OM 550/590 SEPTEMBER 2009

AIR-COOLED WATER CHILLING PACKAGES USING VAPOR COMPRESSION CYCLE

AHRI OM 550/590 October 2009

2111 Wilson Blvd, Suite 500 Arlington, Virginia 22201 (703) 524-8800

Sponsored and administered by:

PREFACE

The following manual outlines the procedures and policies of the AHRI Air-Cooled Water Chilling Packages Using Vapor Compression Cycle (ACCL) Certification Program operated by the AirConditioning, Heating, and Refrigeration Institute (AHRI). This manual is to be used in conjunction with the General Operations Manual for AHRI Certification Programs. Where the General Operations Manual and this product-specific manual differ, this product-specific operations manual shall prevail. The revision of this manual supersedes all previous revisions. The current edition of this manual, as well as the General Operations Manual, can be accessed through the AHRI website, www.ahrinet.org. The Air-Cooled Water Chilling Packages Using Vapor Compression Cycle Certification Program by AHRI provides for independent verification of the performance of the participants equipment. Safety criteria are not within the scope of this program. Participation in the program is voluntary. Any manufacturer, regardless of AHRI membership, may obtain approval of Program Ratings and use of the AHRI ACCL Certification Mark hereinafter referred to as the Mark. The Mark is the participants public representation that the ratings of randomly selected units have been verified by an independent laboratory in accordance with test procedures prescribed by this operations manual. A License Agreement is executed between the manufacturer and AHRI specifying the conditions under which such Ratings and the Mark may be used. No manufacturer has the right to use Program Ratings or to state that their products have been tested in conformance with the procedures outlined in this Rating Procedure unless and until they have received written authority from AHRI to use the Marks as applied to the specific approved Program Ratings. This operations manual has been prepared to assure that administration of the program is carried out in a uniform manner. It is an amplification of the license agreement signed by licensees and AHRI. General information, procedural details, and copies of forms are included in the guide. Provisions of the Operations Manual may be amended as provided in the Certification Agreements. This efficiency certification program complies with requirements of AHRI Standard 550/590, Water Chilling Packages Using Vapor Compression Cycle. Note: For Air-Cooled Chillers, this manual supersedes the ARI Water-Chilling Packages Using the Vapor Compression Cycle Certification Program Operational Manual April 2004. The ARI Water-Chilling Packages Using the Vapor Compression Cycle Certification Program Operational Manual April 2004 will remain in effect for Water-Cooled Chillers (WCCL) until such time as a separate manual for WCCL units is published.

Printed in U.S.A.

Copyright 2009, by Air-Conditioning, Heating, and Refrigeration Institute Registered United States Patent and Trademark Office

CERTIFICATION OPERATIONS MANUAL FOR AIR-COOLED WATER CHILLING PACKAGES USING VAPOR COMPRESSION CYCLE TABLE OF CONTENTS SECTION 1 PAGE Program Overview 1.1 Applicable Rating Standard .................................................................................... 1 1.2 Product Definitions.................................................................................................. 1 1.2.1 Air-Cooled Water-Chilling Package ........................................................... 1 1.2.2 Custom Unit ............................................................................................... 1 1.2.3 Field Trial Unit ........................................................................................... 1 1.2.4 Modular Chiller .......................................................................................... 1 1.3 Program Scope ....................................................................................................... 1 1.3.1 Program Scope Inclusions ........................................................................ 1 1.3.2 Program Scope Exclusions ....................................................................... 2 1.4 Intended Market ...................................................................................................... 2 1.5 Basic Model Groups ............................................................................................... 2 Qualification Process 2.1 Original Equipment Manufacturer (OEM) Applicants ............................................. 2 Step 1 Certification Application Package .............................................................. 2 Step 2 Participation Agreement ............................................................................ 3 Step 3 Qualification Sample Selection and Participation Fee Invoice .................. 3 Step 3.1 Rating Method(s) Approval ....................................................... 3 Step 3.2 Number of Qualification Tests ................................................... 3 Step 3.3 Payment of Participation Fee Invoice ....................................... 3 Step 3.4 Acquisition of Qualification Test Samples/Selection Criteria ........................................................ 3 Step 3.5 Facility Approval and Sample Selection .................................... 3 Step 4 Qualification Testing .................................................................................. 3 st Step 4.1 Qualification Test Options Following 1 Sample Failure .......... 3 nd Step 4.2 Qualification Test Options Following 2 Sample Certified Rating Test Failure ..................................................... 4 Step 5 Signing of License Agreement and Payment of Licensing Fee Invoice ................................................................................ 4 Step 6 Welcome to the Program ........................................................................... 4 2.2 Private Brand Marketer (PBM) Applicants .............................................................. 4 Step 1 Certification Application Package .............................................................. 4 Step 2 PBM License Agreement and Licensing Fee Invoice ................................ 5 Step 3 OEM Participation Agreement on Behalf of the PBM Applicant ................ 5 Step 4 Rating Method(s) Approval ........................................................................ 5 Step 5 Welcome to the Program .......................................................................... 5 Equipment Selection and Testing 3.1 Annual Testing Requirement .................................................................................. 5 3.2 Selection of Test Location ...................................................................................... 5 3.3 Witness Testing Procedures and Operations ......................................................... 5 3.3.1 Application for Witness Testing ................................................................. 5 3.3.1.1 Acknowledgement of Request .................................................. 5 3.3.2 Inspection of Witness Test Facility ............................................................ 6

3.4 3.5

3.6 3.7 3.8 3.9 3.10 3.11 4 5

3.3.2.1 Non-Compliant Inspection Results ............................................ 6 3.3.2.2 Final Approval of Witness Test Facility ..................................... 6 3.3.3 Scheduled Witness Test Facility Re-approval ........................................... 6 3.3.4 Unscheduled Facility Re-approval ............................................................. 6 3.3.5 Witness Test Operations at Participants Facility ...................................... 6 3.3.5.1 Advance Setup of Unit in an AHRI Approved Test Facility ....... 6 3.3.5.2 Duty Assignments of Representative ........................................ 6 3.3.5.3 Primary Instrumentation ............................................................ 6 3.3.5.4 Access Required for Laboratory Instrumentation...................... 7 3.3.5.5 Air Temperature Measurement ................................................. 7 3.3.5.6 Use of Laboratory Instrumentation ............................................ 7 Selection of Scheduled Test Samples .................................................................... 8 Rating Methods ....................................................................................................... 8 3.5.1 Requesting Approval of Rating Methods ................................................... 8 3.5.2 Initial Approval of Rating Software through Published Rating Comparison ................................................................... 8 3.5.3 Updates to Previously Approved Software ................................................ 8 3.5.4 Statements Regarding Certification........................................................... 8 Sample Acquisition Timeframe ............................................................................... 9 Break-in Operation and Start-Up of Test Units ....................................................... 9 Presence of Participant Personnel ......................................................................... 9 Certified Data .......................................................................................................... 9 3.9.1. Selection of Random Operation Point ....................................................... 9 Test Failures ........................................................................................................... 9 st 3.10.1 Options Following 1 Sample Failure ........................................................ 9 3.10.2 Second Sample Certified Rating Test Failure ........................................... 9 Penalty Tests ........................................................................................................ 10

Challenge Tests ............................................................................................................... 10 AHRI Directory of Certified Product Ratings 5.1 Publication of Certified Ratings in Certified Directory...........................................10 5.2 Data Forms ........................................................................................................... 11 Assessment and Payment of Certification Fees 6.1. Test Fees ............................................................................................................. 11 6.3 Equipment Delivery/Disposal Fees ....................................................................... 11 6.4 Universal Monetary Penalty .................................................................................. 11 Proper Claims to Certification 7.1 Publication of Non-Certified Ratings ..................................................................... 11 7.2 AHRI Verification and Monitoring of Computerized Rating Software and Selection Methods .......................................................................... 11 7.2.1 Random Comparisons ............................................................................. 11 7.2.2 Additional Monitoring ............................................................................... 11 7.2.3 Responsibility of Participant for Catalog/Software Revisions .................11 7.2.4 Data Comparison Between Rating Software and Catalog ......................12 7.5 Changes to Certified Chiller Model Groups ..........................................................12

Law of Pertinent Jurisdiction 8.1. Use of Manufacturer Test Facilities for Another Manufacturers Testing ............12 8.2 Provisions for Manufacturers Representative(s) .................................................12

Tables Table 1 Table 2 Table A.1 Table A.2 Table B.1 Table B.2 Table B.3 Figures Figure A.1 Figure A.2 Figure A.3 Figure A.4 Figure B.1 Figure B.2

Instrumentation Requirements ............................................................................... 7 Challenge Test Costs ........................................................................................... 10 Temperature Measurement Requirements ..........................................................13 Criteria for Air Distribution and Control of Air Temperature .................................14 Terms.................................................................................................................... 19 Correction Factor (CF) Coefficients ...................................................................... 19 Correction Factor (CF) Values.............................................................................. 20

Typical Air Sampling Tree .................................................................................... 15 Aspirating Psychrometer ...................................................................................... 16 Determination of Measurement Rectangles and Required Number of Air Sampler Trees ............................................................................... 17 Typical Test Setup Configurations ....................................................................... 18 Capacity Correction Factor ................................................................................... 20 Efficiency Correction Factor ................................................................................. 20

Appendices and Forms Appendix A Chiller Condenser Entering Air Temperature Measurement ................................13 Appendix B Barometric Pressure Adjustment .......................................................................... 19 Appendix C Form ACCL-DS1 - BMG Data Submittal Form ....................................................21 Appendix D Form ACCL-DS2 Certification Directory Listing Form .......................................22 Appendix E Form ACCL-DS3 Private Brand Marketer Product Data ...................................23 Appendix F Form ACCL-WT1 Application for Witness Testing ............................................24 Appendix G Form ACCL-WT2 Personnel Experience Questionnaire ...................................25 Appendix H Form ACCL-WT3 Facility and Equipment Questionnaire..................................26 Appendix I Manufacturers Decision Form.............................................................................. 29

ACCL OM 550/590 OCTOBER 2009 1. Program Overview 1.1 Applicable Rating Standard. It is mandatory for program participants to comply with the provisions of the latest edition of AHRI Standard 550/590, Performance Rating of Water Chilling Packages Using the Vapor Compression Cycle. A copy of this standard is available for download from the AHRI website, www.ahrinet.org. 1.2 Product Definitions. 1.2.1 Air-Cooled Water-Chilling Package. A factory-made and prefabricated assembly (not necessarily shipped as one package) of one or more compressors, condensers and evaporators, with interconnections and accessories including controls, designed for the purpose of cooling water. It is a machine specifically designed to make use of a vapor compression refrigeration cycle to remove heat from water and reject the heat to a cooling medium, air. 1.2.2 Custom Unit. A unit that is not listed, neither in a catalog nor electronically, that is a single instance special order in which customer requested components or additions change the performance such that ratings can no longer be obtained by utilizing the participants computerized rating software. 1.2.3 Field Trial Unit. A unit that is produced and provided to a customer, often at a reduced cost, for the purpose of gathering data on potential new products. These units are intended to transition into regular production should the field trial be successful. AHRI must be informed of any new model designations that will be designed and released for field trial. Once approved by AHRI, this trial may occur outside of the scope of the program. Field trial units will not be certified and will not be listed in the directory. The number of field trial units available shall not exceed two (2) percent of a participants annual unit sales volume. 1.2.4 Modular Chiller. A modular chiller is a unit that is made up of multiple chillers that can function individually or as a single unit. Modular chillers shall be certified provided that the chiller is rated and listed as a complete unit with a specific combination of modules and with a total capacity that is within the scope of the program. In this case, complete units consisting of multiple modules must be tested as a single complete unit as part of the certification program. 1.3 Program Scope. This program applies to Air-Cooled Water-Chilling Packages as defined in Section 1.2 and as follows: 1.3.1 Program Scope Inclusions. The following are included in the certification program for a both 50 Hz and 60 Hz products: Chillers between 0 and 200 tons [703 kW] manufactured prior to July 2011; b Chillers between 0 and 400 tons [1407 kW] manufactured between July 2011 and July 2013; and b Chillers between 0 and 600 tons [2110 kW] manufactured after July 2013 Units selected for use within the range of application rating conditions as per AHRI Standard 550/590 Hermetic or open type, electric motor driven Up to 600 volts All compressor types Units intended for use with glycol or other secondary coolant for freeze protection with a leaving chilled fluid point above 32F [0C] are certified when tested with water at standard AHRI rating conditions. Note a: 50 Hz products selectively certified as per Section 1.4
b

ACCL OM 550/590 OCTOBER 2009 Note b: Tonnage refers to units rated at full load AHRI Standard Rating Conditions per AHRI Standard 550/590.

1.3.2 Program Scope Exclusions. The following are excluded from the certification program for both 50 Hz and 60 Hz products: Condenserless chillers Evaporatively cooled chillers Chillers above 200 tons [703 kW] manufactured prior to July 2011; Chillers above 400 tons [1407 kW] manufactured prior to July 2013; and Chillers above 600 tons [2110 kW] Units for use outside of standard application rating conditions Chillers with voltages above 600 volts Chillers powered by other than electric motor drives, or open type compressors not supplied with motors by the manufacturer Glycol and other secondary coolants are excluded; secondary coolants for freeze protection are included as per Section 1.3.1 Free cooling ratings Heat recovery and heat pump ratings Custom Units as defined in Section 1.2.2 Field Trial Units as defined in Section 1.2.3

1.4 Intended Market. The intended market for this certification program includes all 60 Hz products that are sold for use in North America only (U.S., U.S. provinces, Canada and Mexico). The participant may selectively certify products (both 60 Hz and 50 Hz) that are exclusively sold outside of the intended market by line or basic model group. 1.5 Basic Model Groups. Each certified product offered by the participant will be grouped by basic model. At minimum, a Basic Model Group (BMG) is defined as a family of chillers using the same compressor or combination of compressors. A participant may choose to further subdivide its products into additional BMGs. 2. Qualification Process 2.1 Original Equipment Manufacturer (OEM) Applicants. With the additions noted below, the OEM qualification process will proceed according to the General Operations Manual, Section 4. STEP 1 Certification Application Package. In addition to the Application for AHRI Certification and Annual Certified Sales Volume Form noted in the AHRI General Operations Manual, Section 4, STEP 1, applicants shall submit the following: Form ACCL-DS1, OEM Basic Model Groupings. Data Submittal Form ACCL-DS2 (see Appendix D for sample data submittal form). The participant may upload data via the AHRI Directory of Certified Product Ratings (Directory). Copy of applicants computer catalog with rating software. Rating software shall be personal computer (PC) based, run on MS Windows platform and shall include version number or other revision coding. Rating software shall be furnished with instructions or training for data entry. Copy of applicants paper catalog, if applicable. All required forms per Section 3.3.1 of this manual for Witness Testing Facility Approval (if the applicant wishes to conduct witness testing at its facility).

ACCL OM 550/590 OCTOBER 2009 STEP 2 Participation Agreement. No further action required beyond that listed in Section 4, STEP 2 of the AHRI General Operations Manual. STEP 3 Qualification Sample Selection and Participant Fee Invoice. STEP 3.1 Rating Method(s) Approval. computerized rating method(s). AHRI must approve the applicants

STEP 3.2 Number of Qualification Tests. The number of qualification test(s) will be equivalent to the annual testing requirement noted in Section 3.1 of this manual. STEP 3.3 Payment of Participation Fee Invoice. Payment of the Participation Fee is due within 30 calendar days of the invoice issue date. Testing will not be conducted until the invoice is paid in full. STEP 3.4 Acquisition of Qualification Test Samples/Selection Criteria. Models will be selected based on highest efficiency, or at random. AHRI will utilize the participants AHRI approved computerized equipment rating software to select a unit to operate within the limits of rating conditions per AHRI Standard 550/590. Alternately, AHRI may request a list of all production models scheduled in a defined timeframe. Non-stock units may be selected if deemed necessary by AHRI. Upon notification of selections by AHRI, the applicant will have 30 calendar days to deliver the units to, or conduct witness testing at, an AHRI approved test facility. Extended transit times must be approved by AHRI staff prior to selection. STEP 3.5 Facility Approval and Sample Selection. If the applicant has applied to conduct witness testing at its facility, the Independent Third-Party Laboratory Testing Representative Contracted by AHRI (Representative) will contact the applicant to schedule a witness test facility inspection. Upon final approval of the application for witness testing, facility and equipment inspection, and the approval of the applicants computerized rating method(s), the Representative will contact the applicant to schedule initial qualification testing. Section 3 of this manual further explains the requirements and procedures for applying and conducting witness testing. Qualification testing may be scheduled simultaneously with facility inspection; however, should the facility fail inspection the testing must be delayed until the facility is brought into compliance. If the applicant has not applied to conduct witness testing at its facility, the qualification process will continue with the approval of the applicants computerized rating method(s) in Step 3.1. Upon approval by AHRI, the Representative will contact the applicant to schedule initial qualification testing at either the Independent ThirdParty Laboratory Contracted by AHRI (Laboratory), or at another approved facility as specified in Section 8 of this manual. STEP 4 Qualification Testing. AHRI will supply the Representative with the published ratings. The Representative will test the units, in accordance with AHRI Standard 550/590, against the published ratings. The applicant may prepare the equipment for test in the Laboratory or their approved facility, validate the setup for the operation of the equipment prior to conducting the test(s), and witness the testing. STEP 4.1 Qualification Test Options Following 1 Sample Failure. When the applicant is notified of a first sample certified rating failure, it has seven (7) calendar
st

ACCL OM 550/590 OCTOBER 2009 days to select one of the following options to obtain admission into the ACCL Certification program: Re-rate all models within the failed units BMG and all untested BMGs, proportionate to the failed tests results; Re-rate all models within the failed units BMG and elect to test a unit from an untested basic model group as selected by AHRI (should this unit pass then only the failed units BMG must be rerated, should this unit fail then all untested BMGs must be rerated); Successfully test a second sample of the same model (sample must be available within 30 calendar days following notification of failure).
nd

STEP 4.2 Qualification Test Options Following 2 Sample Certified Rating Test nd Failure. To obtain admission into the ACCL Certification program after a 2 sample failure: Re-rate all models within the failed units BMG and all untested BMGs, proportionate to the failed tests results; Re-rate all models within the failed units BMG and elect to test a unit from untested basic model group as selected by AHRI (should this unit pass then only the failed units BMG must be rerated, should this unit fail then all untested BMGs must be rerated). STEP 5 Signing of License Agreement and Payment of Licensing Fee Invoice. No further action required beyond that listed in Section 4, STEP 5 in the AHRI General Operations Manual. STEP 6 Welcome to the Program. No further action required beyond that listed in Section 4, STEP 6 in the AHRI General Operations Manual. 2.2 Private Brand Marketer (PBM) Applicants. With the additions noted below, the PBM qualification process will proceed according to the AHRI General Operations Manual, Section 5. PBM applicants are not required to undergo witness test facility inspection or initial qualification testing. PBM product certification is contingent upon the certification of the associated OEM product. PBM software must directly correlate to OEM software. If the software has variations, the PBM must register and test as an OEM. STEP 1 Certification Application Package. In addition to the Application for AHRI Certification noted in the AHRI General Operations Manual, Section 5, STEP 1, applicants shall submit the following: Form ACCL-DS3. This form shows the correlation between PBM participant units and OEM participant units. Data Submittal Form ACCL-DS2 (see Appendix D for sample data submittal form). The participant may submit a hard-copy of this form (available through AHRI) or, if available, upload data via the Directory. Copy of applicants computer catalog with rating software. Rating software shall be personal-computer (PC) based, to run on MS Windows platform, and shall include version number or other revision coding. Rating software shall be furnished with instructions or training for data entry. Copy of applicants paper catalog, if applicable.

ACCL OM 550/590 OCTOBER 2009 STEP 2 PBM License Agreement and Licensing Fee Invoice. No further action required beyond that listed in Section 5, STEP 2A of the AHRI General Operations Manual. STEP 3 OEM Participation Agreement on Behalf of the PBM Applicant. No further action required beyond that listed in Section 5, STEP 2B of the AHRI General Operations Manual. STEP 4 Rating Method(s) Approval. AHRI must approve the applicants computerized rating method(s). STEP 5 Welcome to the Program. No further action required beyond that listed in Section 5, STEP 3 of the AHRI General Operations Manual. 3. Equipment Selection and Testing 3.1 Annual Testing Requirement. Each program year, a participant will be assigned a number of tests equal to at least one-third (1/3) of the total number of basic model groups (BMGs), as listed in the Directory. Participants will have a minimum of two (2) tests per year, and no less than one (1) test per year, per country of manufacture. For example, if a participant lists nine (9) BMGs he shall be assigned three (3) tests. Traditional rounding methods will be used, (i.e. 10 BMGs will be three (3) tests, and 11 BMGs will be four (4) tests. The only exception to this rule is if the participant has only one (1) basic model. In such a case, only one (1) unit per country of manufacture will be tested. Countries where units are only reassembled shall not be considered as a location of manufacture. 3.2 Selection of Test Location. Testing shall be performed at an AHRI-approved facility or at the Laboratory. Tests may be run at the participants facility provided that this facility holds current AHRI approval and provided that each certification test is witnessed by the Representative contracted by AHRI. 3.3 Witness Testing Procedures and Operations. The ACCL Certification Program allows for witness testing, a situation where participant personnel, witnessed by a contracted Representative, conduct testing at a specific AHRI approved test facility on the participants premises. With the additions noted below, the witness testing process will proceed according to the AHRI General Operations Manual, Section 9.9. For approval of a test facility, the capacity of chiller that is used to determine the maximum approved capacity of the test facility shall be no less than 85% of the AHRI stated capacity for the test facility. 3.3.1 Application for Witness Testing. A participant shall submit all of the following to AHRI: Form ACCL-WT1, Application for Witness Testing; Form ACCL-WT2, Personnel Experience Questionnaire; Form ACCL-WT3, Facility and Equipment Questionnaire; A complete list of all instruments and equipment being used to perform certification testing in accordance with AHRI Standard 550/590 and a copy of each calibration report showing date of last calibration; A schematic drawing of the area of the test facility in which AHRI certification testing will be performed; and Photographs of the test facility in which AHRI certification testing will take place, which shall include sufficient views to show the location and connection of each instrument.

3.3.1.1 Acknowledgement of Request. AHRI will acknowledge receipt of the participants application to conduct witness testing. AHRI will review the material and will inform the participant if additional information and/or changes are required for the participants test facility to meet AHRI standards.

ACCL OM 550/590 OCTOBER 2009 3.3.2 Inspection of Witness Test Facility. Following preliminary test facility approval based on submitted data, the Representative shall inspect the participants test facility to verify compliance of the data submitted to AHRI Standard 550/590 and to the certification program. A chiller must be running in the facility for the inspection to be completed. 3.3.2.1 Non-Compliant Inspection Results. If the results of the inspection indicate that a participants test facility is non-compliant with AHRI Standard 550/590 or the certification program, all discrepancies must be resolved and resubmitted to AHRI before approval may be granted to proceed with AHRI tests. 3.3.2.2 Final Approval of Witness Test Facility. Upon acceptable results of the inspection, AHRI shall notify the participant, of final acceptance and approval to proceed with AHRI tests. AHRI will provide the participant with a certificate, approving the specific witness test facility for use for AHRI certification testing, that is to be displayed in the approved test facility. 3.3.3 Scheduled Witness Test Facility Re-approval. The participants witness test facility shall remain approved for no more than twenty-four (24) months, after which time re-approval will be required. It is the manufacturers responsibility to contact AHRI when a re-approval is needed. Re-approvals are often scheduled in combination with a witness test, but must be pre-arranged. The Representative shall inspect the test facility to verify compliance with AHRI Standard 550/590 and the certification program. A complete list of all instruments and equipment used to perform certification testing in accordance with AHRI Standard 550/590, and a copy of each calibration report showing date last calibrated, shall be provided to the Representative. Upon re-approval by AHRI, the participant will receive a new certificate of approval to be displayed in the approved test facility. 3.3.4 Unscheduled Facility Re-approval. Any changes that may affect a participant facilitys ability to function per AHRI Standard 550/590 or in accordance with the AHRI certification program will result in the facility requiring re-approval prior to the conducting of any witness testing. Participants shall submit forms and undergo inspection as required for initial witness test facility approval. 3.3.5 Witness Test Operations at Participants Facility. 3.3.5.1 Advance Setup of Unit in the AHRI Approved Test Facility. It is acceptable for a participant to setup the test unit in the test facility prior to the arrival of the Representative. Prior to test commencement, the Representative will verify that the unit is the model selected by AHRI for testing and that the unit has been set up in the test facility in accordance with AHRI Standard 550/590. Units with continuous unloading must reach no more than 102% of full load capacity to ensure that the unit has not been oversized for the test. Units with discrete step unloading must be run at the maximum stage of capacity. 3.3.5.2 Duty Assignments of Representative. Unit testing, data acquisition, and data reduction will be performed by the participant and assisted and witnessed by the Representative contracted by AHRI. Verification of instrument application (in accordance with the procedures defined in AHRI Standard 550/590 and verification of calibrations will be performed by the Representative. 3.3.5.3 Primary Instrumentation. The Representative will use primary test instruments belonging to the Laboratory to measure power input, water pressure drop, and air and water temperatures in accordance with AHRI Standard 550/590.

ACCL OM 550/590 OCTOBER 2009 3.3.5.4 Access Required for Laboratory Instrumentation. Selected measurements require redundant instrumentation due to the fact that a heat balance cannot be obtained. Refer to Table 1 for instrumentation requirements. Table 1: Instrumentation Requirements Measurement Water Flow Water Pressure Drop Water Temperature Test Facility Instrument Requirements two flow meters one gauge or transducer two temperature sensors at each temperature location one temperature sensor in each aspirating psychrometer one thermopile grid per air sampling tree Additional Accommodations for Laboratory Instrumentation (none) one additional pair of inch NPT ports additional thermowell at each temperature location to accept a inch probe with immersion depth of to the diameter of the pipe additional temperature port in each aspirating psychrometer (see Appendix A) (none) Additional Verifications zero out prior to test zero out prior to test

(none)

Air Temperature Air Temperature (secondary) Electrical Power Note:

(none) all thermopiles to be within range of 0.50F [0.28C] at ambient, prior to test

two electrical power location to clamp on current measurement measurement device and taps (none) devices for voltage measurement All instruments shall be under current calibration that is traceable to NIST or a reciprocal agency.

3.3.5.5 Air Temperature Measurement: Participants facility shall utilize sampling tube assembly(s) to ensure air mixing and avoidance of stratification. See Appendix A for definitions and additional information. 3.3.5.6 Use of Laboratory Instrumentation. The Laboratory representative will insert test instruments belonging to the Laboratory in line with those provided by the participant. Readings will be taken from both devices. The readings from the participant data acquisition system will be used provided that: a) b) c) d) The participant equipment is under current calibration; The participant instrumentation and the Laboratory instrumentation do not vary by more than 2% for power input; Each participant instrument and the Laboratory instrument for water temperature at each location shall not differ by more than 0.2F [0.11C]; The water temperature difference across the evaporator as determined by the average of the two sets of participant instrumentation shall not differ by more than 0.2F [0.11C] from the Laboratory instrumentation; The air temperature difference entering the condenser measured by the participant instrumentation and the Laboratory instrumentation do not differ by more than 0.3F [0.17C]; and

e)

ACCL OM 550/590 OCTOBER 2009 f) All data acquisition is in accordance with AHRI Standard 550/590.

Should any of these criteria not be met, steps should be taken to ensure that the discrepancy is resolved. In cases where the discrepancy cannot be resolved and no damage is apparent, the Laboratory instrumentation data for that parameter will be used. 3.4 Selection of Scheduled Test Samples. AHRI will select equipment via the participants AHRI approved computerized equipment rating software, the unit will be selected to operate within the limits of rating conditions per AHRI Standard 550/590. AHRI may request that the participant provide a stock list or a list of all production models that fall within the scope of the program and are scheduled in a defined timeframe so a unit can be selected and/or a test scheduled. Any of the units may then be selected for AHRI testing. Non-stock units may be selected if required by AHRI. 3.5 Rating Methods. 3.5.1 Requesting Approval of Rating Methods. A participant shall request approval of its computerized rating method by submitting all of the following to AHRI: copy(s) of computer rating method(s) this is comprised of data input and output sheets from the participants in-house computer rating program and a copy of the participants computerized rating software; all necessary passwords to access software and updates; instructions or training for use of the computerized rating software; and a copy of the participant(s) published catalog, if applicable.

If the participant has more than one computerized rating method available to users, each method must be verified by AHRI. 3.5.2 Initial Approval of Rating Software through Published Rating Comparison. AHRI upon receiving the necessary materials will, if applicable, utilize the participants computerized rating method to determine computer ratings for a certain set of conditions and compare them for the same conditions as those in the published catalog, if a published catalog exists. Computerized rating output (printout and on-screen display) must match the published certified ratings from the catalog, if applicable. AHRI may also request selection sheets from customers who have received bids. These selection sheets must match the computerized rating output. The participant will be notified when the rating software has been approved for certification. AHRI must approve the computerized rating method prior to field release. 3.5.3 Updates to Previously Approved Software. As per the AHRI General Operations Manual, Section 9.4.1, AHRI must have an updated copy of any software being used in the field. Any updates shall promptly be provided to the program administrator via CD, an FTP site or other electronic transfer. Major changes to software shall go through an initial approval as per Section 3.5.2. 3.5.4 Statements Regarding Certification. When possible, for units within the scope of the program, the AHRI Certification Mark should be included on the computerized rating outputs for certified units in accordance with the AHRI Brand Usage Manual. All computerized rating outputs from an approved computerized rating method must include one of the following statements: for units within the scope of the program: Certified in accordance with the AHRI AirCooled Water-Chilling Packages using the Vapor Compression Cycle Certification Program which is based on AHRI Standard 550/590. Certified units may be found in the AHRI Directory at www.ahridirectory.org. 8

ACCL OM 550/590 OCTOBER 2009 for units outside the scope of the program: Unit is outside of the scope of AHRI certification, but is rated in accordance with AHRI Standard 550/590. 3.6 Sample Acquisition Timeframe. Upon notification of selections by AHRI, the applicant will have 30 calendar days to deliver the units to, or conduct witness testing at, an AHRI approved test facility. Extended transit times must be approved by AHRI staff prior to selection. Prior to test, AHRI will have supplied the Laboratory with the Published Ratings. 3.7 Break-in Operation and Start-Up of Test Units. A participant may instruct the Laboratory to operate the equipment for a manufacturer specified number of break-in hours, not to exceed 16 hours, prior to testing. In such cases the participant is required to pay all costs involved. 3.8 Presence of Participant Personnel. Participant personnel, critical to the operation of the witness test at the participants AHRI approved test facility, are permitted to be present during facility and equipment inspection, setup, and testing. The applicant may prepare the equipment for test in the Laboratory or their approved facility, validate the setup for the operation of the equipment prior to conducting the test(s), and witness the testing. 3.9 Certified Data. In accordance with AHRI Standard 550/590, the following certified ratings are verified by test, at full and part-load performance corrected to standard barometric pressure at sea level as per Appendix B: Standard Rating Conditions: o Full load capacity, ton [kW] o Full load Energy efficiency, EER [COP] o Water pressure drop, ft water [kPa] o Integrated Part Load Value (IPLV), EER [COP] Operating Map Conditions: o Full load capacity, ton [kW] o Full load Energy efficiency, EER [COP] o Water pressure drop, ft water [kPa]

3.9.1 Selection of Random Operation Point. In addition to the specific standard rating conditions noted in AHRI Standard 550/590, AHRI will select a random point within the full load application rating conditions, and the limits of Section 5 of AHRI Standard 550/590, for verification. This random operating point will be selected to allow AHRI to certify the operating map conditions at which the chiller can be run. This point will not be communicated to the participant until the Laboratory Representative is witnessing the test. 3.10 Test Failures. 3.10.1 Options Following 1 Sample Failure. When the participant is notified of a first sample certified rating failure, it has seven (7) calendar days to select one of the following options: Re-rate all models within the failed units BMG, proportionate to the failed tests results; Test second sample of the same model (sample must be available within 30 calendar days following notification of failure); Defective failure; Obsolete the model, which also obsoletes the corresponding BMG.
st

3.10.2 Second Sample Certified Rating Test Failure. All models within the failed units BMG will be re-rated proportionate to the failed second sample tests results.

ACCL OM 550/590 OCTOBER 2009 3.11 Penalty Tests. Participants with any first test failures shall have a scheduled penalty test assigned for each failed sample. These penalty tests shall be applied in the subsequent year with no maximum. All penalty tests shall be paid for by the participant and be performed at the Laboratory or an AHRI approved facility. The number of tests will never fall below the annual testing requirement noted in Section 3.1 of this manual. 4. Challenge Tests Refer to Section 10 of the General Operations Manual for additional information. In case of a conflict, this Operations Manual takes precedence. All fees (e.g. selection, sample shipment and disposition, testing, et.al.) associated with the challenge test will be borne by one of the two parties concerned. When size permits, any challenged unit shall be tested at the Laboratory. When units are of a size that requires testing at a manufacturers facility then the challenged party may select the AHRI approved facility at which the unit will be tested. Due to the variable cost nature of this product, the table below has been created to list the unit costs that would be paid to the challenged party should the unit pass. These values have been determined based off of the cost to refurbish the units. The challenged unit will remain in the possession of the challenged party after the test. If the final outcome of the challenge test is a pass, the challenger is responsible for all costs including the costs listed in the table below. If the final outcome of the challenge test is a fail, the challenged party is responsible for all costs. If the challenged party elects to test a second sample, all associated costs for the second sample testing shall be paid by the challenged party. Permitted costs for challenge units based on tonnages are as follows for 2009. In subsequent years these numbers shall be adjusted per the U.S. Producer Price Index for primary products in the HVACR industry (product code 333415-P). Table 2: Challenge Test Costs Tonnage 0-50 tons 51-100 tons 101-200 tons 201-300 tons 301+ tons Refurbishment Fee $1,000 $2,000 $3,500 $5,000 $7,000

Challenged units shall be provided for test within 90 calendar days of the challenge being issued. 5. AHRI Directory of Certified Product Ratings 5.1 Publication of Certified Ratings in Directory. For each certified model, the Directory of shows: AHRI Reference # Model Status Manufacturer Trade/Brand Name Model Designation Certified Tonnage Range (note max and min tonnage in the directory) Frequency (50 or 60 Hz) Refrigerant Type

10

ACCL OM 550/590 OCTOBER 2009 Compressor Type (Positive Displacement or Centrifugal) Software Version Number Country of Origin

5.2 Data Forms. Each OEM participant will list its products, by BMG, on Form ACCL-DS1. PBM participants shall verify equivalent OEM models to their products on Form ACCL-DS3. All participants shall supply certified model listings to AHRI via a hard copy data submittal form ACCL-DS2 (available through AHRI) or upload data via the Directory. This shall be done any time changes or additions are made to model listings. 6. Assessment and Payment of Certification Fees 6.1 Test Fees. Refer to www.ahrinet.org, or contact AHRI, for information regarding test fees.

6.2 Equipment Delivery/Disposal Fees. If the participant chooses to have its unit(s) tested at the Laboratorys facility, it is responsible for the delivery and all expenses associated with the shipment of the unit(s) to the Laboratory. Following the completion of the test, the participant shall provide instruction to the Laboratory regarding the disposal/shipment of the unit(s). The Laboratory will invoice the participant for expenses associated with the disposal/shipment of unit from the Laboratory to a location designated by the participant. 6.3 Universal Monetary Penalty. Refer to Section 12.3.1 of the General Operations Manual. 7. Proper Claims to Certification 7.1. Publication of Non-Certified Ratings. Some products certified through Certification Program may be capable of operation at conditions outside the scope program. Units where full load operation is within the scope of the certification considered certified. Participants printed materials and computer rating software certified ratings; however it must be clearly indicated that such ratings are outside the ACCL Certification Program as per section 3.5.4. 7.2. the AHRI ACCL of the certification program shall be may contain nonscope of the AHRI

AHRI Verification and Monitoring of Computerized Rating Software and Selection Methods. 7.2.1 Random Comparisons. AHRI will make random comparisons of the catalog ratings, if applicable, and the computer ratings as a further check procedure to guard against a participant using a program not approved by AHRI. 7.2.2 Additional Monitoring. AHRI may request participants, users, consulting engineers, etc. to submit copies of specific job conditions and ratings that they have utilized. Additionally, parties may request that AHRI verify certification of product ratings. AHRI will compare the ratings with the results obtained through use of the participants computerized rating method. Comparison will only be made on jobs in which the rating software implemented by the user matches that of the verified rating method, including issue date or code, of the current software held by AHRI. 7.2.3 Responsibility of Participant for Catalog/Software Revisions. Whenever a participants catalog and/or computerized rating method is revised, the participant shall promptly supply the revised version(s) to AHRI and users. Version numbers shall be constructed such that the revision level can be determined by AHRI. Computer rating methods shall prominently include a revision code, date, or version identification. Catalogs must be consistent with the current computer rating method at time of publication. Current versions must be listed in the Directory at the time of release.

11

ACCL OM 550/590 OCTOBER 2009 7.2.4 Data Comparison Between Rating Software and Catalog. Any published catalog shall make reference to the version number of the computerized rating method to which it corresponds. AHRI considers the computerized rating software output to be the primary source of information. If, at any time, the referenced computerized rating output is not in agreement with the catalog, or if the catalog or computerized rating output do not correspond to the version listed in the AHRI Directory, the participant shall be issued a violation notifying them of the discrepancy and shall have 60 calendar days to resolve the discrepancy. 7.3 Changes to Certified Chiller Model Groups. AHRI must be informed of changes to certified products prior to such changes being implemented. The participant shall submit a report stating the exact changes proposed, indication of any effects on published ratings, and an approximate date on which production of the changed chiller(s) is to begin. If the participant anticipates changes to the product ratings, or if within 60 calendar days of receiving the information AHRI believes the proposed changes may affect published ratings, the participant may be required to test, or provide additional information on, the basic model(s) in question. Certification may not be claimed for the changed product(s) until authorized by AHRI. 8. Law of Pertinent Jurisdiction 8.1 Use of Manufacturer Test Facilities for Another Manufacturers Testing. Several manufacturers' test facilities will be made available to a manufacturer not having a test facility. Manufacturers contemplating such an arrangement should be aware that the delivery of a unit by manufacturer "A" to the test facility of manufacturer "B" may create a relationship between "A" and "B" under the law of pertinent jurisdiction concerning such things as the care and return of the unit. The respective rights and responsibilities of "A" and "B" may possibly be modifiable by agreement between them, to the extent that the agreement does not violate the law or contravene public policy. In some jurisdictions, the rights of the parties are governed by specific statute. Any concerns regarding such arrangements between manufacturers should be addressed to a competent attorney. AHRI is not a party to such an arrangement between manufacturers, and bears no responsibility for, and shall not be subject to liability for, any damage, harm or liability of any nature that might result from, arise from, or be associated with such an arrangement or the delivery, testing, or return of a unit involved with such an arrangement. 8.2 Provisions for Manufacturers Representative(s). The manufacturer being tested (guest manufacturer) shall be permitted to provide representative(s) to witness the setup, testing, and tear down of the unit. These representative(s) shall be escorted at all times by the host test facility personnel. Personnel of the test facility (host manufacturer) shall operate the test facility when conducting the testing to be witnessed by the independent Representative. The representative(s) of the manufacturer being tested (guest manufacturer) shall not be permitted to participate in the operation of the test facility during test but may supervise the operation and adjustment of the chiller.

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ACCL OM 550/590 OCTOBER 2009 Appendix A: Chiller Condenser Entering Air Temperature Measurement A.1 Purpose The purpose of this appendix is to prescribe the preferred method for measurement of the air temperature entering the air-cooled or evaporatively-cooled condenser section of an Air-Cooled Water-Chilling Package. The appendix also defines the requirements for controlling the air stratification and what is considered acceptable for a test. Measurement of the air temperatures are needed to establish that the conditions are within the allowable tolerances of AHRI Standard 550/590. For aircooled chillers operating in cooling mode, only the dry-bulb temperature is required. For evaporativelycooled and heat pump chilled water packages operating in heating mode, both the dry-bulb and wet-bulb temperatures are required for the test. Alternate methods may be used but will require approval of the Independent Third-Party Testing Laboratory Representative as contracted by AHRI (Representative). A.2 Definitions Air Sampling Tree The air sampling tree is an air sampling tube assembly that draws air through sampling tubes in a manner to provide a uniform sampling of air entering the air-cooled condenser coil. See section A.4 for design details Aspirating Psychrometer A piece of equipment with a monitored airflow section that draws a uniform airflow velocity through the measurement section and has probes for measurement of air temperature and humidity. See section A.5 for design details. A.3 General Requirements Temperature measurements shall be made in accordance with ANSI/ASHRAE Standard 41.1. Where there are differences between this document and Standard 41.1, this document shall prevail. Temperature measurements shall be made with an instrument or instrument system, including read-out devices, meeting or exceeding the following accuracy and precision requirements:

Table A.1: Temperature Measurement Requirements Measurement Dry-Bulb and Wet-Bulb Temperatures Thermocouple Thermopile Temperature
1

Accuracy 0.2F [0.11C] 1.0F [0.56C]

Precision 0.1F [0.05C] 0.1F [0.05C]

Note 1: To meet this requirement, thermocouple wire must have special limits of error and all thermocouple junctions in a thermopile must be made from the same spool of wire; thermopile junctions are wired in parallel. To ensure adequate air distribution, thorough mixing, and uniform air temperature, it is important that the room and test setup is properly designed and operated. The room conditioning equipment airflow should be set such that recirculation of condenser discharged air is avoided. To check for the recirculation of condenser discharged air back into the condenser coil(s) the following method, or an equivalent method as approved by the Laboratory Representative must be used: Multiple individual reading thermocouples (at least one per sampling tree location) will be installed around the unit air discharge perimeter so that they are below the plane of condenser fan exhaust and just above the top of the condenser coil(s). These thermocouples may not indicate a temperature difference greater than 5.0F [2.8C] from the average inlet air. The Laboratory Representative will review air distribution at the test facility point of supply to the unit and may require remediation prior to beginning testing. Mixing fans can be used to ensure adequate air distribution in the test room. If used, mixing fans must be oriented such that they are pointed away from the air intake so that the mixing fan exhaust direction is at an angle of 90~270 to the

13

ACCL OM 550/590 OCTOBER 2009 air entrance to the condenser air inlet. Particular attention should be given to prevent recirculation of condenser fan exhaust air back through the unit. A valid test shall meet the criteria for adequate air distribution and control of air temperature as shown in Table A.1. Table A.2: Criteria for Air Distribution and Control of Air Temperature Item Dry-Bulb Temperature Deviation from the mean air dry-bulb temperature to the air dry-bulb temperature at any individual 1 temperature measurement station Difference between dry-bulb temperature measured with air sampler thermopile and with aspirating psychrometer Difference between mean dry-bulb air temperature and the specified target 2 test value Mean dry-bulb air temperature variation over time (from the first to the last of the three sets of data) 3 Wet-bulb Temperature Deviation from the mean wet-bulb temperature and the individual temperature measurement stations Difference between mean wet-bulb air wet bulb temperature and the specified 2 target test value uniform temperature distribution Purpose Maximum Variation F C 2.00 (200 tons) 3.00 (>200 tons) uniform temperature distribution 1.50 1.10 (703 kW) 1.65 (>703 kW) 0.85

test condition tolerance, for control of air temperature test operating tolerance, total observed range of variation over data collection time

1.00

0.55

1.50

0.85

uniform humidity distribution test condition tolerance, for control of air temperature

1.00

0.55

1.00

0.55

test operating tolerance, total observed range of variation Mean wet-bulb air temperature variation 1.00 0.55 over data collection time (from over time the first to the last of the three sets of data) Note 1. Each measurement station represents an average value as measured by a single aspirating psychrometer. Note 2. The mean dry-bulb temperature is the mean of all measurement stations. Note 3. The wet-bulb temperature measurement is only required for evaporatively-cooled units and heat pump chillers operating in the heating mode.

A.4 Air Sampling Tree Requirements The air sampling tree is intended to draw a uniform sample of the airflow entering the air-cooled condenser section. A typical configuration for the sampling tree is shown in Figure A.1 for a tree with overall dimensions of 4 feet by 4 feet sample. Other sizes and rectangular shapes can be used, and should be scaled accordingly as long as the aspect ratio (width to height) of no greater than 2 to 1 is

14

ACCL OM 550/590 OCTOBER 2009 maintained. It shall be constructed of stainless steel, plastic or other suitable, durable materials. It shall have a main flow trunk tube with a series of branch tubes connected to the trunk tube. It must have from 10 to 20 branch tubes. The branch tubes shall have appropriately spaced holes, sized to provide equal airflow through all the holes by increasing the hole size as you move further from the trunk tube to account for the static pressure regain effect in the branch and trunk tubes. The number of sampling holes shall be greater than 50. The average minimum velocity through the sampling tree holes shall be 2.5 ft/sec as determined by evaluating the sum of the open area of the holes as compared to the flow area in the aspirating psychrometer. The assembly shall have a tubular connection to allow a flexible tube to be connected to the sampling tree and to the aspirating psychrometer. The sampling tree shall also be equipped with a thermocouple thermopile grid to measure the average temperature of the airflow over the sampling tree. The thermopile shall have at least 16 junction points per sampling tree, evenly spaced across the sampling tree, and connected in a parallel wiring circuit. On smaller units with only two sampling trees it is acceptable to individually measure the 16 thermocouple points as a determination of room stratification. The air sampling trees shall be placed within 6-12 inches of the unit to minimize the risk of damage to the unit while ensuring that the air sampling tubes are measuring the air going into the unit rather than the room air around the unit.

4.0 dia

3.5 dia

4.87"

4.87"

4.87"

4.87"

4.87"

4.87"

4.87"

4.87"

.50 Dia
5.62"

.50 Dia
5.62"

.38 Dia
5.62"

4.37"

.38 Dia .75 x .50 slot .38 Dia

5.62"

.38 Dia

.50 Dia
5.62"

.50 Dia

Thermopile junction point (16 places) 48.00"

Conversion Table inches (") cm 0.38 0.97 0.50 1.27 0.75 1.91 3.50 8.89 4.00 10.16 4.37 11.10 4.87 12.37 5.63 14.30 48.00 121.92

48.00"

5.62"

4.37"

Figure A.1 Typical Air Sampling Tree Note: The .75 by .50 slots referenced in Figure A.1 are cut into the branches of the sampling tree and are located inside of the trunk of the sampling tree. They are placed to allow air to be pulled into the main trunk from each of the branches.

15

ACCL OM 550/590 OCTOBER 2009 A.5 Aspirating Psychrometer The aspirating psychrometer consists of a flow section and a fan to draw air through the flow section. The flow section shall be equipped with two dry-bulb temperature probe connections, one of which will be used for the facility temperature measurement and one of which shall be available to confirm this measurement using the Laboratorys temperature sensor probe. For applications where the humidity is also required, for testing of evaporatively cooled units or heat pump chillers in heating mode, the flow section shall be equipped with two wet-bulb temperature probe connections one of which will be used for the facility wet-bulb measurement and one of which shall be available to confirm the wet-bulb measurement using the Laboratorys wet-bulb sensor probe. The psychrometer shall include a fan that either can be adjusted manually or automatically to maintain average velocity across the sensors. A typical configuration for the aspirating psychrometer is shown in Figure A.2.

Figure A.2 - Aspirating Psychrometer A.6 Test Setup Description Air wet-bulb and/or dry-bulb temperature shall be measured at multiple locations entering the condenser, based on the airflow nominal face area at the point of measurement. Multiple temperature measurements will be used to determine acceptable air distribution and the mean air temperature. The use of air sampling trees as a measuring station reduces the time required to setup a test and allows the Representative to install sensors for redundant dry-bulb and wet-bulb temperatures. Other methods can be used but will require approval of the Laboratory. Only the dry-bulb sensors need to be used for air-cooled condensers, but wet-bulb temperature shall be used with evaporatively cooled and heat pump chillers running in the heating mode. The nominal face area may extend beyond the condenser coil depending on coil configuration and orientation, and must include all regions through which air enters the unit. The nominal face area of the airflow shall be divided into a number of equal area sampling rectangles with aspect ratios no greater than 2 to 1. Each rectangular area shall have one air sampler tree.

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ACCL OM 550/590 OCTOBER 2009

L L L

2L 2L 3L L

3L

W 0.8L W L

Legend

Condenser Air Inlet Nominal Face Area 4L Equal Area Rectangles L Air Sampler Tree

5L

0.8L H L

6L

7L = Loverall

0.6 Loverall (A+B+C+D+...) Loverall

Figure A.3 Determination of Measurement Rectangles and Required Number of Air Sampler Trees 17

ACCL OM 550/590 OCTOBER 2009

Figure A.4 Typical Test Setup Configurations A minimum of one aspirating psychrometer per side of a chiller shall be used. For units with three (3) sides, two (2) sampling aspirating psychrometers can be used but will require a separate air sampler tree for the third side. For units that have air entering the sides and the bottom of the unit, additional air sampling trees should be used. A minimum total of two (2) air sampler trees shall be used in any case, in order to assess air temperature uniformity. The air sampler trees shall be located at the geometric center of each rectangle; either horizontal or vertical orientation of the branches is acceptable. The sampling trees shall cover at least 80% of the height and 60% of the width of the air entrance to the unit (for long horizontal coils), or shall cover at least 80% of the width and 60% of the height of the air entrance (for tall vertical coils). The sampling trees shall not extend beyond the face of the air entrance area. It is acceptable to block all branch inlet holes that extend beyond the face of the unit. Refer to figure A.3 for examples of how an increasing number of air sampler trees are required for longer condenser coils. A maximum of four (4) sampling trees shall be connected to each aspirating psychrometer. The sampling trees should be connected to the aspirating psychrometer using flexible tubing that is insulated and routed to prevent heat transfer to the air stream. Refer to figure A.4 for some typical examples of air sampler tree and aspirating psychrometer setups.

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ACCL OM 550/590 OCTOBER 2009 Appendix B: Barometric Pressure Adjustment In order to ensure that performance can be uniformly compared from one unit to another and from one manufacturer to another, AHRI performance testing is corrected for air density variations. To accomplish this, AHRI has developed the following two (2) adjustment factors to correct tested data back to standard barometric pressure at sea level. These adjustment factors use industry average values. The adjustment factors are based on pressure rather than altitude, in order to include the effects of weather variations. When performing testing to validate AHRI certified ratings, the corrected test data is then compared to the sea level ratings at standard pressure (14.696 psia, 101.325 kPa). Air-cooled chillers are tested at the local conditions. The data is then corrected to sea level and standard pressure by multiplying the measured data by the appropriate correction factor (CF). Both factors are in the form of a second order polynomial equation:

CF = A P 2 + B P + C Qcorrected = Qtest CFQ corrected = test CF

Table B.1: Terms Variable or Subscript P Q CFQ CF A, B, C test corrected Note 1: Description

Equation B.1 Equation B.2 Equation B.3

pressure, absolute Capacity 1 Efficiency capacity correction factor efficiency correction factor polynomial constants actual measured value during test at local conditions adjusted value equivalent to operation at sea level with standard pressure If efficiency is expressed in kW/Ton then divide by the correction factor CF instead of multiplying. Table B.2: Correction Factor (CF) Coefficients Capacity CFQ Efficiency CF C 1.36304E+00 1.36304E+00 A 2.4308E-03 5.1135E-05 B -9.0075E-02 -1.3064E-02

Units of Measure IP SI psia kPa Ton kW EER COP -

Units of Measure for P IP (psia) SI (kPa) Note:

A 1.1273E-03 2.3713E-05

B -4.1272E-02 -5.9860E-03

C 1.79872E+00 1.79872E+00

E indicates scientific notation, example: 1E-02 = 0.01

Example (IP units): A chiller has published ratings of 200.0 Tons and 9.500 EER at sea level. The chiller is tested at an elevation of about 1100 feet with overcast skies. The measured test results: Capacity Qtested = 198.50 Tons

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ACCL OM 550/590 OCTOBER 2009 Efficiency tested = 9.410 EER Air pressure P = 14.09 psia Correction factor CFQ = 0.0011273 14.09 - 0.041272 14.09 + 1.36304 = 1.0053 Corrected capacity Qcorrected = 198.50 1.0053 = 199.56 Tons Correction factor CF = 0.0024308 14.09 - 0.090075 14.09 + 1.79862 = 1.0120 Corrected efficiency corrected = 9.410 1.0120 = 9.523 EER Sample correction factors are provided in the charts and tables below.

Figure B.1 Capacity Correction Factor

Figure B.2 Efficiency Correction Factor

Table B.3: Correction Factor (CF) Values Pressure (psia) 12.1 12.3 12.5 12.7 12.9 13.1 13.3 13.5 13.7 13.9 14.1 14.3 14.5 14.696 14.9 15.1 CFQ 1.0287 1.0259 1.0233 1.0207 1.0182 1.0158 1.0135 1.0113 1.0092 1.0072 1.0052 1.0034 1.0016 1.0000 0.9984 0.9969 CF 1.0647 1.0586 1.0526 1.0468 1.0413 1.0359 1.0307 1.0257 1.0209 1.0163 1.0119 1.0077 1.0037 1.0000 0.9963 0.9928

Table B.3: Correction Factor (CF) Values Pressure (kPa) 80.0 82.5 85.0 87.5 90.0 92.5 95.0 97.5 100.0 101.325 102.5 105.0 CFQ 1.0359 1.0306 1.0256 1.0208 1.0164 1.0122 1.0084 1.0048 1.0016 1.0000 0.9986 0.9959 CF 1.0809 1.0690 1.0577 1.0471 1.0372 1.0278 1.0191 1.0111 1.0037 1.0000 0.9969 0.9908

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ACCL OM 550/590 OCTOBER 2009 Appendix C: Form ACCL-DS1 - BMG Data Submittal Form
Year: Manufacturer: AIR-COOLED CHILLERS USING THE VAPOR COMPRESSION CYCLE CERTIFICATION PROGRAM PROPOSED BASIC MODEL GROUPINGS (BMG) ACCL-DS1 Basic Model Group Number 1 Basic Model Group by Chiller Model Designation Location of Manufacture (Typically Country, list city if multiple locations) Nominal Tonnage Range 2 Applicable Heat Exchangers Refrigerant Evaporator Code 3 Condenser Code 3 Quantity Compressors Model Number Type 4 (PD,C) FORM: ACCL-DS1

Instructions:

The AHRI Chillers program has a provision that allows manufactures to control their Basic Model Groups (BMG). Each participant must provide the BMG listings to AHRI prior to the start of the testing year. Basic model definition: Each participants listing will be grouped by basic models. A BMG is a family of chillers using the same compressor or combination of compressors. Participants have the option to further subdivide the BMG category. 1 2 3 Participants shall note which chiller model designations are part of the same BMG by labeling them with the same number. Nominal Tonnage range is the range of tonnages at Standard Rating Conditions. If these items are not needed, please leave them blank. List Compressor Type: Positive Displacement (PD) or Centrifugal (C).

Submitted By:

Signature

Title

Printed Name

Date

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ACCL OM 550/590 OCTOBER 2009 Appendix D: Form ACCL-DS2 Certification Directory Listing Form FORM ACCL-DS2
AHRI SYSTEM
1 2

OEM: Location: PROGRAM & PRODUCT IDENTIFIERS AHRI Program: Trade/Brand Name: PRODUCT MODEL CHARACTERISTICS Model Number: Refrigerant Used: Compressor Type: Certified Tonnage Range: Frequency: Country of Origin: Version Number: Computer Method Issue Date or Code:

REQUIRED SECTION (complete all) Manufacturer Name as listed in the directory Manufacturer Location REQUIRED SECTION (complete all) AHRI Certification Program - ACCL

3 4

5 6 7 8 9 10 11 12

COMPLETE ONLY THE APPROPRIATE FIELDS alpha numeric up to 50 characters R-22, R-134a, R-123, R-410A Positive Displacement or Centrifugal Nominal Tonnage range is the range of tonnages at Standard Rating Conditions 50 or 60 Hz Country where manufactured Computer Version Number

13 14

COMMENTS Testing Comments: Ratings Comments: DIRECTORY FOOTNOTES Footnotes:

By submission of this form, I certify that the model listed above meets all of the requirements of the applicable AHRI standards.

OPTIONAL SECTION remarks used for testing purposes remarks used for rating purposes OPTIONAL SECTION

15

Signed:_____________________________________

Title:_____________________________________

22

ACCL OM 550/590 OCTOBER 2009 Appendix E: FORM ACCL-DS3 PRIVATE BRAND MARKETER (PBM) PRODUCT DATA PRIVATE BRAND MARKETER: ORIGINAL EQUIPMENT MANUFACTURER:

PBM MODEL NUMBER

NOMINAL TONNAGE RANGE

COMPRESSOR MODEL NUMBER QTY TYPE

REFRIGERANT TYPE

COUNTRY OF MANUFACTURE

EQUIVALENT OEM MODEL NUMBER

NOTES:

Nominal Tonnage range is the range of tonnages at Standard Rating Conditions List Compressor Type: Positive Displacement (PD) or Centrifugal (C)

Submitted By:

Signature Printed Name

Title Date

23

ACCL OM 550/590 OCTOBER 2009 Appendix F: FORM ACCL-WT1 APPLICATION FOR WITNESS TESTING We, the undersigned, hereby request AHRI to approve our test facility, located at (state exact address): for the purpose of conducting performance certification tests in accordance with the AHRI Certification Program for Air-Cooled Water-Chilling Packages Using the Vapor Compression Cycle. All testing will be conducted in accordance with AHRI Standard 550/590 and witnessed by the Independent Third-Party Laboratory contracted by AHRI. Accompanying this request is the following information: 1. Form ACCL-WT2, Personnel Experience Questionnaire; 2. Form ACCL-WT3, Facility and Equipment Questionnaire; 3. A complete list of all instruments and equipment being used to perform certification testing in accordance with AHRI Standard 550/590 and a copy of each calibration report showing date of last calibration; 4. A schematic drawing of the area of the test facility in which AHRI certification testing will be performed; 5. Drawings of Air Sampling Tree (see figure A3 for an example); 6. Schematic drawing or photographs of placement of Air Sampling Trees for each condenser coil configuration to be tested, with consideration to the range of sizes to be tested; and 7. Photographs of the test facility in which AHRI certification testing will take place, which shall include sufficient views to show the location and connection of each instrument. In signing this form and submitting all information requested above, we acknowledge that the test facility is in conformance with all of the provisions of the latest edition of AHRI Standard 550/590. Signature of Certification Program Compliance Officer Printed Name Title and Company Date Signature of Chief Engineer or Test Facility Director Printed Name Title and Company Date

Final approval of this test facility to conduct witness testing in support of the AHRI Certification Program for Air-Cooled WaterChilling Packages Using the Vapor Compression Cycle is contingent upon AHRIs approval of the information provided and satisfactory completion of a facility and equipment inspection. AHRI will notify the participant, in writing, when final approval of the test facility to conduct witness testing has been granted. Final approval must be received before any AHRI certification tests, including program qualification tests, can be conducted in the test facility.

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ACCL OM 550/590 OCTOBER 2009 Appendix G: FORM ACCL-WT2 PERSONNEL EXPERIENCE QUESTIONNAIRE

Company (Participant) Name Test Facility Address The following personnel are directly responsible for conducting the testing that will be witnessed at the participants test facility in accordance with the AHRI Air-Cooled Water-Chilling Packages Using the Vapor Compression Cycle Certification Program: Primary Contact Name Title Area of Responsibility for Certification Testing: Alternate Contact Name Title Area of Responsibility for Certification Testing:

Submitted By: Signature Printed Name Title Date

25

ACCL OM 550/590 OCTOBER 2009 Appendix H: FORM ACCL-WT3 FACILITY AND EQUIPMENT QUESTIONNAIRE Company (Participant) Name Test Facility Address 1. Test Facility Limitations Operating Range of Facility Water Flow Airflow Power Supply Minimum Cooling Capacity Maximum Cooling Capacity Minimum Cooler Maximum Cooler Maximum CFM Conditioning Equipment for Condenser Air 60 Hz, 3 Phase 50 Hz, 3 Phase Physical Size Dimensions of largest unit you can place in your facility Tons GPM CFM Volts Max Amps Volts Max Amps Length Height Width # of Persons Total # of man-hours # of Persons Total # of man-hours Length of shift, hrs. # of shifts

2.

Time Requirements How long does it take to install and fully instrument a unit for test? How long does it take to conduct a standard rating test from start to finish, including calculations? How many shifts per day will you employ for witness testing? Temperature Measurement Instruments for determining temperature RTD Thermocouple Thermopile Other

3.

Frequency of calibration, months N/A

Is the primary standard traceable to NIST? Yes No Yes No Yes No Yes No

Where do you place your water temperature measuring instruments? What type of mixing device do you employ in the chilled water medium? The mixing device conforms to which standard?

26

ACCL OM 550/590 OCTOBER 2009

4.

Flow Measurement Flow measuring instruments used Rota meter Turbine meter Orifice meter Magnetic meter Other Frequency of calibration, months To what code standard(s), if any, is the instrument installed? Is the primary standard traceable to NIST? Yes No Yes No Yes No Yes No Yes No

Does facility presently have a 24 inch unobstructed section of piping free of elbows, insulation, etc. for several pipe diameters upstream for application of a strap-on flow meter? Yes No 5. Water Pressure Drop Measurement Water pressure drop instruments used Frequency of calibration, months

6.

Power Measurement Power measurement devices Watt meter Watt hour meter Transducers Other Voltage Measurement Type of voltmeter used Analog meter Digital meter Transducers Potential Transformer Other Type of ammeter used Analog meter Digital meter Current Transformer Transducers Other

Frequency of calibration, months

Capable of both 50 and 60 Hz non-sinusoidal measurement? Yes No Yes No Yes No Yes No Frequency of calibration, months

Is the primary standard traceable to NIST? Yes No Yes No Yes No Yes No Is the primary standard traceable to NIST? Yes No Yes No Yes No Yes No Yes No Is the primary standard traceable to NIST? Yes No Yes No Yes No Yes No Yes No

7.

Frequency of calibration, months

Is a regulated voltage supply available for test unit?

Yes No

If not regulated, what is the frequency and the magnitude of change over 24 hours? What is the magnitude of change in the supply voltage between load and no load?

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ACCL OM 550/590 OCTOBER 2009 Is the wave shape of the supply voltage a pure and complete sine wave? Yes If not, attach a sample wave form. Data Acquisition Describe data acquisition system and data obtained: Steady State Loading Can test be fully loaded to steady-state as required by AHRI? No

8.

9.

Yes

No

10. Airflow Is the airflow at a constant rate or is it adjusted depending on the unit being tested? _________________________________________________________________ For the largest size unit you will test, how many air changes will the facility be handling? _________________________________________________________________ How do you measure the entering air temperature and at how many locations? _________________________________________________________ 11. Barometric Pressure Measurement How do you measure barometric pressure at the lab site? ______________________________________________ 12. Refrigerant Charge: What method do you employ to confirm proper refrigerant charge in the unit for test? ______________________________________________ Submitted By: Signature Printed Name Title Date

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ACCL OM 550/590 OCTOBER 2009 Appendix I: MANUFACTURERS DECISION FORM

MANUFACTURERS DECISION FORM TEST FAILURE NOTIFICATION AHRI CERTIFICATION PROGRAM FOR AIR-COOLED WATER-CHILLING PACKAGES USING THE VAPOR COMPRESSION CYCLE (ACCL)
<Date> Dear Certification Program Participant: Please be advised that the following unit, when tested under the AHRI Certification Program for ACCL, failed to perform in accordance with AHRI Standard 550/590, Standard for Water-Chilling Packages Using the Vapor Compression Cycle. Test data is attached to this notification. Manufacturer: Model: AHRI Test #: Date of Test: _________

Per program rules, following notification of a test failure the participant has seven (7) calendar days to elect one of the following options. If a completed manufacturers decision form is not received by AHRI within seven (7) calendar days, all models within the Basic Model Group (BMG) will be re-rated proportionate to the failed tests results.

FOLLOWING A FAILURE, PLEASE CHOOSE ONE OF THE FOLLOWING OPTIONS. THE OPTION CHOSEN MUST CORRESPOND TO ONE AVAILABLE PER THE AHRI GENERAL OPERATIONS MANUAL AND THE ACCL CERTIFICATION PROGRAM OPERATIONS MANUAL.
Defective Failure. The participant claims that defective part(s) and/or assemblies caused the test failure. Within seven (7) calendar days of returning this manufacturers decision form to AHRI, the participant must provide AHRI with a detailed defect report stating the reason for the defective part(s) and/or assemblies. If AHRI agrees that the programs definition of a defect has been met, AHRI will notify the participant to supply new part(s) and/or assemblies, to replace only those that have been deemed defective, to the testing laboratory. These new part(s) and/or assemblies must be supplied to the testing laboratory within 14 calendar days of AHRIs request to the participant to supply replacement parts. Failure to provide a defect report and/or new part(s) and/or assemblies by their respective deadlines will forfeit the participants opportunity for a replacement test, thus automatically re-rating the model to the failed test samples results. The participant may send its own representative to install the replacement part(s) and/or assemblies or may request the testing laboratory to perform the replacement. If the participant chooses to have the testing laboratory install the replacements part(s) and/or assemblies, the participant may not claim improper installation of the part(s) and/or assemblies by the test lab. Upon receipt of payment for the replacement test, the unit will be re-tested with the replacement part(s) and/or assemblies installed. If the unit passes, the participant will not be issued a first sample test failure. If the unit fails, the participant will be issued a first sample failure and will have the option to re-rate the unit or perform a second sample test. The participant is responsible for the costs associated with the installation of the replacement parts or assemblies, as well as the cost to re-test the unit. The testing laboratory will directly invoice the participant for the costs associated with the replacement part installation. Prior to conducting the re-test, AHRI will invoice the participant for the cost of the test. Payment must be received within 30 calendar days from date of invoice. Failure to make payment within this timeframe will result in termination from the certification program. Participants with an annual testing requirement (not including penalty, qualification, second sample, or replacement tests) of 50 units or less are allowed one defective failure claim per program test year. Participants with an annual testing requirement of 51 units or greater are allowed two defective failure claims per program test year.

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ACCL OM 550/590 OCTOBER 2009

Re-rate. The participant will re-rate the model no higher than test results; efficiency, water pressure drops, IPLV/NPLV, and additional application point no lower than the average resulting from the test. All models within the BMG shall be re-rated proportionate to the failed tests results. These re-rates will be reflected in the AHRI Directory of Certified Product Ratings. Within 14 calendar days of this failure notification, the participant is required to advise AHRI of the steps being taken to correct advertising literature, specifications, software, etc. Within 60 calendar days of this failure notification, the participant is required to have withdrawn all known advertising literature, specifications, software, etc. and to have submitted corrected publications/software to AHRI, distributors, dealers, and all other affected parties. The draft public notification of corrections, a copy of the distribution list of those to receive the notification and corrections, as well as a copy of the corrected publication(s)/software, must be reviewed by AHRI prior to dissemination to the public. Failure to comply with program rules regarding publication/software correction will result in a program violation. 2 Sample (Following 1 Sample Failure). The participant must have a 2 sample available for test within 30 calendar days from the date of this failure notification. Failure to have a sample available within this timeframe will nd forfeit the participants opportunity for a 2 sample test, thus automatically re-rating all models within the BMG proportionate to the failed tests results. AHRI will invoice the participant for the 2 sample test prior to conducting the test. Payment must be received within 30 calendar days from date of invoice. Failure to make payment within that timeframe will forfeit the participants nd opportunity to conduct a 2 sample test, thus automatically re-rating all models within the BMG proportionate to the failed tests results. Obsolete. Obsolete Models are those that the manufacturer stops producing following an AHRI test failure. Obsolete models, with their correct ratings, are shown in the AHRI Directory of Certified Product Ratings for six (6)months. Within 14 calendar days of this failure notification, the participant is required to advise AHRI of the steps being taken to correct its advertising literature, specifications, software, etc. Within 60 calendar days of this failure notification, the participant is required to have withdrawn all known advertising literature, specifications, software, etc. and to have submitted corrected publications/software to AHRI, distributors, dealers, and all other affected parties. The draft public notification of corrections, a copy of the distribution list of those to receive the notification and corrections, as well as a copy of the corrected publication(s)/software, must be reviewed by AHRI prior to dissemination to the public. Failure to comply with program rules regarding publication/software correction will result in a program violation. To ensure your opportunity to preserve this BMG, please return this completed manufacturers decision form via email or fax within seven (7) calendar days to the certification engineer noted below. More details on the above options can be found in the AHRI General Operations Manual and the ACCL Operations Manual. The engineer can address any questions you have regarding the available options. Certification Engineer Phone: (703) 524-8800 Fax: (703) 562-1942 Thank you for your participation in this AHRI Certification Program.
(Please complete all fields)
nd nd st nd

Company: Submitted by: Print Email: Fax: Phone:

Signature: Title:

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