements indicated herein. B.1. Bear the UL Mark B.2. Bear the ETL mark B.3. Remote control panel provided shall be assembled in a UL or ETL Certified facility. B.4. Hardware JACE – All hardware shall be open protocol Tridium JACE using Niagara Framework technology. Execution code shall run live on industrial JACE hardware. The use of SoftJACE or compiled code running in MS Windows Embedded shall not be acceptable. B.5. The EOC shall be designed to natively operate with all major versions of Building

1 ARCTICJACE CCPEOC SPECIFICATION September 2013, Version 1.2 Automation Systems without the use of external protocol translators. B.6. EOC Input/Output modules and interface screens shall be hardware commonly available at supply companies. EOC containing proprietary hardware available from a single supplier is not accepted.

FUNCTIONAL REQUIREMENTS A. General Software Requirements A.1. EOC software shall monitor and optimize the energy required for chilled water production using engineered control software approaches as measured in input kW energy at each node and the total kW of the chilled water plant with all connected components. A.2. The software and the user interface functionality shall be designed to provide complete operator control of functions and set points as prescribed in this Specification. A.3. The Software shall utilize control and wiring in a home-run method where each connected components shall be directly connected to terminal blocks of the EOC. To facilitate serviceability and troubleshooting the use of series control loops that connect more than one controlled node component shall not be acceptable. Only dedicated connections and control between the EOC and the controlled device shall be accepted.

B. Optimization Functions: The EOC shall control and optimize the following: B.1. Staging and VSD Speed Control of Chillers B.1.a.) Stage entire chillers in and out of service as required to meet dynamic building thermal loads and minimize the total kW required for chilled water production at each chiller. Dynamically set chiller sequencing based on load side variations in demand, scheduled load timing and pull-down rate. B.1.b.) Dynamically adjust chiller sequencing set points based on real time calculation of compressor kW efficiency and available operating envelope at that set of conditions. B.1.c.) Dynamically adjust the chilled water temperature set point in response to user dictated sequences to facilitate energy reduction when AHU loads are reduced to a prescribed and controller settable level and to meet demand-response requirements, if any.

B.2. Staging and VSD Speed of Chilled Water Pumps B.2.a.) Stage and optimize the rotational speed and energy of connected chilled water pumps and their VSD drives to provide adequate flow in the chiller to maintain correct fluid velocities and avoid laminar flow conditions. B.2.b.) EOC shall correlate chiller staging with pump staging and speed and shall automatically operate chilled water isolation valves at any chiller piped in parallel to assure no chilled water or condenser water mixing occurs during chiller staging sequences and to prevent excessive fluid velocities in parallel installations.

2 B.2.c.) Dynamically set chilled water pump VSD speed to maintain load-side AHU differential pressure corresponding with the dynamic load. Continuously monitor differential pressure transmitters installed at load-side AHU(s) to correlate chilled water pump speed with variations of load.

B.3. Cooling Tower Staging and Condenser Water Pumping B.3.a.) Utilize ambient temperature and RH sensors to dynamically calculate enthalpy at the cooling towers. EOC shall utilize these values to set cooling tower fan speed and condenser water pump speed and bypass valve positions to maximize available outdoor conditions and dynamically reduce chiller energy. B.3.b.) Dynamically adjust cooling tower staging of multiple parallel cooling towers and VSD fan speed and connected condenser water pumps to correlate the optimum condenser water temperature and flow rate to minimize chiller compressor energy while minimizing combined total kW of chillers, fans and condenser water pumps. B.3.c.) EOC shall have settable minimum flow rates for condenser water VSD pumps to meet the minimum flow requirements of the flow nozzles of the cooling tower and to assure complete distribution of condenser water across the tower fill. B.3.d.) Energy optimization methods which rely on simple cooling tower sump temperature and not enthalpy calculations, or methods than employ simple chiller and drive power input without adaptive calculation of real-time compressor operating envelopes, including so-called “wire-to-water”, “natural curve” and “Equal Marginal Performance Principal” methods are not accepted. EOC shall have direct communications with the chiller controller and use the data from each compressor in order to meet this requirement.

B.4. Condenser Water Bypass Valve Operation B.4.a.) Dynamically adjust condenser bypass valve position to maintain correct compressor head pressure during cold start operations and to assure minimum capacity is met during energy-optimized low condenser water temperature operation. B.4.b.) EOC shall have user control settings that define the priority of capacity over energy, or energy over available capacity and shall automatically protect the compressor from surge and choke conditions that can be caused by reduced condenser water temperatures by reducing capacity and/or changing chilled water temperature set points to compensate. EOC methods that do not have the ability to correlate real-time dynamic compressor envelopes with bypass valve operation, but rely on simple input energy to the chiller shall not be acceptable.

B.5. User Interface Requirements B.5.a.) EOC shall provide an industrial 15” or larger high-contrast 16-bit color touch- screen user interface using standard non-proprietary hardware. The UI shall display and

3 ARCTICJACE CCPEOC SPECIFICATION September 2013, Version 1.2 provide drill-down capabilities for all current plant optimization nodes. Valve positions, component staging, chiller energy and total plant kW/ton, set points and current values from sensors and actuators shall be clearly displayed. B.5.b.) The interface screen operation shall not be dependent on the EOC controller hardware so that the EOC can operate normally even if the screen is absent or not functioning. EOC systems where the screen and controller are mutually dependent for normal plant operation shall not be acceptable. B.5.c.) EOC shall provide native RJ45 Ethernet capabilities and shall provide LAN based or Wireless WiFi based secure VPN communications for remote user access and control using industrial grade DIN mounted and panel wired access point. Access protocols that rely on Microsoft Windows runtime layers or that do not provide industrial DIN mount standard VPN connectivity or require separate VPN access licenses shall not be acceptable. B.5.d.) Remote communications that rely on consumer or commercial grade static IP routers or gateways shall not be acceptable. EOC manufacturers shall provide IT support for Owners to configure secure VPN access and firewall 1:1 Network Address Translation settings to assure reliable operation and secure remote access. B.5.e.) Failure of any EOC connected device or operating conditions that results in a change in optimization functions shall be indicated on the display. To facilitate serviceability and troubleshooting, all connected devices shall be wired in home-run fashion. Systems that use series BUS loops that contain more than one control or sensing node shall not be acceptable. An alarm condition shall cause the EOC to change registers that can be monitored by the building BAS control system. B.5.f.) Documentation shall be accessible at the EOC interface and shall include at a minimum Operations and Maintenance Manual, Sequence of Operation and Wiring Diagrams with final, as commissioned terminal block landing locations for all connected and separately run nodes. B.5.g.) Integrated Compressor Software – The EOC shall include an industrial form- factor PC with capability to run Danfoss Compressor Monitoring Software.

1. SUBMITTALS a. The EOC hardware including manufacturer supplied sub-systems, drives and periphery instrumentation shall be presented in a formal Submittal within one week of Order. The Submittal and related documents shall be reviewed by the consulting engineer in a timely manner and returned with mark-ups or authorization to the Manufacturer or its authorized representative. b. Component purchasing, factory engineering or fabrication shall not commence until a signed Submittal authorizing a release for manufacturing is received and accepted. c. The CCPEOC supplier shall submit the following within 10 days of contract award: Hardware Submittals:

4 c.i.1. Process and Instrumentation diagram showing the controller and connected pump and fan drives, sensors and actuators that are connected to the EOC system. c.i.2. A system hardware listing of equipment indicating unit quantity, manufacturer, model number and component manufacturer’s technical data sheets. c.i.3. Diagrams of connection points of all hardware devices with reference documents for power and control wiring with terminal locations.

c.ii. Software Submittals: c.ii.1. Narrative sequence of operation for the EOC optimization control logic and the connected chillers, pumps and fan energy nodes under its control. c.ii.2. Basic operator instructions with referenced screen images for EOC controller, interface screen and any control adapters utilized in the control or communications protocol employed. c.ii.3. Energy analysis showing the predicted performance in kW/ton and total projected kW consumption of the CCP across one annualized period correlating in 10% increments:

(a) the annualized load profile of the EOC thermal requirement (b) the annualized condenser water temperature profile and (c) the CCP equipment energy profile including all EOC chillers and drives. (d) the kW/ton effect of utilizing chilled water resets at various load points

c.ii.4. The chiller(s) performance shall be AHRI Certified at AHRI conditions and AHRI documents for the chiller(s) models chosen shall be provided showing standard IPLV rating and NPLV performance under the conditions prescribed in the Specifications and Schedule. NPLV performance shall not be AHRI Certified for performance, and be selected to optimize the chosen compressor technology to minimize total plant energy consumption while meeting minimum system load requirements. c.ii.5. A list and description of controller data registers for use with the Building Automation System

1.5 EXECUTION

5 ARCTICJACE CCPEOC SPECIFICATION September 2013, Version 1.2 C. The EOC supplier shall engineer, program and configure components to meet the load profile requirements of the site while minimizing component and total chiller plant energy using optimized component staging and loading and correlating in real time chiller energy, available condenser temperature and tower fan drive speed and other dynamic set points. D. The EOC supplier shall provide manufacturer supplied hardware to the appropriate Mechanical and Controls Contractors for installation. EOC that are engineered for remote mounting (not inside the chiller) shall arrive in a NEMA rated ETL or UL enclosure completely assembled and wired. The EOC manufacturer shall not be responsible for installation of cables or conduit for the operation of the EOC. All installation tasks shall be the responsibility of site contractors so that commissioning of the EOC and connected components can take place on one site visit of factory personnel. E. Upon completion of the installation of the EOC hardware and Manufacturer Certified commissioning, and upon final acceptance of the equipment by the owner, the manufacturer shall provide the services and documentation described below. The Owner shall certify in writing that the EOC operation is accepted and meets Engineers specifications.

A.1. EOC Settings and Commissioning – The EOC shall be fully commissioned, including verification and documentation of the EOC settings for the operation and optimization control sequences of all EOC connected chillers, fans, pumps, valves, drives and reset functions, to assure all communication nodes and control logic is functioning in accordance with the submittal. A.2. Project Specific Software – Software, screen images and documentation developed specifically this EOC installation shall be transferred to the Owner in its source format. A.3. Owner Training and Documentation – The EOC supplier shall provide owner’s technical representative(s) complete training in the use, operation and administration of the EOC, including factory certified instructions regarding the chiller and its controls. Training shall take place at the location of the EOC installation and shall be not less than one day in length. Training shall include in-depth understanding of the control methods and settings. A.4. Perpetual Use License for EOC software. Use license includes the provision for annual maintenance and site support fees as applicable. A.5. Electronic files containing the EOC user programs and display screen software, if any. A.6. Equipment warranties for EOC and manufacturer supplied and connected components. A.7. First-Year Continuous Commissioning. The EOC provider shall provide at no charge to the Owner monthly monitoring of the installation using the secure VPN internet access provided. Internet access, RJ45wiring to the panel and/or WiFi SIM cards are the responsibility of the Owner and must be in place for Remote Continuous Commissioning to occur. The following services shall be provided with this Service. A.7.a.) On a monthly basis, EOC personnel shall with the Owners on-site technician perform analysis and adjustment of the thermal load profile, component level energy and staging and energy optimization settings to assure the EOC is operating at intended and peak performance. A.7.b.) Analysis of the chiller and plant energy usage versus baseline. A.7.c.) Verification of operating sequence during the previous month staging events.

6 A.7.d.) Review of previous month alarm logs and relevant changes or insights from the logs. A.7.e.) Dynamic Commissioning Service, DCS - After the initial year, the EOC provider shall offer dynamic system monitoring, including the automatic secure remote server- based polling and transfer of all analog and digital values on the EOC controller. Owners can “Subscribe” to a web based service that provide a dashboard of current values, trended history, and enables automatic user-settable triggers to alert users of changes to any digital state or analog value. The system shall enable remote access and optional direct control over register values and settings. This DCS service shall provide expert oversight by experienced EOC personnel.

1.2 ACCEPTANCE AND WARRANTY A. Hardware: 18 Month Warranty - EOC hardware shall be warranted free from defects for a period of twelve (12) months after date of acceptance, not to exceed 18 months from date of shipment. Hardware failures during the warranty period shall be adjusted, repaired, or replaced at no charge to the Owner when installed, configured and used as designed and commissioned. B. Software: Ten-Year Warranty - EOC software shall be warranted to operate as designed to control and energy-optimize commissioned energy nodes for ten years from date of acceptance.

7 ARCTICJACE CCPEOC SPECIFICATION September 2013, Version 1.2