Draft - DX BOOST PRECONDITIONED AIR UNIT

1.1

GENERAL
A. Provide a Hybrid DX-Boost type Aircraft Preconditioned Air System (PCA) located
inside a technical room.
B. The PCA shall be designed for installation in a technical room and connected to PCA
Pop-up Pit via underground air ducts.
C. The PCA system shall include a Central PCAir component, supplied either by the
Building chilled water system and a fixed package air-cooled direct expansion (DX
Boost) unit, controls and accessories for the cooling, heating and ventilation of
commercial aircraft. The PCA shall be connected to the input power source provided
at the gate (380V nominal/50 Hz).

1.2

SCOPE OF WORK
A. This section includes selection, design, fabrication, delivery, installation, testing,
putting into service of the DX Boost unit, and final acceptance. The DX Boost Unit
shall be a hybrid type with chilled water cooling coils and DX compressor.
B. Provide all plant, labor, materials, tools, equipment, apparatus, facilities, design
services, and perform all operations and incidentals necessary to fabricate, deliver,
install, test and certify for operation the DX Boost unit as specified.
C. The Work includes but is not limited to, the following:
1. Supports and structural members including anti-vibration pads for each DX Boost
Unit to be mounted as shown on drawings.
2. Flexible connection from DX Boost Unit to aircraft connection point, pit, or flexible
hoses as required by owner.
3. Display and control unit on control station and DX Boost unit. Link
communication module shall be bus communication.

1.3

APPLICABLE CODES AND STANDARDS

A.

All equipment, materials, construction and installation supplied or performed by

the contractor shall be in accordance with the applicable requirements of the
following codes and standards, of latest issue in effect on the date of the
contract:
1.

NEC National Electrical Code

2.

NFPA National Loading Walkways

3.

NEMA National Electrical Manufacturers Association

4.

ANSI American National Standards Institute

5.

ASME American Society of Mechanical Engineers

6.

OSHA U.S. Government, Occupational Safety and Health

7.

ARI Air Conditioning and Refrigeration Institute

a. 410: Standard for Forced-Circulation Air Cooling & Heating
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Coils
b. 850: Commercial and Industrial Filter Equipment

2.0

8.

ASHRAE American Society of Heating, Refrigeration and

Air Conditioning Engineers
a. 15 Safety Code for Mechanical Refrigeration
b. 52 Method of Testing Air Cleaning Devices Used in General
Ventilation for Removing Particulate Matter

9.

AFBMA Anti-Friction Bearing Manufacturers Association

10.

UL Underwriters Laboratory

11.

All codes, regulations, and ordinances in effect by authorities having

jurisdiction over the construction site.

PRODUCTS
A.

GENERAL
1.

Provide PCA equipment comprised of fixed, packaged, hybrid direct

expansion (DX boost) units, controls and related accessories for the
cooling, heating and ventilation of commercial aircraft. Each packaged
PCA unit shall be called the DX Boost unit.
a. The Work includes the detailed design, manufacture, procurement,
shipping, installation, project management, testing, startup, training
and warranty support of the pc air system and all necessary
components as specified herein.

2.

The Work shall include the following general tasks to provide the Owner
with a complete operational system in accordance with the requirements
specified herein.
a. System design: calculations and analyses, definition of interface
requirements, preparation and submittal of system installation and
equipment, drawings and catalog cuts for the Owners approval
submittal of recommended spare lists and test procedures.
b. Preparation and submittal of shop drawings and other information
necessary for local agencies to issue a permit to do the work on
site.
c. Manufacturing and procurement of all equipment and material
required for a complete operating system as defined herein.
d. Factory testing of major functional equipment items as specified.
e. Project management, scheduling, work phasing, and coordination of
the project with the Owner and other contractors on site.
f.

Installation of all materials and equipment, including shipping to site,

site preparation as defined herein, unloading and setting in place,
mounting and affixing as required, interconnection of power, control,
chilled liquid supply and return lines, and drain lines.

g. In-process inspection and testing of all installations.

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h. Complete acceptance testing of the installed system and all gates,

with complete documentation.
i.

As-built drawings of the completed installation.

j.

An optional formal operating and maintenance training course for

the owners designated personnel.

k. Operating and maintenance manuals

B.

3.

The system shall be based on the installation of a fixed electrically

operated DX Boost unit to serve a single aircraft position (or) a mixing
chamber can be provided to use for MARS type of design.

4.

Each DX Boost unit shall consist of first stage chilled water coil, second
stage multiple VFD controlled scroll-type refrigeration compressors,
evaporators, piping, etc., together with blower and inlet filter, outlet
plenum section, electrical strip heaters and controls and safety devices,
completely packaged in a single weatherproof unit.

5.

Automatic control: Each dx boost unit shall be equipped with a digital

controller using ddc technology to provide automatic cabin temperature
control to within +/- 2F of the pre-programmed internal units set point,
via a cabin temperature sensor probe to be placed in the aircraft cabin by
bridge arrival crew and removed prior to departure.

6.

Accessories shall be provided to deliver the preconditioned air to the

aircraft low pressure air connection via a flexible air service hose and
fitting for connection to each of the aircraft types listed in Table 3-1. A
storage basket mounted at the appropriate point at the base of each
bridge shall be provided to store the flexible hose(s) when not in use.

7.

Each DX Boost unit shall be provided with required hardware, software,

databases and any required site licenses to provide remote monitoring
and control features as specified herein.

SYSTEM PERFORMANCE REQUIREMENTS

1.

General Requirements:
a. The PCA shall be capable of providing all heating, cooling,
ventilation and control requirements as specified herein for the
occupation of each design aircraft as indicated in Table 3-1 on
design days and as required to maintain cabin comfort on days of
less extreme climates.

2.

Design Conditions:
a. Summer Design Ambient:
b. Winter Design Ambient
(Owner should insert actual summer and winter design
ambient conditions for project site. ASHRAE 0.4% conditions
should be used as the most stringent historical information
available)

3.

Aircraft Loads: The PCA shall be designed to provide the specified

cooling and heating based on the requirement from user/end client.

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4.

System Design Rating: The electrical power distribution system from the
Owner supplied PCA power to the DX boost unit and the dx boost unit
shall be designed to attain and maintain cabin temperature specified for
aircraft which may be at service has to be in accordance with
requirement. The equipment shall be capable of meeting the stated
conditions at 100 percent passenger and crew load, 100 percent solar
and electrical load as defined by the aircraft manufacturers and as
defined in paragraph C.5 below.

5.

DX Boost unit shall be a hybrid configuration with chilled water cooling

coil with a minimum capacity for 45% cooling with the balance of cooling
to be supplied via the DX Section of the unit. Chilled water shall have a
range of 42F in and 64/68F out.

6.

Cooling Performance Requirements: The DX Boost unit and air delivery

system shall be capable of maintaining a cabin temperature of 75 +/- 2F
and 30 percent R.H. with a full passenger and crew load as defined in
Table 3-1, under design summer ambient conditions. It shall also be
capable of adjusting temperature and mass-flow to compensate for
reduced passenger loads, lower ambient temperatures, or smaller
aircraft.
a. The above cooling performance requirements shall be met using
100 percent outside make-up air to the DX Boost unit.
b. In addition to maintaining cabin temperature as defined above, the
system shall be capable of performing a cabin temperature pull
down of a heat soaked aircraft, from a temperature of 100F to a
temperature of 80F or lower on a summer design day within a
period of 45 minutes, with no occupants and all doors closed.

7.

DX Boost Unit Minimum Cooling Air Ratings: Not withstanding the

performance requirements of paragraphs 1 and 2 above, DX Boost units
and air delivery components shall have the following minimum cooling
and airflow ratings for each aircraft type rating as indicated: Supplier
must indicate the dx boost units ability to simultaneously meet all
performance requirements.
Narrow
Body Aircraft

Wide Body
Aircraft

Jumbo
Aircraft

A380
Aircraft

(Code C)

(Code D)

(Code E)

(Code F)

Rated Air Flow:

Lbs./min

170 - 190
lbs/min

244 - 265
lbs/min

440 - 550
lbs/min

440 550
lbs/min

Pressure at unit
outlet at rated
air flow: in H2O

22 inches
water

28 inches
water

31 inches
water

31 inches
water

Air Supply
Temperature at
Unit Outlet, at
rated air flow:

28F

30F

30F

30F

Minimum

92 KW

180KW

320 KW

2X

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refrigeration
KW required

320 KW

a. The above are minimum requirements only. Contractor shall provide

greater performance if his calculations determine that such is needed
in order to meet the cooling performance requirements of Paragraph
2.
b. Note that sizing information as shown above and on drawings are
indicative sizes only and the Contractor is responsible for final
engineering and selections to ensure that adequate cooling capacity
is provided.
c. The contractor shall present with his submittal performance
calculations demonstrating the capability of the high pressure blower,
each evaporator stage and condenser(s) to meet the above listed
minimum performances. The calculations shall take into account
losses in the air delivery hose, identifying the type and length of hose
used with its overall insulation value. The contractor shall provide for
hoses of different manufacturers in these calculations so as not to
limit the Owner from future use of any standard insulated hose
available for aircraft air conditioning.
8.

Heating Performance Requirements: The DX Boost unit shall contain

electrical strip heaters sufficient to attain the defined heating performance.
The unit, control and air delivery system shall be capable of maintaining a
cabin temperature of 68F minimum for up to the largest aircraft type
designated at each bridge, during flight turnaround conditions, including
those with no passenger load, at winter design ambient, without the use
of recirculation return air. In addition, temperature and volume
modulation capability shall be provided to automatically and efficiently
compensate for higher ambient, higher passenger loads or smaller
aircraft.
a. The system shall also be capable of maintaining an overnight
heating mode on empty aircraft with all doors closed, with cabin
temperature set for 60 degrees minimum in lieu of 68 degrees F,
during ambient temperatures as much as 10 degrees F lower than
the winter design condition. Each DX Boost unit shall contain
means for remotely resetting the preset cabin ambient control for
this purpose.
b. Each gate system shall be capable of pulling up the temperature of
a cold-soaked aircraft cabin from 32 degrees F to 65 degrees F
within a 45-minute period during design winter conditions with an
empty aircraft of the largest size identified for the gate, with all doors
closed.
c. A minimum electric heating rating of 30 kW for narrow body, and 45
kW for wide body and jumbo gates shall be provided.

9.

Ventilation Requirements: The system shall be designed to provide

minimum air flow corresponding to 10 cfm per passenger in the cooling

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and ventilation modes and 5 cfm in the heating mode while maintaining
the required cabin temperature.
a. A combination of temperature air flow modulation shall be used to
support the heating or cooling requirements during moderate
climate conditions
2.1

PCA SYSTEM COOLING DESIGN

A..

Casing
1. Formed and reinforced aluminum panels for non-corrosive purposes, fabricated to allow
removal for access to internal parts and components, with sealed joints between
sections.
2. Outer panels shall be primed and painted with corrosion protection coatings.
3. Insulation shall be minimum 1 inch thick thermal insulation.

B.

Fan Section
1. Fan section shall be constructed with a direct drive high pressure centrifugal fan
consisting of wheel at (3550 rpm at 60 Hz or 2965 rpm at 50 Hz) max. fan shaft,
bearings, motor and disconnect switch, drive assembly, and support structure and
equipped with formed-steel channel base for integral mounting of fan, motor and casing
panels. Mount fan motor assembly on isolators.
2. Fan assembly shall be statically and dynamically balanced and designed for continuous
operation at maximum rated fan speed and motor power.
3. Airfoil-Fan wheels shall be steel construction with smooth-curved inlet flange, heave
back plate and hollow die-formed airfoil-shaped blades continuously welded at tip flange
and back plate, cast iron or cast-steel hub riveted to back plate and fastened to shaft
with set screws.
4. Backward-inclined fan wheels shall be steel construction with curved inlet flange back
plate and backward-inclined blades welded or riveted to flange and back plate, cast iron
or cast steel hub rived to back plate and fastened to shaft with set screws.
5. Pre lubricated and sealed shaft bearing shall be self aligning, pillow-block type ball
bearings with rating lift ABMA 9, L50 of 200,000 hours.

C.

Refrigerant Compressors
1. Provide hermetically sealed scroll type for cooling capacity out of total unidirectional
compressors, each with a solidly mounted compressor base assembly and an oil sight
glass and oil charging valve. Arrange the equipment so that any of the compressors
may be accessed via access panels without removal of the entire PCA.
2. Provide compressors having a Mean-Time-Between-Failure (MTBF) rate of less than
0.9% during the first year of operation.
3. Refrigerant used shall be R407C or R410a.
4. Compressor should be able to work at ambient temperatures of 125F to 131F.

D.

Evaporator Coils

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1. Coils shall be of aluminum fins and seamless copper tube type, mounted on galvanized
steel casing with connections accessible for service.
2. Water coils shall utilize minimum 0.03 inch copper tube wall.
3. The number of tubes and fin spacing shall be submitted on coil selections made.
4. DX coils shall be proof tested at 2760 KPa and leak tested at 1724KPa with air pressure
under water, then cleaned, dehydrated, and sealed with a holding charge of nitrogen.
5. Chilled water coils shall be proof tested at 1375 KPa.
6. Provide for each DX coil: electronically controlled hot gas bypass solenoid and
electronically controlled expansion valve (ECEV) and distributor.
7. Coil shall be provided with polyurethane coating. For very corrosive environment blygold
high temperature coating shall be applied.
8. Coils shall be selected to avoid moisture carry over without drift eliminators.
9. Coils shall be designed and installed to shed condensate without water clogging or
causing an uneven air distribution across the face of the coil.
10. All sheet metal parts shall be corrosion protected and coated.
11. Drain pans shall be manufactured of Grade 316 stainless steel (or equivalent aluminum)
material with closed cell insulation
E.

Filters Section : PCA Units shall be equipped with 2 stages of air filtering
1. Metal mesh pre-filter
2. Polyester filter media
3. A pressostate shall be installed for the detection of filter fouling.
4. Provide filters with rated face velocity of 98 inches/sec, initial resistance of not greater
than 75 Pa. Final rated resistance of 125 Pa and average resistance of 80 percent.

F.

Variable Frequency Drives (VFD)

1. Provide VFD for airflow modulation for the complete range of aircraft.

G.

Motor
1. The electrical motors shall be TEFC or ODP type to reduce energy consumption
2. Motor kW shall be selected based on the named Subcontractors choice of equipment
which affects the external resistance of the system.

H.

Contractor shall furnish the fan motor and unit size adequate for final total static
pressure and maximum brake power requirements.

I.

The construction of the units shall be of a material sufficient to provide a maximum

sound level for the PCA units, at maximum cooling, of 85dba at a distance of 15 feet
from the unit. Sound power level radiated by the unit outlet and at the unit inlet when the
unit is operated at the designated capacity shall be furnished with the submittal.
Plate Heat Exchanger

J.

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1. Provide plate heat exchanger condenser of the refrigeration circuit

2. Plate heat exchanger is composed of a stack or corrugated stainless steel grade 316 on
which the contact points and periphery are brazed with copper.
3. Operating range: -40F and 30 bar at 270F.
K.

Electrical Work
1. Provide wiring, raceways, motor starters, relays, switches, transformers, control devices,
and other equipment necessary for PCA operation and control and to facilitate interfaces
between the PCA field sensors (e.g. smoke detectors).
2. Grounding: Interconnect the PCA and any associated electrical items with the PCA
grounding conductor.
3. Safety Provisions and Components: Include the following safety features in the PCA for
the protection of the equipment and personnel.
4. Provide circuit breakers for short-circuit or ground protection for the following
components:
a) The entire PCA circuitry
b) Each blower motor
c) Each compressor motor
d) Each damper motor
e) Each heater circuit, if provided
f)

Each transformer winding (if transformers are required/used).

5. Provide overload protection relays for each of the following motors:

a) Compressor motors
b) Blower motors
6. Refrigerant overpressure protection. Provide high and low pressure limit switches and
associated circuitry to protect each of the cooling airflow circuits.
7. Provide compressor with protection against short cycling (multiple starts and stops over
a short period) via a run-limit timer or other means.
8. Smoke detection. Provide an ionization detection type smoke detector to sense smoke
(either smoke in the ambient air or smoke produced internal to the PCA) and shut down
the PCA. Make the detector actuate an alarm message, to be displayed at the control
console of the loading bridges.
9. Status Indication: Provide status indication and annunciation of critical PCA functions:
on/off indications, PCA faulty shutdown indications, and smoke detection indications.
10. Control panel shall include, but not be limited to:
A remote start/stop pushbutton station shall be provided so as to be accessible from
the ground level for each PCA
ONlight / Start button (integral)
OFF Button
Emergency Stop

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Ready indicator
Cool / Ventilate push-button
NB / WB / J / SJ Selector switch (as required for aircraft serviced at gate)
Selection and adjustment of temperature control
Aircraft probe
Discharge Air Probe
11. Remote control shall include On/Off Pushbuttons and Aircraft Selector switch as required
for aircraft at gate.
L..

Spare Parts
1. Furnish spare parts that are required for the commissioning and start-up of the
equipment.
2. Information required with the recommended spare parts includes the following:
a)
b)
c)
d)

A.

Part description, serial or part number

Reference to assembly drawing
Total number of identical parts in the equipment
Number of on-hand parts recommended

Cabin Temperature Control: The system shall be equipped with direct digital controls to
automatically supply air volume and temperature to attain and maintain the set cabin
temperature within +/- 2 degrees F at the sensing point. This shall be facilitated by use
of a small temperature probe connected to the system by way of a small cable and jack
in the bridge cab. The probe will be placed on board the aircraft in a designated location
by the gate agent after the arrival of the flight and removed after APU start up and prior
to departure. The automatic controller shall select the appropriate operating mode (cool,
ventilate, heat) depending upon the DX Boost unit inlet air temperature and aircraft onboard conditions. The cabin temperature set point for the cooling mode and heating
mode shall be resettable via software control from within the ddc controller.
1.

The unit shall have a manual control mode in case of failure of the automatic
temperature sensing circuit. A manual override control to increase or decrease air
flow or temperature shall be mounted in the bridge cab; this control shall become
active whenever the cabin sensor probe or its cable is either missing or is detected
as an open or short circuit. Switch over to the manual mode shall be automatic.

2.

In the automatic mode, the system shall perform all functions without any human
intervention except for the following:
-

Connect aircraft service hose(s) (ground crew)

Place sensor in cabin (gate agent)
Press START button (ground crew)
Press STOP button after APU is started (ground crew)
Remove temperature sensor probe (gate crew)
Remove and store hose (ground crew)

B. Air Delivery to Aircraft: The system shall be include accessories to supply air from the
DX Boost unit via underground duct as required to reach service pit. Flexible hoses
shall be provided as part of the PCA Service pit for all types of aircraft specified.

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2.3

1.

The total air delivery system shall, in combination with the operating parameters
of the DX Boost unit, provide the performance requirements stated in paragraphs
B.4, 5, and 6. All pressure drops and heat gain or loss of the air delivery
accessories shall be considered in rating and sizing the system and DX Boost
unit capacities.

2.

Remote Control and Monitoring: Each DX Boost unit shall have an on/off pushbutton station located at the apron level for convenient access by ground crew
personnel. This on/off station shall be remote from the DX Boost unit and
mounted to the pit or bridge wheel assembly in a location as approved by the
Owner. Additionally this station shall have provisions for selection of aircraft type
to be serviced at the gate position.

3.

The unit shall have dry contacts or an approved digital I/O signal level for
connection by others to remote location for monitoring the status of the DX Boost
unit on/off status and summary fault condition.

INTERFACES WITH EXISTING FACILITIES OR WITH FACILITIES TO BE PROVIDED

UNDER ANOTHER RELATED SPECIFICATION SECTION
A

2.4

Electric Power: The DX Boost unit and any other accessories shall utilize 480
volt, 3-phase, 60 Hz power, or 380 volt 3-phase 50 Hz power as required by
project location. Power shall be brought by others to a junction box located near
the DX Boost unit.

EQUIPMENT, INSTALLATION AND MATERIAL REQUIREMENTS.

The location of the DX Boost unit and air delivery devices shall meet the following
requirements.
2.4.1

All performance and safety standards are met.

2.4.2

All equipment, piping, hoses and air duct shall be continuously insulated as
necessary to prevent condensation and reduce heat gain/loss.

2.4.3

All condensate runoff from the DX Boost unit shall be piped to a drain location
specified by Owner. Condensate pumps shall be provided as necessary.

2.4.4

DX Boost unit Power Connection and Motor Starter Panel: Incoming

electrical power connection points, power fuses, control power transformer(s)
and starters for the blower motor, compressor motors and condenser fan as
well as power control devices for the electrical strip heaters shall be housed
in a single weatherproof cabinet section integral with the DX Boost unit main
housing and accessible from outside the unit.
a. All devices that operate on voltage above 50V shall be mounted in this
cabinet (with the exception of the motors, and strip heaters, if used) such
that only control power or logic-level signals are present in other areas of
the unit. Starters shall be NEMA-rated and UL recognized. For motors
over 60HP, starters shall be reduced-voltage start type.
b. Supply Air Blower: The blower shall be of the centrifugal type and sized
for the appropriate variable volume airflow requirements at 3600 rpm
max. The unit size shall be selected so that the fan brake horsepower
does not exceed the maximum required over the design operating range
of the unit at the total static pressure. Horsepower shall be selected
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based on the contractors choice of equipment that affects the external

resistance of the system. The blower shall be statically and dynamically
balanced and designed for continuous operation at the maximum rated
fan speed and horsepower. The fan shaft shall be turned, ground and
polished steel designed to operate at no more than 70 percent of the first
critical speed at the top of the speed range of the fans class.
Provide shaft bearings having a median life (AFBMA) of 200,000 hrs
calculated in accordance with AFBMA 90 for ball bearings or AFBMA 11
for roller bearings.
c. Blower Motor: The blower shall be high-efficiency type, TEFC, of standard
frame size, with permanently lubricated bearings. Motor shall be
accessible for inspection or replacement from outside the unit via access
panel, without requiring removal of any other components. Motor shall be
UL-recognized.
d. Condenser Fans and Motors: Condenser fans shall be propeller type, directdriven with permanently lubricated bearings. Condenser fan motors shall
be of standard frame size, 3600 rpm maximum, TEFC, with permanently
lubricated bearings.
e. Evaporator and Condenser Coils: Coils shall be seamless copper tube with
aluminum fins and removable from the unit. The evaporator coil section
shall be completely insulated. The number of tubes and fin spacing shall
be submitted. Coils shall be proof tested to 400 psig and leak tested to
250 psig with air pressure under water, then cleaned, dehydrated and
sealed with a holding charge of nitrogen. No more than two compressor
circuits shall be combined with a single evaporator coil.
f.

Compressors and Related Components: Compressors shall be serviceable,

hermetic scroll type. Each circuit shall have thermal expansion valves,
filter drivers, sight glasses, minimum of two refrigeration circuits, fan
cycling control for low ambient control to 45 degrees.
1. Safety Controls: Low pressure cutout, high pressure cutout,
compressor motor overload, manual reset, anti-recycling timer,
adjustable low-ambient lockout, compressor over temperature safety
module.

g. Air Filters: Provide factory-fabricated, viscous-coated flat panel type

replaceable air filters with holding frames, with 2-inch thick UL Class 2
throwaway media material. Construct media of interlaced glass fibers,
spray with nonflammable adhesive and frame in throw away fiberboard
casings. Construct holding frames of galvanized steel or aluminum,
gasketed as necessary to limit bypass air. Filters shall have rated face
velocity of 500fpm, initial resistance of not greater than 0.30 inches H2O
and average efficiency of 30 percent. The filter face area shall be such
that the rated filter face velocity is not exceeded.
h. Noise Level: The maximum sound level for the DX Boost unit at maximum
operating condition shall not exceed 90dbA at a distance of 15 feet (4.5M)
from the unit.

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.
3.0 SYSTEM TESTING
A.

Factory Tests: The first unit manufactured shall be tested in accordance

with Manufacturers Factory Acceptance Test Procedure, in an
environmentally controlled test chamber, under the summer design day
ambient conditions to demonstrate the ability to perform to the
specification requirements, including chilled water and associated DX
components. Test procedure shall be submitted 60 days after receipt of
contract and Owners representative shall review and approve the test
procedure prior to test being performed. Owner has the right to witness
testing, and shall be notified 15 days in advance of the scheduled test in
order to make necessary arrangements to witness the test. Owner will
provide for travel and per diem expenses of their representatives.

B.

Each additional unit shall be inspected and tested at the factory prior to
shipment. Complete test reports shall be submitted within 2 weeks of
factory test. .

C.

In-Process Field Testing and Inspection: All installed equipment shall be

inspected, all wiring checked for proper continuity, and DX Boost unit
checked for leaks in accordance with the applicable specs and standards.

D.

Site Acceptance Tests: Recognizing that it is impractical to

simultaneously duplicate the design ambient, aircraft activity and
passenger loads for performing system capacity, acceptance criteria for
system rating will be based on certain capacity measurements and
interpolation/extrapolation of data. These criteria and procedures will be
mutually agreed to by the Contractor and Owner prior to the performance
of the acceptance tests.
1. Following check out and inspection by the contractor, a complete
acceptance test shall be made of each gate system using live aircraft
and shall be witnessed by the owners representative. Tests shall
comprise those in the approved test procedure. Complete test reports
shall be submitted within 10 working days of completion of the actual
tests. Test reports shall contain suitable data reduction and
calculation to verify the goals of the test plan and the system capacity.

3.1 SUBMITTALS
A.

The following drawings and other data shall be submitted by the contractor for
approval by the Owner and/or the Engineer.
1.

Product Data: Submit manufacturers technical product data, including

rated capacities of selected model clearly indicated, dimensions,
mounting provisions, required clearances, weights, power requirements,
furnished accessories, and installation instructions, including the
following:
a.

Blower performance curves indicating operation condition points.

b.

Blower motor ratings and electrical characteristics.

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c.

Condenser fan performance curves indicating operation points.

d.

Condenser motor ratings and electrical characteristics.

e.

Compressor operating characteristics, performance points

1)
Refrigerants.

f.

Compressor motor ratings and electrical characteristics.

g.

Overload protection devices for all motors.

h.

Strip heater characteristics

i.

Starter and contactor catalog cuts and other performance data.

j.

Materials, gauges and finishes.

k.

Dampers, linkages, housing, operators.

l.

Air Filters: catalog cuts, dimensions, required clearances and

access, flow capacity, pressure drop at rated air flow, efficiency
and test method, fire classification, installation instructions.

2.

Shop Drawings: Submit equipment shop drawings detailing electrical and

mechanical requirements for wiring and mounting, including control
wiring. Include control logic diagrams. Submit installation shop drawings
showing materials and methods of mounting and wiring, including
electrical cable, conduit, junction boxes, fittings, clamps, grounding,
brackets, hardware, NEMA classification or other industry rating as
applicable.

3.

Operation and Maintenance Data: Submit maintenance data and overall

system parts list. Include troubleshooting and maintenance guide,
service and repair guide, preventative maintenance schedule and
procedures, theory of operation, recommended spare parts lists, special
tools and factory contact procedures.

3.2 WARRANTY
Equipment furnished under this specification shall be guaranteed against defective parts
and workmanship under the terms of the manufacturers warranty for a period of not less
than 1 year from the date of initial start-up at the project site.
3.3 OPERATION AND MAINTENANCE MANUALS
A.

Technical manuals, prepared in accordance with Air Transport Association

Specification 101, Revision 4 shall be provided in a protective binder or cover at
least 10 days prior to site acceptance. Three manuals shall be provided to the
Owners representative.

B.

As a minimum, the manuals shall consist of the following:

1.

One section defining the overall operation of the system, start-up and
shut-down and adjustment procedures, overall preventative maintenance
charts, flow charts and a listing of major system components, with a guide
to finding detailed information on these components in other sections.

2.

One section containing maintenance and operating details of the air

handlers, with theory of operation, control diagrams, schematics,
troubleshooting charts, complete alignment instructions, preventive

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maintenance details, parts lists, all in the general format and intent of
ATA-101 as adapted for fixed facility equipment.
3.

One or more sections containing the standard vendors operating and

maintenance manuals of all functional assemblies, including
compressors, pumps, control valves, coils, etc., with catalog cuts of all
devices.

4.

One section detailing system controls: operation, theory, control and

ladder diagrams, program parameter adjustments, manual override
techniques, parts lists.

5.

Cross reference parts list, indicating contractors part numbers as they

appear in the manuals with corresponding original manufacturers part
numbers (if different than contractor).

6.

Capacity information, curves, etc., same as provided for submittals.

3.4 AS-BUILTS
As-built drawings shall be submitted within 30 days after system acceptance.
3.5 RECOMMENDED SPARES LIST
A recommend spares list shall be submitted covering all items of equipment and
categorized accordingly, with current unit prices as well as recommended lot price. This
list shall be submitted within 90 days after drawing approval.
3.6 SYSTEM SUPPORT
A.

Training: During the checkout and test phases above, the appropriate owner
personnel shall be invited to witness and to receive over-the-shoulder
operation/adjustment training. Immediately prior to or within one week after
system acceptance tests or beneficial use of the system, whichever comes first,
contractor shall conduct a 3-day training class for up to 12 personnel. The class
shall consist of 50 percent classroom and 50 percent hands-on operation. This
class shall be aimed at operating and maintenance personnel for basic operation,
preventative maintenance, adjustment and initial fault response.

B.

Contractor shall make available, under separate contract, optional additional

training courses dealing with detailed maintenance of the controls and overall
system troubleshooting and realignment, either at his factory, or at the job site.
END OF SECTION

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