Specification - Solar Hot Water System

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Proposed 4 Star Hotel Development in Umm Hurair, Health Care City-Phase-1 PACKAGED SOLAR WATER HEATING
MECHANICAL SPECIFICATIONS BAS-12345-MS80
SECTION 23 56 16
PACKAGED SOLAR WATER HEATING
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and apply to this Section.
1.2 SUMMARY
A. This Section includes Packaged Solar water Heating system as indicated in the drawings.
1.3 SUBMITTALS
A. General: Submit the following according to Conditions of Contract and Division 1 Specifications
Sections.
B. Product Data: Size, dimensions, capacity, pressure rating, accessories and special features and
operating characteristics of all equipments.
C. Shop Drawing: Detailed equipment assemblies indicating dimensions, required clearances,

method of field assembly, components and location and size of each field connection.
D. Wiring Diagrams: Detailed wiring diagram for each item of equipment with electric power supply.
E. Maintenance Data: Submit maintenance data and parts list for solar heater, control and
accessories, including trouble shooting maintenance guide. Include this data and product
data in maintenance manual in accordance with the requirements of Division 1.
1.4 QUALITY ASSURANCE
A. Comply with Australian standards or equivalent American standards.
B. Technical design, construction quality and measurement of performance (accelerate ageing,

continuous control) all shall be done as per Australian standards AS 2712.
C. Manufacturers Qualification: Firms regularly engaged in manufacture of solar heaters or types

and capacities required whose products have been satisfactory used in similar services in
several international markets and conditions for not less than twenty years. They should have a
minimum experience of 25 yrs in manufacturing and 7yrs installing similar large systems in the
GCC. The complete system including tanks, collectors, sensors, pumps, controllers etc shall
ideally be supplied by a single manufacturer with the tanks and collectors to be manufactured
by a single manufacturer or the tank can be from the list of approved manufacturer and who
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shall provide a comprehensive 5 year warranty. Systems put together by assemblers

/integrators shall not be accepted.
1.5 COORDINATION
A. Coordinate size and location of concrete bases. Concrete, reinforcement and framework
requirements are to be coordinated with respective civil work.
1.6 DELIVERY STORAGE AND HANDLING
A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or

replace front- and rear-door refractories and heat exchangers of boilers that fail in materials or
workmanship within specified warranty period.
B. Product shall be delivered to site stored and protected under provisions of General Conditions
of Contract.
C. Factory packaged items shall be stored in shipping containers or in safe covered storage until
time of installation.
1.7 WARRANTY
A. The complete system shall be Manufactured and Supplied by a Single Manufacturer who should
extend their Warranty on the complete HW System, with a 5-year comprehensive warranty
covering Parts and 1 year for Labor. The local agent shall only assist the manufacturer in the
installation of the system.
1.8 SYSTEM DESCRIPTION
A. Solar water heaters will be installed in the solar plant room of the building along with all other
specified related equipment to generate required temperature for the proper operation of hot
water supply for the equipments.
PART 2 - PRODUCTS
2.1 GENERAL
A. Supply, deliver and install where indicated one numbers of solar water heaters, Solar hot water
systems shall comply with Australian Standard AS2712 or equivalent to American, and
manufactured under a Quality Assurance System complying to ISO 9001. Technical design,
construction quality and measurement of performance (accelerate ageing, continuous control)
all shall be done as per AS 2712, SRCC & Solar Key Mark.
2.2 APPROVED MANUFACTURER
A. The followings are approved manufacturer for solar water Heating system
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1. SOLAHART - Australia
2. EZINC - Turkey
3. EDWARDS - Australia
2.3 SYSTEM CAPACITY:
A. The solar system capacity shall be calculated by the specialist contractor and submitted for
engineers approval the proposed solar water heating system shall supply hot water at 60 deg
C for the at an annual solar contribution of minimum 75%.
2.4 SYSTEM DESCRIPTION:
A. The system shall be designed as a fully integrated, packaged heating system incorporating the
high performance solar collectors, drain back thermal storage tanks, primary circulating pumps,
and all other necessary controls for safe and efficient operation.
B. The solar circuit shall be an 'active' pumped system that utilizes drain back technology. When
the unit is at the target temperature with the solar pump stopped the heat transfer fluid is able
to drain back from the solar collectors into the Heat Store. This technology provides over
temperature protections in times of high solar gain with little or no potable water use;
additionally it affords total freeze protection to the collectors and closed circuit. The closed
circuit is controlled by a temperature differential controller that gives preference to any effective
energy available from solar rather than the back-up boost.
C. The system shall be effective in taking care of over-heating and wet stagnation in summer
season in a simple and cost effective manner.
D. Fully-flooded systems utilising additional heat exchangers, inercooler and chemical makeup
system on the primary side to prevent over heating in summers shall not be acceptable.
2.5 SOLAR COLLECTORS:
A. The number of collectors shall be as per the drawings in order to produce hot water at a daily
average annualised solar contribution of 75% based on 5626 W/m2/day of solar radiation.
B. Each collector shall have a harp design with a nominal absorption surface area of 2m2.
Collectors shall be accredited to EN 12975, constructed of copper waterways with 13 risers
mechanically bonded to the copper absorber sheet capable of taking maximum working
pressure of 1400kPa. Insulations shall be 38mm and 12kg/m3 glass wool insulation in the base
and 28mm,32 Kg/m3 polyster insulation on the sides, 0.7mm marine grade aluminium outer
casing and 0.2mm copper absorber plate. The absorber plate shall be copper, Tinox sputtered
Titanium Oxide surface having a minimum absorbtance factor of 0.95+/-2 and maximum
emissivity factor of 0.04+/-2. The collector shall be glazed with low iron toughened safety matt
glass of thickness 3.2mm with a maximum iron oxide content of 0.04%. The net weight of each
collector shall not exceed 35 Kgs to keep the roof load within limits. The collectors shall have a
stagnation temperature greater than 208C.
C. The collectors shall be manifolded in parallel into the appropriate number of rows with a
maximum of 8 collectors per bank.
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D. Each collector shall have a design flow rate of 2.25 L/min. The flow and return lines from the
collectors to the storage tank shall be of minimum required diameter and insulated with a
minimum of 13 mm thick UV stabilized insulation.
2.6 STORAGE TANK:
A. It shall operate with neutral treated water at a pH level of 8.5 to 9.0. The storage tank has a fully
welded carbon steel cylinder but rated to 4 bar working pressure and is treated on the outside
to prevent corrosion. The storage tank shall be fully insulated with minimum 100 mm Eco
fibertech, Polyethylene (PE) with R value = 36mW/mK. The insulation must be rot proof,
resistant to mould, bacteria, rodents, hypoallergenic, water-repellent, 100% recyclable &
fireproof. Tank must be cladded 100mm Fibretek insulation with bonded aluminium cladding.
B. The storage tank maintains a low pressure, closed circuit fluid that is used to store and transfer
heat. The storage capacities are as per requirements. Multiple tanks of the same capacity can
be manifolded in parallel to store larger volumes of fluid at high temperatures. The storage tank
is supplied with two flanges to allow the fitment of electric heating unit bundles. Storage tank
suits to maximum temperature rise of 90C and be equipped with all necessary pressure relief
valves.
2.7 POTABLE WATER DELIVERY SKID:
A. Delivery skid shall be used to transfer energy from the drain back tank. Delivery heat exchanger
skid are equipped with a dual head pump for duty/standby redundancy with Wireless
duty/standby function, 316 stainless steel single brazed plate-type heat exchangers, and
exhibit extremely low pressure loss with BMS interface option. Dual heat exchangers provide
redundancy and a temperature controlled variable speed circulator for the primary fluid circuit
to regulate the rate of energy transfer to the potable water from the thermal solar fluid.
B. The heat exchangers are Insulated single wall BPHX to maximize efficiency
C. The delivery skid controls allow maximum solar energy to be stored in the heat store and
accurate safe temperature to be delivered on the potable side.
D. The Delivery skid to be equipped with fittings to allow in-situ cleaning of the entire heat
exchanger, or each heat exchanger can be separately isolated and removed for individual
maintenance, thus providing redundancy capability. All fittings and pipe work to be stainless
steel.
E. The primary and secondary side pressure and temperature shall be as follows:
1. Primary side:
Inlet temperature 80
Max pressure drop 40 kPa
2. Secondary side
Inlet temperature 20
Max pressure drop 52 kPa
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2.8 FLUID:
A. Only Anti scaling, Anti-corrosion inhibitor liquid shall be used on the primary closed circuit.
Water shall not be used in the primary circuit.
2.9 AXILARY BOOST BY GAS AND HEAT PUMP:
A. Storage tank shall have the provision for auxiliary heating by heat pump and LPG gas system
by Boiler as indicated in the drawings.
2.10 SOLAR CIRCULATING PUMP SKID:
A. Solar circulating pump skid are equipped with a dual head pump for duty/standby redundancy
with duty/standby function & BMS interface option. The solar circulating pumps designed to
facilitate the automatic drain back with a by- pass line.
B. A solar circulating pump shall be supplied along with the heat store to circulate the fluid
between the heat store and the collectors. The working of this pump shall be controlled through
a delta T controller. The pump shall circulate the fluid only if the temperature in the system falls
below the set point and if there is enough radiation to heat the fluid.
C. The solar pump shall be of a centrifugal design and circulate (as required) L/s at a total
pressure head of (as required) kPa.
2.11 SOLAR CONTROLLER:
A. Description:
Solid state differential temperature thermostat with capacity for up to 12 low resistance platinum
resistance thermometers, solar pump contactors and overload protection. It has relay outputs to
be connected to diverter valves and pump contactors.
B. Functions:
1. Standard: When collector outlet temperature exceeds storage temperature, close

contacts to start solar pump and pump the primary fluid to flood the collector array.
2. Over Temperature Protection: When collector temperature is less than 3 deg C

differential with stored primary fluid, open contacts shall switch off the pump to allow
primary fluid to drain back into Heat Store Cylinder/Tank
3. Freeze Protection: When no solar gain is available, open contacts shall switch off the
pump and allow primary fluid to drain back into Heat Store Cylinder thus preventing
freezing
4. High Limit Off: When Heat Store Cylinder/Tank temperature rises above required set
point, user defined between 55 85 degrees C, open contacts. Primary fluid shall drain
back preventing over-heating.
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2.12 HOT WATER STAINLESS STEEL CALORIFIER WITH HEAT BOILER / PUMP BACK UP:
A. Hot Water Electrically/ external source heated Storage Water Calorifiers, made of stainless
steel AISI 316 / MS tank with Glass lined/Enamel vitroflex coating suitable for potable water as
per EN with thermostat protected heating elements, suitable inspection/cleaning flange,
polyurethane insulation (cfc-free), non-sacrificial electric anodes and accessories.
B. Designed and produced acc. to European Pressure Vessel Directive 97/23/EC or ASME .
C. Factory test certificate from the manufacturer conforming to PED/ ASME
1. Calorifier Capacity each :
As per site requirement - storage capacity. Should deliver hot water equal to the storage
capacity through a Delta T of 40 C, based on the required recovery period.
2. Material:
AISI 316 stainless steel/ MS tank with Glass lined/Enamel vitroflex suitable for potable
water as per EN
3. Welding quality:
Shall be automatic, high grade inert gas full penetration welding free from porosity and
undercuts of parent metal on the weld seam resistant to corrosion. Finished tank shall be
given pickled baths to give a smooth surface finish and providing an envelope of resis-
tance to corrosion and fouling.
4. Anodes:
The non-sacrificial impressed current anode remains permanently intact for 10yrs. A tita-
nium rod and a potentiostat continuously compares the potential inside the tank againt
the theoretical potential and constantly applies the current to protect the tank. It shall not
need maintenance with an annual power consumption of less than 10kWh.
5. Pressure Rating:
Operating pressure 6/10 bar as per site pressure requirement. Test pressure 9/15 bar.
6. Internal coil U-Tube Heat exchanger:
Shall be SS 316, 10 bar rated with connection port sizes as required to connect an exter-
nal heating source, say boiler or heat pumps. The Electric Heating Coil of 3 Nos. Existing
1850 liters calorifier shall be replaced with the Interal coil U tube Heat Exchangers as per
the specification.
7. Insulation & Cladding:
60 mm removable, Rigid polyurethane upto 5000 Lit and Soft above 5000 Lit capacity
tanks. CFC/HFC-free as per EU Directive 2002/95/EC and 2003/11/EC insulation with a
thermal conductivity of 35-37mW/mK. Aluminium cladded.
8. Accessories :
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The proposed Heat pump shall be provided with the following accessories
Automatic air vent

Temperature gauge 0100C
Pressure gauge 60mm 010bar
Safety release valve
Low level pressure switch
Anti-vacuum valve of adequate rating
1 Nos fitted inspection flange cover.
1 No. non-sacrificial electric anodes
Sensor- 3 nos. for each tank. Top sensor for o/t cut off at 75C, middle sensor for PLC
control and low level sensor for monitoring
Lifting hook
9. Connection Ports ( sizes as per site)
HW outlet- At the top of dish end

CW inlet- At the lower bottom
HW return At the middle of the tank ( 65% height)
Drain- At the bottom of dish end with extended pipe
Ports for Anode, Temperature sensors, PG, TG, Safety valves, Ant- vacuum valve
Spare- 2 nos, 20% & 75% heights
10. Master Control panel
PLC controller based Industrial standard IP55 control panel mounted on wall for control-
ling single or multiple tank operation with stage heating, door inter-locked isolator. Heater
indicator LED for each heating stage.Power-on/off LED, auto-off-manual switch for each
stages. 3 nos. PT100 temperature sensor per tank. 6 LCD digital display and volt free
output contacts. If the temperature reaches 75C, the power to the elements shall be cut
off.
The control panel shall be with BACNet/IP protocol for BMS connectivity. Also All the ex-
isting calorifiers also shall be connected to the BMS for monitoring.
11. Warranty:
2 years warranty on the full system
12. Manufacturers capability
The proposed Manufacturers shall be ISO 9001:2008 certified, have a minimum of 25

years experience in the manufacture of such Calorifiers and the ability to manufacture a
capacity of 50m3. Shall have the ability to manufacture at their premises ASME certified
tanks and tank thickness of 50mm, if required. Ability to manufacture to Japanese MHWL
standards shall be an added advantage. Shall demonstrate the ability to manufacture
high capacity and high quality tanks consistently. Each tank shall be tested in the factory
prior to despatch. Shall have separate assembly lines of manufacture for SS and MS
tanks.
D. Approved Manufacturers:
1. AMERICAN WATER HEATERS

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2. SICC
3. ICI CALDAIE
4. AO SMITH
5. ECOVAL
2.13 WATER COOLED HEAT PUMP FOR LOW TEMPERATUE APPLICATION
A. The proposed Heat pump shall produce high temperature hot water for both space heating and
sanitary purposes. The special compressor used shall guarantees hot water production up to
65C. The heating only heat pump shall completely meet any system and application
requirements, with a vast range of applications, hydronic configurations and accessories. The
Heat pump range shall be ideal for commercial (offices, hotels), domestic (homes, apartments)
or industrial installations (domestic hot water production only).
B. Units shall be supplied complete with non-freezing oil and refrigerant charge, and factory tested.
Only water and electrical connections are required on site. Units charged with R410A
ecological refrigerant.
1. STRUCTURE
Load-bearing base and structure made from suitably thick hot galvanized steel plate. All
parts painted with polyester power coat RAL9006.
2. PANELLING
Cosmetic panels made from hot galvanized metal plate and painted with epoxy powder
coat RAL9003.
Lined on the inside with textured heat insulation and soundproofing material.The panels
are easy to remove for quick and easy access to the inside components from either side
of the unit.
3. COMPRESSORS
Latest generation hermetic rotary scroll compressors operating on R410A, complete with
sump heater, electronic thermal protector with centralized manual reset, and two-pole
electric motor.
4. LOAD-SIDE HEAT EXCHANGER

Braze-welded AISI 316 plate heat exchanger. The heat exchangers are lined on the out-
side with a layer of closed-cell neoprene to prevent condensation. When the unit is not
operating, the heat exchangers are protected against no flow conditions by a water diffe-
rential pressure switch. The unit is also ready to operate using non-freezing fluid mixes.
5. SOURCE-SIDE HEAT EXCHANGER

Braze-welded AISI 316 plate heat exchanger. The heat exchangers are sized to operate
with well water, cooling towers or dry coolers.
6. REFRIGERANT CIRCUIT
Main components of the refrigerant circuit:
- Single circuit for sizes 0071-0151 and one compressor
- Single circuit for sizes 0152-0302 and two compressors in tandem - filter-drier
- Electronic thermostatic valve
- High pressure safety valve
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- High and low pressure transducers
7. POWER AND CONTROL ELECTRICAL PANEL

Power and control electrical panel built in compliance with EN 60204-1/IEC 204-1, com-
plete with:
- Transformer for the control circuit
- Fuses and contactors for compressors and pumps
- Main door interlock disconnect switch
- Thermal cut-out switches and contactors for compressors
- Cumulative alarm terminals (BCA)
- Remote ON/OFF terminals
- Spring terminal blocks for the control circuits
- Valve control terminals,
- Electronic controller
Power supply: 400V~ 10% - 50 Hz - 3N.
8. CERTIFICATION
Unit compliant with the following directives and amendments:
- Machinery Directive 2006/42/EC.
- EMC 89/336/EEC + 2004/108/EC.
- Low Voltage Directive 2006/95/EC.
- Pressure Equipment Directive 97/23/EC. Model A1. TV Italy
9. TESTS
Checks performed throughout the entire manufacturing process according to the proce-
dures specified by ISO 9001. Performance or noise emission tests can be conducted by
highly qualified technical personnel withthe customer present.
Performance tests involve measuring:
- Electrical data
- Water flow-rates
- operating temperature
- Power consumption
- Capacity delivered
- Pressure drop on the water-source heat exchanger at both full load (in rated conditions
and at the most critical conditions for the condenser) and at part load.
During performance testing the main alarm conditions can also be simulated. Noise
emission tests verify the units sound power levels according to ISO 3744.
10. CONTROLLER
The controller is the new device designed especially for heat pump applications with in-
corporated logic for high temperature hot water production. The keypad features function
controls and a complete LCD display for viewing data and activating the unit, via a multi-
level menu, with settable display language. The controller provides temperature control
for the heating and cooling systems in the air-conditioned rooms, as well as for domestic
hot water. These different temperatures are managed automatically based on the differ-
ent conditions in which the system operates, with the possibility to assign specific levels
of priority to domestic hot water production, depending on the needs of the application.
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Diagnostics include complete alarm management, with black box functions (via PC) and
alarm log (display or PC) for best analysis of unit behaviour. For systems made up of
multiple units, differentiated device management means just a certain portion of the ca-
pacity installed can be dedicated to domestic water production, in this way ensuring more
efficient energy distribution and, at the same time, guaranteeing simultaneous water deli-
very to the different distribution systems. The built-in clock can be used to create an op-
erating profile containing up to 4 typical days and 10 time bands, essential for efficient
programming of energy production, and fundamental for managing the Legionella preven-
tion cycles. Supervision is available with different options, using proprietary devices or by
integration into third party systems using ModBus, BACnet, BACnet-over-IP and Echelon
LonWorks protocols. A dedicated wall-mounted keypad can be used for remote control of
all the functions.
C. Approved Manufacturers:
1. COMBITHERM
2. CLIMAVENETA
2.14 WATER COOLED HEAT PUMP FOR HIGH TEMPERATUE APPLICATION
A. The proposed heat pump shall consists of one or more refrigerant cycles for heating of water. A
raw water tank, chilled water return, or similar shall serve as heat source.
B. The plant shall be built in accordance with the EU Machineries Directive (42/2006/EC) in the
draft 91/368 EWG.
C. The unit consist of the following components:
1. Piston compressors, semihermetic, with integrated oil management, enclosed drive motor
with part-winding start and required accessories, each:
1 automatical start unloader
2 shut-off valves,
1 oil-level-surveillance and oil heater,
2 high pressure switches,
2 low pressure switches,
1 non-return valve,
1 capacity controler,
appropriate amount of oil,
anti-vibration mountings under the compressor.
2. Condenser as heat exchangers for heating the water, in plate heat exchanger design
suitable for dry condensation. The heat exchanger is manufactured from stainless-steel
with high quality copper welding. Design operating pressure 25 bar. Condenser insulated
with vapour-tight 19 mm Armaflex insulation and protection shell.
3. Direct expansion heat exchangers for cooling the water, in plate or shell and tube heat
exchanger design suitable for dry evaporation. The heat exchanger is manufactured from
stainless-steel with high quality copper welding. Design operating pressure 25 bar.
Evaporator insulated with vapour-tight 19 mm Armaflex insulation and protection shell.
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4. Refrigerant collector units with to contain the complete refrigerant filling, fitted with a sight
glass for level indication as well as a safety release valve. The collector unit is
manufactured from steel pipe with formed ends. Designed operating pressure 28 bar.
The collector unit is approved by the TV.
5. Heat exchanger for liquid subcooling and suction gas overheating for high efficient
energy ratios.
6. Refrigeration accessories as required, installed within the refrigeration cycle as follows:

filter dryer
sight glass
electronic expansion valve
manometer
7. Refrigeration filling of the plant with R 245fa and special refrigerant oil.
8. Housing with profile frame, casing made of galvanized steel sheet.
9. Vibration attenuators for the unit under base frame.
D. Control Equipment:
1. Control and switching components for the unit installed in the control panel and
connected electrically in accordance with their function.
2. 1 Temperature control mechanism to switch on/off the compressor stages consisting of:
1 electronic controller with microprocessor system to controll the
compressors capacity,
1 digital display for actual and control values,
1 temperature sensor with sensor housing in the water inlet line,
1 temperature sensor with sensor housing in the water outlet line,
1 set point switcher by using a 0-10V signal,
automatic base load changer of the compressors,
1 additional time relay to limit cycle frequency of the compressors,
flow controller in the evaporator inlet
3. 1 Electric panel, built according to the german and international standards, including all
switch and safety components for the chiller as well as the complete control system as
described above.
4. The following components are included within the electric panel:

1 main switch,
current protection for all electric motors (threephase current),
relay combination for star-delta start with current protection for the compressor mo-
tors,
current protectors for the control circuit,
Manual-0-Automatic-Switch for all electric motors,
operation lamps for all electric motors,
fault indication lamps separate for each fault as:
refrigerant high pressure
refrigerant low pressure
oil level
over-current/motor over-temperature
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lamp tester switch for all lamps,

operation hour counter for each compressor motor,
flow switch alarm including a 10s time delay relay,
unlock push-button,
collective fault alarm signal,
relay for external release,
all required time relays and auxiliary contactors,
terminals and labelling of compenents on the panel.
5. The electric panel includes all connecting wiring. The components described above are
installed within the panel and connected in accordance with their function. All motors,
switch and safety components are connected with the panel.
E. Performance Data
1. Min./max. heat source : C +27/+65
2. Min./max. heat sink : C +70/+120
3. Refrigerant : R 245fa
4. GWP : 1.030
5. OPD : 0
6. Max. temp difference on condenser or evaporator C: 40 (or higher)
F. Operational Configuration
1. Bus communication (Profibus, Modbus,),
2. Sound-absorbing housing to reduce the noise level outside to 10-15 decibels,
3. Design of heat exchangers for special requirements,
4. Gas warning device,
5. Inline pumps w/o frequency inverter and mechanical, electrical, or pneumatic valves with
controller mounted on plant,
6. Further hydraulic components (Strainer, check valves,),
7. Adaption of dimensions to the requirements.
G. Approved Manufacturers:
1. COMBITHERM
2. CLIMAVENETA
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2.15 HOT WATER BOILER
A. GENERAL
1. Supply, deliver and install where indicated of hot water boiler & burner package
automatic fully packaged, forced draft horizontal Three Pass Reverse Flame, fire tube
type hot water Rex Dual boiler designed and constructed in accordance with current
edition European Pressure Equipment Directive and comply with the requirements of the
latest Factories Act as well as the Health and Safety Executive Guidance Notes.
B. CHARACTERISTICS OF BOILER:
1. Quantity:
a. The hot water boiler shall be completely factory assembled with all necessary
components, refractory, insulation, pipes and shall be on a heavy structure steel
skids base ready for installation and operation. The wiring between control
components and all safety devices shall be completed at the factory. Each unit
shall have all safety and operating controls adjusted, set and tested at the factory.
b. The boiler shall have a capacity as stated on the drawings and the following design
/ working and test pressures:
c. Type Horizontal, forced draft, fire tube Packaged Three Pass Reverse Flame,
Diesel fired packaged steel construction.
2. Technical Data:
a. Rated heating capacity max.: as per schedule
b. Quantity : 1 + 1( stacked)
c. Boiler efficiency min : 92 %
d. Width : 3935 mm
e. Length : 1870 mm (without burner)
f. Height : 2146 mm
g. Weight : Net 5700 kg
h. Gross : 9350 kg
i. Max. Operating pressure : 5 bar
j. Test pressure : 7.5 bar
k. Max. Temperature : 105 C
l. Insulation boiler body : 80 mm
m. Electrical : 400 v/3PH/50 Hz

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3. The boilers shall be high performance reverse flame hot water boilers designed for
gaseous and liquid fuel supply and shall combine excellent reliability and long-lasting life
with high thermal efficiency (>92%) fully meeting the requirements provided 92/42/CEE,
directive on efficiency.
4. Product quality and reliability shall be guaranteed by ISO 9001 Quality Certification of
materials, components and processing precision, but also by correctly sizing thermal
loads according to the volume of the combustion chamber and the boiler transfer
surfaces. The design shall be well balanced to provide high performance with a focus
savings on fuel, low gas temperature and reduction of polluting emissions (CO and NOx).
5. The boiler shell should be in RST37.2 DIN 17100 steel; all boiler components should be
laser cut for top precision semi-finished products; high ampere robotic welding machines
should be used to guarantee perfect welded material-to-sheet melting. ST37.0 DIN1629
steel flue pipes should be inserted in AISI 304 stainless steel laminar turbulator to
increase the gas/water transfer factor and therefore generator efficiency.
6. The front tube shall be flanged towards the furnace thus enabling efficient mechanical
and thermal stress absorption.
7. The combustion chamber should be cylindrical with a fully wet back. A stay support is to
be welded between the bottom and the rear tube plate supports of the furnace.
8. In designing the boiler, special attention should be given to the problem of scaling. Since
this problem affects the areas in which temperature is higher, this risk should be
eliminated by removing all sources of overheating and by adopting a unique tube and
front plate that distribute the temperature evenly.
9. The boiler shall be fitted with special devices that reduce the risk of gas condense, and
Improve the working life of a generator.
10. The design shall include a special system that conveys internal hot water flows to protect
the rear plate and tubes where the risk of excessive gas cooling is the highest.
11. The inside of the manhole shall be made of ceramic fibre for high insulation and low
thermal inertia. This shall contribute to a higher seasonal efficiency of the plant. The
boiler has to be insulated with 80-mm high-density rock wool panels. Casing shall be
made of easy-to-mount steel panels and reduce heat dispersions by almost 1%.
12. The boiler above 1200 KW shall be lagged and clad with circular stucco aluminium
casings which are fitted at the factory.
13. The efficiency shall be guaranteed by the manufacturer to be not less than 90% over the
complete range. The efficiency shall be complete as per the EN Standards using the
lower calorific value (higher calorific value) efficiency values with the gross calorific
values shall not be considered.
14. The control panel supplied with the boilers is made of self-extinguishing plastic and
houses the regulation and safety instruments
15. Control panel shall be complete with:
a. 2 boiler control thermostats
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b. 2 safety limit thermostats manual reset
c. pump thermostat
d. main switch
e. pump on/off switch
f. boiler thermometer
C. BURNER:
1. Shall be Monoblock forced-draught with modulating control and suitable for Light Oil/ NG
fuel operation,
2. Make: Weishaupt (Germany)/ Reillo / Equivalent.
3. TECHNICAL CHARACTERISTICS
LPG / SNG/ NG burner, modulating, with electric fan, electric ignition and regulation by a
pressure transmitter, composed by:
a. Burner casing in Aluminum up to 2200 KW & steel casing for above 2200 KW with
electrical panel integrated on the burner body.
b. Electric fan for combustion air directly assembled to the electric engine
c. Adjustable combustion head for fine tuning / matching.
d. Mechanical movable head with turn down ratio of 1: 5
e. firing head with adjustable system for primary air.
f. Gas filter & governor
g. Flame detector
h. Gas train
i. Power Min: ... kW
j. Power Max: .. kW
k. Electric power: ..... kW
4. DOCUMENTATION
a. Burner Users Manual
5. MASTER CONTROL PANEL
a. Quantity: 1 no.
b. The master controller shall control multiple boilers and shall include the following:
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DHW circuit control

Boiler Cascade control
Calorifier sensor
Daily heating programme
Room sensor
Volt free kit with 3 contacts for remote signals
D. CHIMNEY
1. Quantity: 1 no.
2. The stack shall be supplied by the boiler manufacturer or locally fabricated in sections
complete with rain-cap and hardware, with sizes and gauge steel as per his
recommendations.
3. The stack sections shall be twin shell insulated stainless steel with SS 316 internal and
SS 304 outer shell.
4. Number of sections as required clearing the top roof by 2 m min.
5. The sections supplied loose shall be delivered with the necessary assembly hardware,
bolts, nuts and gaskets.
6. An inspection opening assembly complete with the relevant hardware shall be supplied
loose for field assembly and mounting.
7. A rain-cap assembly complete with the relevant hardware shall be supplied loose for field
assembly and mounting.
8. If guying is required for stack stability and wind effect, this will be done locally and the
section flange bolts shall be used as guy lines tie joints to suit local conditions.
E. INSTALLATION AT SITE
1. Examine area to receive boiler for compliance with requirements for installation
tolerances and other conditions affecting boiler performance. Do not proceed with
installation until unsatisfactory conditions have been corrected.
a. Install boilers level and plumb, according to manufacturer's written instructions and
referenced standards.
b. Install according to NFPA & ASME or local code..
c. Support boilers on minimum 100-mm thick reinforced concrete base, 100 mm

larger on each side than base of unit. Dowel base to floor on 450-mm centers
along perimeter of base. Cast anchor-bolt inserts through base into floor.
d. Assemble boiler trim according to manufacturer's written installation instructions.
e. Install electrical devices furnished with boiler, but not specified to be factory
mounted.
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P 1621 23 56 16
F. CONNECTIONS
1. Connect gas piping full size to boiler gas-train inlet with union.
2. Connect as indicated, boiler feed water piping, vents, drains etc
3. Connect breeching to boiler outlet, full size of outlet
4. Electrical: Comply with to applicable requirements in Division 16 Electrical works.
5. Ground equipment
6. Tighten electrical connectors and terminals according to manufacturer's published

torque-tightening values. If manufacturer's torque values are not indicated, use those
specified in UL 486A and UL 486B.
G. FIELD QUALITY CONTROL
1. Manufacturer's Field Service: Engage a factory-authorized service representative to

supervise the field assembly of components and installation of boilers, including piping
and electrical connections. Test and adjust controls and safeties. Replace damaged and
malfunctioning controls and equipment.
2. Hydrostatically test assembled boiler and piping, according to applicable sections of the
ASME Boiler and Pressure Vessel Code.
H. CLEANING
1. Flush and clean boilers on completion of installation, according to manufacturer's written

instructions.
2. After completing system installation, including outlet fittings and devices, inspect exposed
finish. Remove burrs, dirt, and construction debris and repair damaged finishes including
chips, scratches, and abrasions with manufacturer's touchup paint.
I. COMMISSIONING
1. Engage a factory-authorized service representative to provide startup service.
2. Verify that installation is as indicated and specified.
3. Verify that electrical wiring installation complies with manufacturer's submittal and
installation requirements in Division 16 Sections. Do not proceed with boiler startup until
wiring installation is acceptable to equipment Installer.
4. Complete manufacturer's installation and startup checklist and verify the following:
a. Boiler is level on concrete base.
b. Flue and chimney are installed without visible damage.
c. No damage is visible to boiler jacket, refractory, or combustion chamber.
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P 1621 23 56 16
d. Pressure-reducing valves are checked for correct operation and specified relief
pressure. Adjust as required.
e. Clearances have been provided and piping is flanged for easy removal and
servicing.
f. Heating circuit pipes have been connected to correct ports.
g. Labels are clearly visible.
h. Boiler, burner, and flue are clean and free of construction debris.
i. Burner blower rotates in correct direction.
j. Pressure and temperature gages are installed.
k. Control installations are completed.
5. Before starting the boiler, check that:
a. The rating plate specifications and power supply network (electricity, water, gas or
fuel oil) specifications correspond.
b. The burner power range is compatible with the power of the boiler.
c. The boiler room also contains the instructions for the burner;
d. The flue gas exhaust pipe is operating correctly;
e. The air inlet supply is well dimensioned and free from any obstacle;
f. The manhole, the smoke box and the burner plate are closed in order to provide a
complete flue gas seal;
g. The system is full of water and that any air pockets have therefore been
eliminated;
h. The water circulation pumps are operating correctly.
i. The expansion vessel and the safety valve(s) have been connected correctly (with
no interception) and are properly operating.
j. Check the electrical parts and thermostat operation.
J. APPROVED MANUFACTURERS:
1. ICI Caldaie - Italy
2. Hoval - Switzerland
2.16 DIGITAL RE-CIRCULATING VALVE (DRV/DMC) The Brain
A. The Brain Re-Circulating Valve shall be digital of lead free stainless steel/polymer construction.
________________________________________________________________________________________________________________________
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B. Shall be1 to 3 inlet/outlet connections, deliver a mixed water flow and shall have no
minimum system draw off requirement.
C. Shall have all of the following operational capabilities:
1. +/- 1 Deg C on outlet water temperature control
2. The valve to perform should have minimum 1 Deg C inlet to outlet water temperature
deferential
3. Should automatic shut off the hot water supply upon the failure of cold water inlet supply
4. Should automatic shut off the hot water supply in the event of a power failure.
5. Should be able to Program and set the outlet water temperature range from 81-158F
(27-70C)
6. Should have the provision to Program for thermal disinfection mode
7. Should be Programmable for 1st level hi/lo temp alarm display
8. Should be able to Program for temperature error level for safety shutdown
D. Shall have all of the following BMS connectivity capabilities:
1. SPCO relay outputs which are energized during operation.
2. LCD display which indicates: set point, delivered temperature, error codes and alarm
conditions.
3. MODBUS 485 port for remote set point adjustment and remote operating temperature
visibility.
4. RS485 Serial Port for connection to a performance matched hot water monitoring system.
E. Shall be compliant with ASSE Standard 1017 and CSA B125 and CE so certified and identified.
F. Shall be UL/CE listed and identified.
G. Power Supply : 1Ph / 220V 240V / 50Hz
H. Approved Manufacturers:
1. ARMSTRONG
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PART 3 - EXECUTION
3.1 INSTALLATION
A. Solar hot water collectors must be installed with tilt and exposed to direct sun (without
shadowing). They should be tilted towards equator (south direction) with angle of 25 . Single
unit or multiple units can be connected together in parallel and connected to common Headers
(CWS, HWS , HWR) to cover the desired daily hot water load and shall be as per the design of
specialist solar manufacturer.
B. The system shall also be equipped with all necessary safety devices that guarantee the system
shall function in a satisfactory way. Such safety devices shall involve cold inlet relief valve and
Pressure & Temperature relief valves. A pressure reduction valve should also be fitted to
maintain the incoming pressure less than 850 kPa. The Pressure & Temperature relief valve
shall be set to relieve water at 1000kPa and/or 99 C
C. The piping between the solar collectors and the storage shall be of brazed copper with proper
insulation with a continuous slope towards the heat store tank to avoid air-locks. No
compression fittings shall be used in the primary circuit.
D. The storage tank shall be equipped with all necessary fittings on cold and hot water side, in
order to connect with piping network (by the specialist contractor).
E. It shall be the contractors responsibility to ensure that all civil, electrical, mechanical (piping etc)
and all work related to solar water heater system are done according to the specifications. All
hot water piping shall be adequately insulated to ensure minimum heat losses during re-
circulation. A hot water circulation pump set (with 24 hrs timer) shall be provided to ensure
continuous hot water availability in the ring main.
3.2 INSTALLATION AT SITE
A. Each building zone will consist of 1 set of central solar heating system supplying hot water
through a common manifold to all the hot water outlets.
B. The bottom of the collectors shall be a minimum of 1 Mts above the top of the heat store to
enable the Natural Drain Back of close circuit fluid to take place.
C. Hot water circulating pump set to be installed in the return line to ensure continuous hot water
availability
D. The solar collectors shall face south with an inclination of 25 deg and shall be mounted on a
stand or plinth.
E. A 2-core cable from the hot sensors in the panels to the each heat store to be conduited.
3.3 FIELD QUALITY CONTROL
A. Manufacturer's Field Service: Engage a factory-authorized service representative to supervise

the field assembly of components and installation of solar system, including piping and
electrical connections. Test and adjust controls. Replace damaged and malfunctioning controls
and equipment.
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B. After completing system installation, including outlet fittings and devices, inspect exposed
finish. Remove burrs, dirt, and construction debris and repair damaged finishes including chips,
scratches, and abrasions with manufacturer's touchup paint.
3.4 COMMISSIONING
A. Engage a factory-authorized service representative to provide startup service.
B. Verify that installation is as indicated and specified.
C. Verify that electrical wiring installation complies with manufacturer's submittal and installation
requirements. Do not proceed with startup until wiring installation is acceptable to equipment
supplier.
END OF SECTION 23 56 16
________________________________________________________________________________________________________________________

Specification - Solar Hot Water System

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P 1621 23 56 16

PACKAGED SOLAR WATER HEATING

1.1 RELATED DOCUMENTS

C. Shop Drawing: Detailed equipment assemblies indicating dimensions, required clearances,

1.4 QUALITY ASSURANCE

A. Comply with Australian standards or equivalent American standards.

B. Technical design, construction quality and measurement of performance (accelerate ageing,

C. Manufacturers Qualification: Firms regularly engaged in manufacture of solar heaters or types

shall provide a comprehensive 5 year warranty. Systems put together by assemblers

1.6 DELIVERY STORAGE AND HANDLING

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or

1.8 SYSTEM DESCRIPTION

2.2 APPROVED MANUFACTURER

2.3 SYSTEM CAPACITY:

2.4 SYSTEM DESCRIPTION:

2.5 SOLAR COLLECTORS:

2.6 STORAGE TANK:

2.7 POTABLE WATER DELIVERY SKID:

2.9 AXILARY BOOST BY GAS AND HEAT PUMP:

2.10 SOLAR CIRCULATING PUMP SKID:

2.11 SOLAR CONTROLLER:

1. Standard: When collector outlet temperature exceeds storage temperature, close

2. Over Temperature Protection: When collector temperature is less than 3 deg C

C. Factory test certificate from the manufacturer conforming to PED/ ASME

1. Calorifier Capacity each :

6. Internal coil U-Tube Heat exchanger:

7. Insulation & Cladding:

Automatic air vent

9. Connection Ports ( sizes as per site)

HW outlet- At the top of dish end

10. Master Control panel

2 years warranty on the full system

12. Manufacturers capability

The proposed Manufacturers shall be ISO 9001:2008 certified, have a minimum of 25

1. AMERICAN WATER HEATERS

2.13 WATER COOLED HEAT PUMP FOR LOW TEMPERATUE APPLICATION

4. LOAD-SIDE HEAT EXCHANGER

5. SOURCE-SIDE HEAT EXCHANGER

- High and low pressure transducers

7. POWER AND CONTROL ELECTRICAL PANEL

2.14 WATER COOLED HEAT PUMP FOR HIGH TEMPERATUE APPLICATION

C. The unit consist of the following components:

6. Refrigeration accessories as required, installed within the refrigeration cycle as follows:

8. Housing with profile frame, casing made of galvanized steel sheet.

9. Vibration attenuators for the unit under base frame.

4. The following components are included within the electric panel:

lamp tester switch for all lamps,

1. Min./max. heat source : C +27/+65

2. Min./max. heat sink : C +70/+120

6. Max. temp difference on condenser or evaporator C: 40 (or higher)

1. Bus communication (Profibus, Modbus,),

2. Sound-absorbing housing to reduce the noise level outside to 10-15 decibels,

3. Design of heat exchangers for special requirements,

4. Gas warning device,

6. Further hydraulic components (Strainer, check valves,),

7. Adaption of dimensions to the requirements.

2.15 HOT WATER BOILER

a. Rated heating capacity max.: as per schedule

c. Boiler efficiency min : 92 %

e. Length : 1870 mm (without burner)

g. Weight : Net 5700 kg

i. Max. Operating pressure : 5 bar

j. Test pressure : 7.5 bar

k. Max. Temperature : 105 C