SECTION 120.6 – MANDATORY REQUIREMENTS FOR COVERED PROCESSES

Refrigerated Warehouses that are greater than or equal to 3,000 square feet shall meet the requirements of Subsections 1, 2, 3, 6 and 7 of Section 120.6(a).

Refrigerated Spaces that are less than 3,000 square feet shall meet the requirements of the Appliance Efficiency Regulations for walk-in coolers or freezers contained in the Appliance Efficiency Regulations (California Code of Regulations, Title 20, Sections 1601 through 1608).

Refrigerated Spaces that (i) comprise a total of 3,000 square feet or more; and (ii) are collectively served by the same refrigeration system compressor(s) and condenser(s) shall meet the requirements of Subsections 4, 5 and 7 of Section 120.6(a).

1. Insulation Requirements. Exterior surfaces of refrigerated warehouses shall be insulated at least to the R-values in TABLE 120.6-A.

TABLE 120.6-A REFRIGERATED WAREHOUSE INSULATION

SPACE	SURFACE	MINIMUM R-VALUE (°F∙hr∙sf/Btu)
Freezers	Roof /Ceiling	R-40
	Wall	R-36
	Floor	R-35
	Floor with all heating from productive refrigeration capacity¹	R-20
Coolers	Roof/Ceiling	R-28
Coolers	Wall	R-28
^1. All underslab heating is provided by a heat exchanger that provides refrigerant subcooling or other means that result in productive refrigeration capacity on the associated refrigerated system.

2. Underslab heating. Electric resistance heat shall not be used for the purposes of underslab heating.

EXCEPTION to Section 120.6(a)2: Underslab heating systems controlled such that the electric resistance heat is thermostatically controlled and disabled during the summer on-peak period defined by the local electric utility.

3. Evaporators. New fan-powered evaporators used in coolers and freezers shall conform to the following:

A. Single phase fan motors less than 1 hp and less than 460 Volts in newly installed evaporators shall be electronically commutated motors or shall have a minimum motor efficiency of 70 percent when rated in accordance with NEMA Standard MG 1-2006 at full load rating conditions.

B. Evaporator fans served either by a suction group with multiple compressors, or by a single compressor with variable capacity capability shall be variable speed and the speed shall be controlled in response to space temperature or humidity.

EXCEPTION 1 to Section 120.6(a)3B: Addition’, alteration’ or replacement of less than all of the evaporators in an existing refrigerated space that does not have speed-controlled evaporators.

EXCEPTION 2 to Section 120.6(a)3B: Coolers within refrigerated warehouses that maintain a Controlled Atmosphere for which a licensed engineer has certified that the types of products stored will require constant operation at 100 percent of the design airflow.

EXCEPTION 3 to Section 120.6(a)3B: Areas within refrigerated warehouses that are designed solely for the purpose of quick chilling/freezing of products (space with design cooling capacities of greater than 240 Btu/hr-ft² (2 tons per 100 ft²)).

C. Evaporator fans served by a single compressor that does not have variable capacity shall utilize controls to reduce airflow by at least 40 percent for at least 75 percent of the time when the compressor is not running.

EXCEPTION to Section 120.6(a)3C: Areas within refrigerated warehouses that are designed solely for the purpose of quick chilling/freezing of products (space with design cooling capacities of greater than 240 Btu/hr-ft² (2 tons per 100 ft²)).

4. Condensers. New fan-powered condensers on new refrigeration systems shall conform to the following:

A. Design saturated condensing temperatures for evaporative-cooled condensers and water-cooled condensers served by fluid coolers or cooling towers shall be less than or equal to:

i. The design wetbulb temperature plus 20°F in locations where the design wetbulb temperature is less than or equal to 76°F; or

ii. The design wetbulb temperature plus 19°F in locations where the design wetbulb temperature is between 76°F and 78°F; or

iii. The design wetbulb temperature plus 18°F in locations were the design wetbulb temperature is greater than or equal to 78°F.

EXCEPTION to Section 120.6(a)4A: Compressors and condensers on a refrigeration system for which more than 20 percent of the total design refrigeration cooling load is for quick chilling or freezing, or process refrigeration cooling for other than a refrigerated space.

B. Design saturated condensing temperatures for air-cooled condensers shall be less than or equal to the design drybulb temperature plus 10°F for systems serving freezers and shall be less than or equal to the design drybulb temperature plus 15°F for systems serving coolers.

EXCEPTION 1 to Section 120.6(a)4B: Condensing units with a total compressor horsepower less than 100 HP.

EXCEPTION 2 to Section 120.6(a)4B: Compressors and condensers on a refrigeration system for which more than 20 percent of the total design refrigeration cooling load is for quick chilling or freezing, or process refrigeration cooling for other than a refrigerated space.

C. All condenser fans for evaporative-cooled condensers or fans on cooling towers or fluid coolers shall be continuously variable speed, and the condensing temperature control system shall control the speed of all fans serving a common condenser high side in unison. The minimum condensing temperature setpoint shall be less than or equal to 70°F.

D. All condenser fans for air-cooled condensers shall be continuously variable speed and the condensing temperature or pressure control system shall control the speed of all condenser fans serving a common condenser high side in unison. The minimum condensing temperature setpoint shall be less than or equal to 70°F.

E. Condensing temperature reset. The condensing temperature set point of systems served by air-cooled condensers shall be reset in response to ambient drybulb temperature. The condensing temperature set point of systems served by evaporative-cooled condensers or water-cooled condensers (via cooling towers or fluid coolers) shall be reset in response to ambient wetbulb temperatures.

EXCEPTION to Section 120.6(a)4E: Condensing temperature control strategies approved by the Executive Director that have been demonstrated to provide at least equal energy savings.

F. Fan-powered condensers shall meet the condenser efficiency requirements listed’ in TABLE 120.6-B. Condenser efficiency is defined as the Total Heat of Rejection (THR) capacity divided by all electrical input power including fan power at 100 percent fan speed, and power of spray pumps for evaporative condensers.

G. Air-cooled condensers shall have a fin density no greater than 10 fins per inch.

TABLE 120.6-B FAN-POWERED CONDENSERS – MINIMUM EFFICIENCY REQUIREMENTS

CONDENSER TYPE	REFRIGERANT TYPE	MINIMUM EFFICIENCY	RATING CONDITION
Outdoor Evaporative-Cooled with THR Capacity > 8,000 MBH	All	350 Btuh/Watt	100°F Saturated Condensing Temperature (SCT), 70°F Outdoor Wetbulb Temperature
Outdoor Evaporative-Cooled with THR Capacity < 8,000 MBH and Indoor Evaporative-Cooled	All	160 Btuh/Watt
'Outdoor Air-Cooled	Ammonia	75 Btuh/Watt	105°F Saturated Condensing Temperature (SCT), 95°F Outdoor Drybulb Temperature
'Outdoor Air-Cooled	Halocarbon	65 Btuh/Watt
Indoor Air-Cooled	All	Exempt

5. Compressors. Compressor systems utilized in refrigerated warehouses shall conform to the following:

A. Compressors shall be designed to operate at a minimum condensing temperature of 70°F or less.

B. New open-drive screw compressors in new refrigeration systems with a design saturated suction temperature (SST) of 28°F or lower that discharges to the system condenser pressure shall control compressor speed in response to the refrigeration load.

EXCEPTION 1 to Section 120.6(a)5B: Refrigeration plants with more than one dedicated compressor per suction group.

EXCEPTION 2 to Section 120.6(a)5B: Compressors and condensers on a refrigeration system for which more than 20 percent of the total design refrigeration cooling load is for quick chilling or freezing, or process refrigeration cooling for other than a refrigerated space.

C. New screw compressors with nominal electric motor power greater than 150 HP shall include the ability to automatically vary the compressor volume ratio (Vi) in response to operating pressures.

6. Infiltration Barriers. Passageways between freezers and higher-temperature spaces, and passageways between coolers and nonrefrigerated spaces, shall have an infiltration barrier consisting of strip curtains, an automatically-closing door, or an air curtain designed by the manufacturer for use in the passageway and temperature for which it is applied.

EXCEPTION 1 to Section 120.6(a)6: Openings with less than 16 square feet of opening area.

7. Refrigeration System Acceptance. Before an occupancy permit is granted for a new refrigerated warehouse, or before a new refrigeration system serving a refrigerated warehouse is operated for normal use, the following equipment and systems shall be certified as meeting the Acceptance Requirements for Code Compliance, as specified by the Reference Nonresidential Appendix NA7. A Certificate of Acceptance shall be submitted to the enforcement agency that certifies that the equipment and systems meet the acceptance requirements:

A. Electric resistance underslab heating systems shall be tested in accordance with NA7.10.1.

(b) Mandatory Requirements for Commercial Refrigeration

Retail food stores with 8,000 square feet or more of conditioned area, and that utilize either: refrigerated display cases, or walk-in coolers or freezers connected to remote compressor units or condensing units, shall meet the requirements of Subsections 1 through 4.

1. Condensers serving refrigeration systems. Fan-powered condensers shall conform to the following requirements:

A. All condenser fans for air-cooled condensers, evaporative-cooled condensers, air or water-cooled fluid coolers or cooling towers shall be continuously variable speed, with the speed of all fans serving a common condenser high side controlled in unison.

B. The refrigeration system condenser controls for systems with air-cooled condensers shall use variable-setpoint control logic to reset the condensing temperature setpoint in response to ambient drybulb temperature.

C. The refrigeration system condenser controls for systems with evaporative-cooled condensers shall use variable-setpoint control logic to reset the condensing temperature setpoint in response to ambient wetbulb temperature.

EXCEPTION to Section 120.6(b)1B and C: Condensing temperature control strategies approved by the executive director that have been demonstrated to provide equal energy savings.

D. The minimum condensing temperature setpoint shall be less than or equal to 70°F.

E. Fan-powered condensers shall meet the specific efficiency requirements listed in Table 120.6-C.

TABLE 120.6-C FAN-POWERED CONDENSERS –SPECIFIC EFFICIENCY REQUIREMENTS

CONDENSER TYPE	MINIMUM SPECIFIC EFFICIENCYa	RATING CONDITION
Evaporative-Cooled	160 Btuh/W	100°F Saturated Condensing Temperature (SCT), 70°F Entering Wetbulb Temperature
Air-Cooled	65 Btuh/W	105°F Saturated Condensing Temperature (SCT), 95°F Entering Drybulb Temperature
a See Section 100.1 for definition of condenser specific efficiency.

EXCEPTION 1 to Section 120.6(b)1E: Condensers with a Total Heat Rejection capacity of less than 150,000 Btuh at the specific efficiency rating condition.

EXCEPTION 3 to Section 120.6(b)1E: Existing condensers that are reused for an addition or alteration.

F. Air-cooled condensers shall have a fin density no greater than 10 fins per inch.

EXCEPTION 2 to Section 120.6(b)1F: Existing condensers that are reused for an addition or alteration.

EXCEPTION to Section 120.6(b)1: New condensers replacing existing condensers when the attached compressor system Total Heat of Rejection does not increase and less than 25 percent of both the attached compressors and the attached display cases are new.

2. Compressor Systems. Refrigeration compressor systems and condensing units shall conform to the following requirements.

A. Compressors and multiple-compressor suction groups shall include control systems that use floating suction pressure logic to reset the target saturated suction temperature based on the temperature requirements of the attached refrigeration display cases or walk-ins.

EXCEPTION 1 to Section 120.6(b)2A: Single compressor systems that do not have continuously variable capacity capability.

EXCEPTION 2 to Section 120.6(b)2A: Suction groups that have a design saturated suction temperature of 30°F or higher, or suction groups that comprise the high stage of a two-stage or cascade system or that primarily serve chillers for secondary cooling fluids.

B. Liquid subcooling shall be provided for all low temperature compressor systems with a design cooling capacity equal or greater than 100,000 Btu/hr with a design saturated suction temperature of -10°F or lower, with the subcooled liquid temperature maintained continuously at 50°F or less at the exit of the subcooler, using compressor economizer port(s) or a separate medium or high temperature suction group operating at a saturated suction temperature of 18°F or higher.

EXCEPTION to Section 120.6(b)2B: Low temperature cascade systems that condense into another refrigeration system rather than condensing to ambient temperature.

EXCEPTION to Section 120.6(b)2A and 2B: Existing compressor systems that are reused for an addition or alteration.

3. Refrigerated Display Cases. Lighting in refrigerated display cases, and lights on glass doors installed on walk-in coolers and freezers shall be controlled by one of the following:

A. Automatic time switch controls to turn off lights during nonbusiness hours. Timed overrides for any line-up or walk-in case may only be used to turn the lights on for up to one hour. Manual overrides shall time-out automatically to turn the lights off after one hour.

B. Motion sensor controls on each case that reduce display case lighting power by at least 50 percent within 30 minutes after the area near the case is vacated.

EXCEPTION to Section 120.6(b)3: Stores which are normally open for business 140 hours or more per week.

A. HVAC systems shall utilize heat recovery from refrigeration system(s) for space heating, using no less than 25 percent of the sum of the design Total Heat of Rejection of all refrigeration systems that have individual Total Heat of Rejection values of 150,000 Btu/h or greater at design conditions.

EXCEPTION 2 to Section 120.6(b)4A: HVAC systems or refrigeration systems that are reused for an addition or alteration.

B. The increase in hydrofluorocarbon refrigerant charge associated with refrigeration heat recovery equipment and piping shall be no greater than 0.35 lbs per 1,000 Btu/h of heat recovery heating capacity.

Mechanical ventilation systems for enclosed parking garages where the total design exhaust rate for the garage is greater than or equal to 10,000 cfm shall conform to all of the following:

1. Automatically detect contaminant levels and stage fans or modulate fan airflow rates to 50 percent or less of design capacity provided acceptable contaminant levels are maintained.

2. Have controls and/or devices that will result in fan motor demand of no more than 30 percent of design wattage at 50 percent of design airflow.

3. CO shall be monitored with at least one sensor per 5,000 square feet, with the sensor located in the highest expected concentration locations, with at least two sensors per proximity zone. A proximity zone is defined as an area that is isolated from other areas either by floor or other impenetrable obstruction.

4. CO concentration at all sensors is maintained at 25 ppm or less at all times.

5. The ventilation rate shall be at least 0.15 cfm/ft2 when the garage is scheduled to be occupied.

6. The system shall maintain the garage at negative or neutral pressure relative to other occupiable spaces when the garage is scheduled to be occupied.

A. Certified by the manufacturer to be accurate within plus or minus 5 percent of measurement.

D. Certified by the manufacturer to require calibration no more frequently than once a year.

E. Monitored by a control system. The system shall have logic that automatically checks for sensor failure by the following means. Upon detection of a failure, the system shall reset to design ventilation rates and transmit an alarm to the facility operators.

i. If any sensor has not been calibrated according to the manufacturer’s recommendations within the specified calibration period, the sensor has failed.

ii. During unoccupied periods the system compares the readings of all sensors, e.g. if any sensor is more than 15 ppm above or below the average of all sensors for longer than 4 hours, the sensor has failed.

iii. During occupied periods the system compares the readings of sensors in the same proximity zone, e.g. if the 30 minute rolling average for any sensor in a proximity zone is more than 15 ppm above or below the 30 minute rolling average for other sensor(s) in that proximity zone, the sensor has failed.

8. Parking Garage Ventilation System Acceptance. Before an occupancy permit is granted for a parking garage system subject to Section 120.6(c), the following equipment and systems shall be certified as meeting the Acceptance Requirements for Code Compliance, as specified by the Reference Nonresidential Appendix NA7. A Certificate of Acceptance shall be submitted to the enforcement agency that certifies that the equipment and systems meet the acceptance requirements specified in NA7.12.

EXCEPTION 1 to Section 120.6(c): Any garage, or portion of a garage, where more than 20 percent of the vehicles expected to be stored have non gasoline combustion engines.

EXCEPTION 2 to Section 120.6(c): Additions and alterations to existing garages where less than 10,000 cfm of new exhaust capacity is being added.

(d) Mandatory Requirements for Process Boilers

A. All process boilers with an input capacity of 2.5 MMBtu/h (2,500,000 Btu/h) and above, in which the boiler is designed to operate with a non-positive vent static pressure.

B. All process boilers where one stack serves two or more boilers with a total combined input capacity per stack of 2.5 MMBtu/h (2,500,000 Btu/h).

2. Process boiler combustion air fans with motors 10 horsepower or larger shall meet one of the following for newly installed boilers:

B. The fan motor shall include controls that limit the fan motor demand to no more than 30 percent of the total design wattage at 50 percent of design air volume.

3. Newly installed process boilers with an input capacity of 5 MMBtu/h (5,000,000 Btu/h) to 10 MMBtu/h (10,000,000 Btu/h) shall maintain excess (stackgas) oxygen concentrations at less than or equal to 5.0 percent by volume on a dry basis over firing rates of 20 percent to 100 percent. Combustion air volume shall be controlled with respect to firing rate or measured flue gas oxygen concentration. Use of a common gas and combustion air control linkage or jack shaft is prohibited.

4. Newly installed process boilers with an input capacity greater than 10 MMBtu/h (10,000,000 Btu/h) shall maintain excess (stack-gas) oxygen concentrations at less than or equal to 3.0 percent by volume on a dry basis over firing rates of 20 percent to 100 percent. Combustion air volume shall be controlled with respect to measured flue gas oxygen concentration. Use of a common gas and combustion air control linkage or jack shaft is prohibited.

(e) Mandatory Requirements for Compressed Air Systems.

All new compressed air systems, and all additions or alterations of compressed air systems where the total combined online horsepower (hp) of the compressor(s) is 25 horsepower or more shall meet the requirements of Subsections 1 through 3. These requirements apply to the compressors and related controls that provide compressed air and do not apply to any equipment or controls that use or process the compressed air.

EXCEPTION to Section 120.6(e): Alterations of existing compressed air systems that include one or more centrifugal compressors.

1. Trim Compressor and Storage. . The compressed air system shall be equipped with an appropriately sized trim compressor and primary storage to provide acceptable performance across the range of the system and to avoid control gaps. The compressed air system shall comply with Subsection A or B below:

A. The compressed air system shall include one or more variable speed drive (VSD) compressors. For systems with more than one compressor, the total combined capacity of the VSD compressor(s) acting as trim compressors must be at least 1.25 times the largest net capacity increment between combinations of compressors. The compressed air system shall include primary storage of at least one gallon per actual cubic feet per minute (acfm) of the largest trim compressor; or,

B. The compressed air system shall include a compressor or set of compressors with total effective trim capacity at least the size of the largest net capacity increment between combinations of compressors, or the size of the smallest compressor, whichever is larger. The total effective trim capacity of single compressor systems shall cover at least the range from 70 percent to 100 percent of rated capacity. The effective trim capacity of a compressor is the size of the continuous operational range where the specific power of the compressor (kW/100 acfm) is within 15 percent of the specific power at its most efficient operating point. The total effective trim capacity of the system is the sum of the effective trim capacity of the trim compressors. The system shall include primary storage of at least 2 gallons per acfm of the largest trim compressor.

EXCEPTION 1 to Section 120.6(e)1: Compressed air systems in existing facilities that are adding or replacing less than 50 percent of the online capacity of the system.

EXCEPTION 2 to Section 120.6(e)1: Compressed air systems that have been approved by the Energy Commission Executive Director as having demonstrated that the system serves loads for which typical air demand fluctuates less than 10 percent.

2. Controls. Compressed air systems with more than one compressor online, having a combined horsepower rating of more than 100 hp, must operate with a controller that is able to choose the most energy efficient combination of compressors within the system based on the current air demand as measured by a sensor.

3. Compressed Air System Acceptance. Before an occupancy permit is granted for a compressed air system subject to Section 120.6(e), the following equipment and systems shall be certified as meeting the Acceptance Requirements for Code Compliance, as specified by the Reference Nonresidential Appendix NA7. A Certificate of Acceptance shall be submitted to the enforcement agency that certifies that the equipment and systems meet the acceptance requirements specified in NA 7.13.