McQuay TFH Installation Manual

SINGLE AND DUAL COMPRESSOR CENTRIFUGAL
TEMPLlFlER@
HEAT PUMPS
13600 Industrial Park Blvd., P 0. Box 1551 Minneapolis, Minnesota 55440

GENERAL

The McQuay Model TEH and TFH Centrifugal Templifier units are complete, self contained, automatically trolled liquid heating units. Each unit is completely assembled and factory tested prior to shipment.
Installation of the Templifier units is the responsibility of the installing contractor and/or the owner’s sentatives, and normally consists of properly setting
con-
repre-

UNIT IDENTIFICATION

Each unit is assigned a unique series of identifying numbers which are stamped on the unit nameplate. As soon as the unit is received, these identifications should be checked with the shipping papers and project infor­mation. If any discrepancies exist, contact your McQuay representative immediately.
Some McQuay Templifiers are equipped with a second condenser as required by project conditions.
In addition to the unit nameplate shown in Figure 1, each component has a nameplate affixed with certain data for the installer, including electrical data for the compressors and oil pumps.
sentatives, and normally consists of properly setting the unit in place and connecting the necessary wiring and piping services to the machine.
All McQuay Templifiers must be started only by a
McQuay Service Representative. The installer should make no attempt to start the machine before the complete system checkout has been made by McQuay and the unit has been initially started.
MODEL STYLE SERIAL S.O. NO.
~~~~
~_
FACTORY CHARGED
~
LBS. REFRIGERANT
LEAK TEST PRESSURE 100 PSIG.
MOTOR
- COMPRESSOR
AND OVERLOAD PROTECTION FIELD
SUPPLIED. SEE SPEC.
UNIT NAMEPLATE
CONTROLLER
PE-D4
FIGURE 1
_

SAFETY CONSIDERATIONS

McQuay equipment is designed to provide safe and reliable service when properly installed and operated within the design specifications. The installer and operator should observe good safety precautions to prevent damage to the equipment or injury ‘to per­sonnel. Particular attention should be given to the following:
.
Do not climb on the unit or step on electrical or refrigerant lines.
.
Never exceed specified test pressures. Verify allow­able test pressures by checking the instruction literature and/or the equipment nameplates.
.
Do not use oxygen to purge or to pressurize the unit.
.
Do not obstruct or valve off any safety or relief devices.
Never open valves or connections under pressure in a way that can cause loss of refrigerant or oil or create a personnel hazard.
Nameplate and warning/instruction tags should not be removed.
Fluorocarbon refrigerants must be handled with caution and release to the atmosphere should be minimized.
Use only the correct refrigerant nameplate.
Only qualified electricians should make electrical installations.
Make certain that rigging equipment is adequate for the unit weights.
-
consult the unit

RECEIVING AND HANDLING

INSTALLATION

The unit should be inspected immediately after receipt for possible shipping damage.
All
McQuay
Centrifugal Templifier Heat Pumps are
shipped F.O.B. factory and all claims for handling and
shipping damage are the responsibility of the consignee.
Leave the shipping skid in place until the unit is in its final position. This will aid in handling the equipment.
Extreme care should be used when rigging the equip­ment to prevent damage to the control center, or refrigerant piping.
On units with top mounted compressors, the unit can
be lifted by fastening the rigging hooks to the 4
corners of the evaporator where the rigging eyes are
located. (See Figure 2.) Spreader bars should be used
between the rigging lines to prevent damage to the control center and other components.
On units with side mounted compressors, the unit can be lifted by the three corner fitting eyes and the extended eye at the compressor end. The center of gravity is located approximately where the discharge line enters the upper condenser shell. Adjust cable or chain lenghs accordingly. The compressor support is not designed to support the full weight of the unit. Therefore, unit must be lifted so that it is level or canted to assure that the compressor supports leave the ground first and touch down last. Spreader
bars are a must. (See Figure 3). For equipment weights for rigging and installation
requirements, refer to the certified equipment data.
1.
2.
3.Condenser Water
4.Condenser Water
FIGURE 3
SIDE MOUNTED COMPRESSOR UNITS
Lifting Eyes Shipping Skid 6.Source Water - Out
-
In 7.
-
Out 8.
Source Water - In
5.
Control Center Condenser Relief Valves
TOP MOUNTED COMPRESSOR
FIGURE 7.
UNITS

LOCATING AND MOUNTING

INSTALLATION
The unit should be mounted on a level concrete or steel base and should be located so as to provide service clearance at one end of the unit for possible
removal of evaporator tubes and/or condenser tubes. Clearances required are 16 feet for units with 14 foot long shells, 14 feet for units with 12 foot shells, and
feet for units with 8 foot long shells. Evaporator and
condenser tubes are rolled into the tube sheets to permit replacement if necessary. Clearance at all other points, including the top, is 3 feet.
Make certain that the floor or structural support is
adequate to support the full operating weight of the
complete unit.

WATER PUMPS

The use of 3600 rpm or two pole pump motors is not
recommended. It is not uncommon to find these
pumps operate with objectionable noise and vibration.
It is also possible to build up a frequency beat due to
the slight difference in the operating rpm of the pump
motor and the McQuay centrifugal motor. McQuay encourages the use of motors whenever possible.
1750
rpm or four pole pump
10
Rubber Shearflex or “lsomode”, pads are supplied with unit, for use under each corner of the base members. These pads are packed in the control box for shipment.
It is not normally necessary to bolt the unit to the mounting slab or framework; but should this be desirable, the unit supports at the four corners and under the
compressor base on the side mounted compressor
units. The unit must be level.
The condenser is connected with the coolest water entering at the bottom.
The piping should be supported to reduce the weight and strain on the fittings and connections. Piping should also be adequately insulated. A cleanable 20
mesh water strainer should be installed at both inlets. Sufficient shut-off valves should be installed to permit draining the water from the evaporator or condenser
without draining the complete system.
1-1/8
inch mounting holes are provided in
EVAPORATOR AND CONDENSER
WATER PIPING
All Templifier evaporators and condensers come equipped with groove-type mechanical clamp or flange
connections. The installing contractor must provide matching mechanical connections of the sizes given in the system dimension and capacity tables. NOTE: IF WELDING IS TO BE PERFORMED ON THE MECHANICAL OR FLANGE CONNECTIONS, THE SOLID STATE TEMPERATURE SENSOR AND THERMOSTAT BULBS MUST BE REMOVED FROM THE WELLS TO PREVENT DAMAGE TO THOSE COMPONENTS.
Small water pressure test valves or pipe plugs are provided at both the inlets and outlets of the vessel heads. The test valves permit the water flow pressure drops to be checked. The pressure drops and flow
rates for the evaporator and condenser are specified on
each installation.
Figures 2 and 3 show the inlets and outlets of the evaporators and condensers. The evaporator is con­nected with the warmest water entering at the top.
NOTE: NEITHER THE EVAPORATOR NOR THE CON-
DENSER IS SELF-DRAINING: BOTH MUST BE BLOWN OUT. THE PIPING SHOULD ALSO INCLUDE
THERMOMETERS AT THE INLET AND OUTLET
CONNECTIONS AND AIR VENTS AT THE HIGH POINTS.
In cases where the water pump noise may be objec­tionable, rubber isolation sections are recommended at both the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration eliminator sections in the condenser inlet and outlet water lines;
but where noise and vibration are critical (for example, where a pipe chase goes through walls), they may be
required. A bypass around the evaporator and/or
condenser must be provided where uninterrupted source and/or process water flow is required.
Where a cooling tower is used to supply source water, a flow balancing valve is required when the evaporator
does not have full flow.

OIL COOLER PIPING

Templifier oil coolers normally utilize water for remov­ing heat from the lubricating oil. The water source
must never exceed
gOoF.
In some applications,
refrig-
5
INSTALLATION
erant cooled oil coolers are provided and are com­pletely piped up in the factory. Refrigerant cooling is usually limited to the
TP050
models.
Water Cooled Oil Coolers
When water is to be the coolant, the oil cooler is factory mounted with the oil piping installed. Water piping for the oil coolers must be installed in the field according to good piping practice and should include: stop valves to isolate the cooler for servicing, cleanable strainer
(40
mesh maximum), balancing valve to adjust water flow, solenoid operated water shut-off valve wired in accordance with Field Connection Control Diagram, and a drain valve or plug. Water supply for the oil cooler may be obtained from:
A. Source Water Circuit. See Figure 4.
B. Independent source, such as city water. C. Cooling tower makeup if the flow is adequate and
continuous and the temperature never exceeds 90°F. See Figure 5.
TABLE 1
1
Maximum Oil Cooler Water Requirements
Model
TEH063 TEH079 TEH100 TEH126 16.0
*Pressure drop through two oil coolers with water sides piped in
series
-
TEH 126 only.
When the oil cooler is piped into the source water supply, its water piping should be connected across the source water pump so that the full pressure differential of the pump is maintained across the cooler system at all times the pump is running. This is the
recommended arrangement, and most systems will
accommodate it. For those installations where it could
be desirable to pipe the oil cooler system across the
evaporator, this may be done providing the water
pressure drop through the evaporator is greater or equal to the oil cooler pressure drop.
Under no circumstances should the oil cooler be piped in parallel with a single pass evaporator. This will result in inadequate cooling water to the oil cooler due to the low evaporator pressure drop.
When supplied with city water, the oil cooler water piping should discharge into an open drain to prevent
draining the cooler by siphoning. This water may also
And Pressure Drops
Maximum
Water Requirement
@
85 F Entering
GPM
8.0
8.0
12.25 5.2
Water
Pressure Drop Thru
Oil Coolers Only
PSI
1.8
1.8
10.4’
be used for cooling tower makeup by discharging it into the tower sump from a point above the highest possible water level.
On
R12
units, the water flow through the oil cooler must be adjusted with the balancing valve so that the temperature of oil supplied to the compressor bearings (entering the compressor) is not less than 90°F nor more than 120°F. On systems using source water for a cooling medium, the leaving oil temperature should be on the low side of the acceptable temperature range when operating with the coldest water.
For
R114
units oil temperatures are normally higher.
For settings consult special instructions furnished with
the unit.
I
I
FIGURE 5
OIL COOLER PIPING
On some units, oil cooler water solenoid valves are
factory furnished. On those units where the solenoid
valve is required and not furnished, the installing contractor must supply the solenoid.
Refrigerant Cooled Oil Coolers
On those Templifier units furnished with refrigerant oil cooling, the shut-off and flow control are built into the refrigerant piping.
Subcooled liquid from the condenser is fed to the oil cooler through an oil temperature control valve whose control bulb is located on the oil line leaving the oil cooler. The gas the evaporator. Refrigerant flow is controlled to tain an oil temperature of approximately R12 Templifiers. Oil Coolers in at higher temperatures.
-
liquid mixture returns to the inlet of
R114
Templiers operate
main-
90-lOOoF
in
6
INSTALLATION
1.
CEO63 Compressors
2.Lube Boxes
3.Suction Shutoff Valve
4.Condenser Relief Valves
5. Expansion Valves
6. Oil Pumps
7.Oil Level Sight Glass
8.Hot Gas Bypass
9.
Oil Coolers
10.
Discharge Check Valve
11. Motor Cooling Liquid Line
12. Motor Cooling Liquid Filter-Drier
TFH063

VENT PIPING

As a safety precaution, each system is equipped with pressure relief valves located on the condenser and on the evaporator for the purpose of relieving excessive
refrigerant pressure to the atmosphere. Many local codes require that relief valves be vented to the outside, and this is desirable installation practice for all installations. NOTE: Remove plastic thread protectors
from the inside of the valves prior to making pipe
connections. Whenever vent piping is installed, the lines should be run in accordance with local code requirements; or where local codes do not apply, ANSI
B9-1
-Sec. 12 code recommendations should be
followed.
Current condenser design incorporates two relief
valves
the two valves. (See Figure 7). When piping the vent line to a dual valve set, it may be sized for one relief valve and piped to both valves. If one relief valve of the two valve set fails, the shut-off valve may be used to isolate the faulty relief valve, easing replacement. On
(1
set) with a
3-way
shut-off valve separating
FIGURE 6
(Rear View)
13.
CondenserInlet
14.
CondenserOutlet
15.
EvaporatorInlet
16.
Evaporator
17. Motor Terminal Cover
18. Liquid Line Shutoff Valve
Outlet
Condenser Relief Valve Set
1. #l Relief
2.
3.
4.
larger capacity condenser designs, two sets of dual
relief valves are used. These vents must be sized for
the total of two valves.
Valve
#2
Relief
Valve
Relief Valve 3-Way
Access Valve
3-Way
Shutoff
FIGURE 7

THERMAL INSULATION

INSTALLATION
Factory installed thermal insulation is furnished on all parts of the Templifier unit as needed to prevent sweating, to retain thermal efficiency, and to protect operating personnel from hot surfaces.

ELECTRICAL

Wiring, fuse and wire size must be in accordance with
information provided in the Electrical Data. Standard NEMA motor starters require modification to meet McQuay specifications. Refer to Electrical Data sup­plied with the unit for details.
IMPORTANT: The voltage of these units should be within the limitation of plus or minus voltage unbalance between phases must not exceed 3%. Since a 3% % voltage unbalance will cause an approximate 25% increase in motor temperature, it is
most important that the unbalance between phases be at a minimum.
NOTE: Do not make final power connections to the starter until wiring has been checked and approved by an authorized McQuay Service Representative. Under
no circumstances should the compressor be brought
up to speed unless proper phase sequence and rotation
have been established. Serious damage may result if
the compressor starts in the wrong direction. Jog the
machine to check rotation using the sight glasses on
the rear motor cover to observe direction.

Power Wiring

Power wiring to the compressor must be in proper phase sequence. Motor rotation is set up for clockwise rotation facing motor end cover with phase sequence of l-2-3. Care should be taken that proper phase sequence is carried through the starter to the compres­sor. With the phase sequence of l-2-3 and connected to T1 and T6, L2 connected to T2 and T4, and L3 connected to T3 and T5, rotation is proper. See diagram in terminal box cover.
T**063/079/100/126
10%,
and the
Care should be taken not to tear, damage or remove any of this factory insulation.
All field piping connections to the Templifier should be insulated by the installer if required by good practice and personnel safety.
CAUTION: Wiring connection to compressor terminal studs must be made with copper lugs and copper wire.
Power Wiring
All
T**048/050 factory wired and mounted star delta starter equipped with ambient compensated quick trip overloads, fac­tory set at 1
be in accordance with information located in the elec-
trical data supplied with the unit
cal Data pertaining to your unit. The power wiring to the compressor starter must be in
proper phase sequence. See second paragraph under
T**063/079/100/126 All units are factory equipped with open transition
starters. Closed transition starters are supplied on a special order basis. Transition should be set to 15 seconds.
15% F.L.A. Wiring, fuse and wire size must
T**048/050
units are normally supplied with a
or the
McQuay Electri-
Power Wiring.

Control Wiring

The control circuit on the McQuay and 126 Templifiers is designed for 1 15 volts. Power
should be supplied from a separate circuit and fused at
10 amps. (See Table 2). The control circuit on the
TP048/050
power is provided to the control panel by a .75 or 1 KVA 1 15 volt transformer supplied and mounted in the starter package.
L1
unit is also designed for 115 volts, but
TABLE 2 MAXIMUM CONDUCTOR LENGTH*
T**063/079/100
Phase sequence can be determined by using GE No. 546703265 phase sequence meter or equal. Before connecting the starter load leads to the compressor terminals and while checking the field connection wiring, the transition timer in the starter should be adjusted to make the transition in 15 seconds. This should be reset when the compressor is put on the
line. The timer should be adjusted to actuate (discon-
nect Star winding connection and connect Delta)
when the motor has come up to speed and before any
speed reduction occurs.
-I
l Maximum length is distance conductor will traverse between
control power source and the unit control panel. Wire size based on voltage drop not to exceed 3 percent.
Panel terminal connectors will accommodate wire size up to 10 AWG, larger conductors will require an intermediate junction box.
The disconnect switch should be tagged to prevent current interruption. SWITCH IS TO REMAIN ON AT
ALL TIMES IN ORDER TO KEEP OIL HEATERS
8
INSTALLATION
b
8
1.
CEO63 Compressor
2.Evaporator
3.Condenser
4.Relief Valves
5.
Control Panel
6.
Lube Box
Oil Pump
7. Oil Level Sight Glass
8. Discharge Line
9. Hot Gas Bypass
10. Expansion Valve
11.
OPERATIVE AND PREVENT REFRIGERANT FROM ACCUMULATING IN OIL.
The control center off-on switch should be turned to the “Off” position any time compressor operation is
not desired.
If the control voltage is supplied by a transformer, the transformer should be rated at 2 KVA, with an inrush rating of 12 KVA minimum at 80% power factor and 95% secondary voltage. For control wire sizing, refer to the N.E.C. article 215 and 310. In the absence of complete information to permit calculations, the volt­age drop should be physically measured.
Control Interlocks
Water flow interlock terminals are provided on the control center terminal strip. See field connection diagram in the Electrical Data or in cover of control center for proper connections.
The purpose of the water flow interlocks is to prevent compressor operation until both the source water and condenser water pumps are running and flow is proven.
12.
Liquid Line Shut-Off Valve
13.
Oil Cooler
14.
Motor Liquid Cooling Line
15.
Motor Terminal Cover
16.
Discharge Check Valve
FIGURE 8
TEH063
Operation of the source water pump may be to cycle
the pump with the compressor or it may be operated
continuously. The hot water (condenser) pump nor­mally will be run continuously. The holding coil of
the cooling tower pump motor starter must be rated at
115 volts 60 Hz with a maximum 25 volt-ampere rating.
All interlock contacts must be rated for no less than 10 inductive amps. The alarm circuit provided in the control center utilizes 115 volts. The alarm used should
not draw more than
10
volt-amperes.

TESTING CONTROL CIRCUIT

The installing contractor should complete all field connections to the Templifier control panel after which
he should check out all remote interlocks for proper operation. Do not disturb the internal wiring of the control center or change the factory settings of operating and safety controls.
At the time of startup the will completely check out the power and control circuits. Final power connections to the compressor should be made only after the inspection.
McQuay
Service Technician
McQuay
pre-startup
9
@--
@-----
INSTALLATION
10
Q
CE126 Compressor
1. Motor Terminal Cover
2. Lube Box
3. Oil Coolers
4. Expansion Valves
5. Liquid Line Shut-Off Valve
6.
7.Evaporator
8.Condenser
9.Control Center Discharge Check
10. Oil Pump
11.
REPAIR OF SYSTEM (If Necessary)
Pressure Testing No pressure testing is necessary unless some damage
has been incurred during shipment. Damage may be
determined upon a visual inspection of the exterior
piping assuring no breakage occurred or fittings loosened. Panel gauges should show a positive pres­sure (except R-114 units in cold locations). If no pres-
sure is evident on the gauges, a leak may have oc-
curred discharging the entire refrigerant charge. In this
case, the unit should be leak tested to determine the
location of the leak. R-114 units must be above an
ambient of
Leak Testing
50°F
to show a positive pressure.
FIGURE 9
TEH 126
Oil Level Sight Glass
12.
13.
Oil Sump Oil Cooler Water Lines
14.
Valve
Motor Liquid Cooling Line
15. Condenser Relief Valves (Hidden)
16.
test pressure given above. When the test pressure is
reached, disconnect the gas cylinder. If any leaks are found in welded or brazed joints or if it
is necessary to replace a gasket, relieve the test pressure in the system before proceeding. For copper
joints, braze alloy is recommended.
After making any necessary repair, the system should be evacuated as described in the section following.
Evacuation After it has been determined that there are no
refrigerant leaks, the system should be evacuated using a vacuum pump with a capacity of approximately 3 cu.
ft./min.
and that will reduce the vacuum to at
least 1 millimeter (1000 microns).
In the case of loss of the entire refrigerant charge, the unit should be checked for leaks prior to charging the complete system. This can be done by charging enough refrigerant into the system to build the pressure up to approximately
1-
psig and adding sufficient dry nitrogen to bring the pressure up to a maximum of 125 psig and then leak test with a Halide or electronic leak detector. WATER FLOW THROUGH THE VESSELS SHOULD BE MAINTAINED ANY TIME
REFRIGERANT IS ADDED OR REMOVED FROM THE SYSTEM. CAUTION: DO NOT USE OXYGEN TO BUILD UP PRESSURE AS A SERIOUS EXPLOSION CAN RESULT. A pressure regulating valve should always be used on the nitrogen drum being used to build up the system pressure. Also, do not exceed the
A mercury manometer, electronic or other type of micron gauge should be connected at the farthest point from the vacuum pump. For readings below 1 millimeter, the electronic or other micron gauge should be used.
The triple evacuation method is recommended and is particularly helpful if the vacuum pump is unable to obtain the desired 1 millimeter of vacuum. The system
is first evacuated to approximately 29 inches of mercury. Enough refrigerant vapor is then added to the system to bring the pressure up to zero pounds.
Then the system is once again evacuated to approxi-
mately 29 inches of mercury. This is repeated 3 times. The first pull down will remove about 90% of the
10
INSTALLATION
non-condensables, the second about 90% of that
remaining from the first pull down and after the third
only 1
/10
of 1% of the non-condensables will remain. Charging the System All Templifier Heat Pumps are leak tested at the
factory and shipped with the operating charge of refrigerant as indicated on the unit nameplate. In the event the refrigerant charge was lost due to shipping damage, the system should be charged as follows after first repairing the leaks and evacuating the system.
Connect the refrigerant drum to the gauge port on the liquid shut-off valve and purge the charging line between the refrigerant cylinder and the valve. Then open the valve to the mid position.
Turn on both the supply water pump and source
water pump and allow water to circulate through the condenser and the evaporator.
If the system is under a vacuum, stand the refriger­ant drum with the connection up and open the drum and break the vacuum with refrigerant gas.
With a system gas pressure higher than the equiva-
lent of a freezing temperature, invert the charging
cylinder and elevate the drum above the condenser. With the drum in this position, valves open, water pumps operating, liquid refrigerant will flow into the condenser. Approximately 75% of the total require­ment estimated for the unit can be charged in this manner.
After 75% of the required charge has entered the condenser,
reconnect the refrigerant drum and
charging line to the service valve on the evaporator. Again purge the connecting line, stand the drum with the connection up and place the service valve in
the open position.
The normal ambient pressure of
R114
refrigerant is
so low that a refrigerant pump may be desirable and
helpful in charging with that refrigerant.
Important At this point, the charging procedure should be inter-
rupted and pre-start checks made before attempting to complete refrigerant charge. The compressor must not be started at this time.
Operation and Maintenance manuals pertaining to the individual units are available from your local McQuay Service Representative.

PRE-START SYSTEM CHECKLIST

SOURCE (EVAPORATOR) WATER
Cooling tower flushed, filled and vented Water system filled, vented (if used) Pumps installed, (rotation checked) strainers cleaned Controls (3-way valves, by-pass valves, etc.) operable Water system operated and flow balanced to meet unit design requirements
HOT (CONDENSER) WATER
Piping complete
Water system filled, vented (if
Pumps installed, (rotation checked) strainers cleaned Controls (3-way valves, face and by-pass dampers, by-pass valves, etc.) operable Water system operated and flow balanced to meet unit requirements
used)
ELECTRICAL
-
service completed, but not connected to control panel
*Power leads connected to starter; load leads run to compressor ready for connection when
Service Engineer is on hand for start-up (Do not connect to starter or compressor terminals) All interlock wiring complete between control panel and complies with specifications Starter complies with specifications
“Oil cooler solenoid wired to control panel as shown on wiring diagram
Pump starter and interlock wired Cooling tower fans and controls wired Wiring complies with National Electrical Code and local codes
*Condenser pump starting relay
MISCELLANEOUS
Oil cooler water piping complete. (Units with water cooled oil coolers Relief valve piping complete Thermometer wells, thermometers, gauges, control wells, controls, etc. installed A minimum system load of 25% of machine capacity is available for testing and
adjusting controls
(if
used)
(HWR)
installed and wired.
only)
No
Not
Applicable
11
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