McQuay TSC 100 Installation Manual
Installation, Operating and Maintenance Manual
IOMM TSC
The McQuay
Templifier
Water Heater
Single Compressor Centrifugal Mod els
TSC 063, 079, 087, 100, 126
Group:
Part Number:
Effective:
Supersedes:
Chiller
January 2003
736015427
New
Table of Contents
Introduction......................................................................................................................... 3
General Description ....................................................................................................................................3
Application.................................................................................................................................................. 3
Installation........................................................................................................................... 4
Receiving and Handling..............................................................................................................................4
Water Piping................................................................................................................................................ 6
Physical Data and Weights..........................................................................................................................7
Oil Coolers.................................................................................................................................................. 9
Relief Valves ............................................................................................................................................. 11
Electrical ................................................................................................................................................... 12
Prestart System Checklist.......................................................................................................................... 18
Operation........................................................................................................................... 19
Operator Responsibilities.......................................................................................................................... 19
Nomenclature............................................................................................................................................ 19
MicroTech II Control............................................................................................................................. 20
Capacity Control System...........................................................................................................................20
Lubrication System....................................................................................................................................23
Hot Gas Bypass.........................................................................................................................................24
Maintenance...................................................................................................................... 25
Pressure/Temperature Chart...................................................................................................................... 25
Routine Maintenance.................................................................................................................................25
Annual Shutdown...................................................................................................................................... 29
Annual Startup...........................................................................................................................................30
Repair of System....................................................................................................................................... 30
Maintenance Schedule......................................................................................................33
Service Programs.............................................................................................................. 35
Operator Schools...............................................................................................................35
McQuay" is a registered tradem ark of McQuay International
Information and illustrations cover the McQuay International products at the t i me of publication and we reserve the right to
make changes in design and construction at anytim e without notice.
2003 McQuay International
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Centrifugal Templifier Units IOMM TSC
Introduction
General Description
The McQuay Centrifugal Templifier Water Heaters are complete, self-contained, automatically
controlled, fluid heating units. Each unit is completely assembled and factory tested before
shipment.
Templifier units use refrigerant R-134a to reduce the size and weight of the package and operate at a
positive pressure over the entire operation range.
The controls are pre-wired, adjusted and tested. Only normal field connections such as piping,
power wiring and flow/pump/control interlocks are required, thereby simplifying installation and
increasing reliability. All necessary equipment protection and operating controls are factory
installed in the control panel.
Application
The operation and maintenance procedures presented in this manual apply to the standard TSC
family of water heaters.
All McQuay centrifugal Templifier units are factory tested prior to shipment and must be initially
started at the job site by a factory-trained McQuay service technician. Failure to follow this startup
procedure can adversely affect the equipment warranty.
One very important consideration in the operation of Templifier units is the relationship between the
source heat flowing through the evaporator and the heating load being satisfied by the unit
condenser. Figure 1 illustrates a Templifier using cooling tower water as the source of heat. The
comments following the illustration also apply for other sources of waste heat.
Figure 1, Templifier Flow Diagram
COOLING
TOWER
125°F
(52°C)
(29°C)
45°F
(7°C)
85°F
CONDENSER
EVAPORATOR
CHILLER
95°F
(35°C)
55°F
(13°C)
HEATING
LOAD
CONDENSER
EVAPORATOR
TEMPLIFIER
SUPPLE-
MENTAL
HEATER
135°F
(57°C)
90°F
(32°)
COOLING
LOAD
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3
The heat being supplied to the heating load by the Templifier condenser comes from two sources:
1. The heat being absorbed in the evaporator from the waste heat stream (cooling tower water
in the diagram).
2. Compressor motor energy that goes into the refrigerant as it is compressed.
If there is insufficient source heat going to the Templifier evaporator, the unit cannot produce
sufficient heat in the condenser.
The Templifier capacity is controlled by the hot water temperature leaving the condenser, but the
temperature is reset downward as the delta-T decreases to give, in effect, a constant entering
water temperature. The leaving hot water temperature decreases with decreasing heat load.
The unit cools the source water to whatever extent is required to meet the heating load at any
given time. If there is insufficient source heat available, the Templifier unit will try to pull down
the source water temperature (perhaps to unacceptable levels) in an effort to extract the required
heat.
This will lower evaporator leaving water temperature and can cause the compressor to pump
against a higher refrigerant pressure difference than it was designed for. Centrifugal compressors
(as contrasted to reciprocating and screw compressors) are selected for a specific head (pressure
difference) for a specific job. If that head is exceeded by a relatively small amount, the
compressor can go into an undesirable stall or surge condition.
As a protection against this happening, TSC Templifier units have a special software design
(designated as "TFG") that does the following:
1. If the leaving evaporator water temperature drops below a predetermined value, the
2. If the evaporator leaving water temperature drops further, below the setpoint in #1 above, to
Insufficient source heat manifested as lower source water temperature (assuming constant flow)
can occur in closed loop systems such as cooling tower water or solar collectors, or in open loop
systems such as process waste streams or ground water.
Installation
Receiving and Handling
The unit should be inspected immediately after receipt for possible shipping damage.
All McQuay centrifugal Templifier units are shipped FOB factory and all claims for handling and
shipping damage are the responsibility of the receiver.
Insulation corners from the unit’s rigging hole locations are shipped loose and should be glued in
place after the unit is finally placed. Neoprene vibration pads are also shipped loose. Check to be
sure that these items are delivered with the unit.
controller lowers (resets) the leaving hot water setpoint. The unit is basically saying "there
is insufficient source heat and I am lowering the hot water temperature. The supplemental
heater may have to come on to make up the difference between the heating requirement and
the Templifier's limited heat output".
another lower setpoint, the controller will shut the unit off.
Leave the shipping skid (if so equipped) 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. See submittal certified dimension sheets for the center of gravity of the unit.
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Centrifugal Templifier Units IOMM TSC
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the
rigging eyes are located (see Figure 2). Use spreader bars between the rigging lines to prevent
damage to the control center and motor terminal boxes.
Figure 2, Unit Components
Rigging
Locations
(6) Available
Evaporator
Compressor
Control Panel
Unit Control
Panel
Rigging
Locations
(6) Available
Starter, Unit
Mounting Optional
Condenser
3-Pass
Location and Mounting
Clearance
The unit must be mounted on a level concrete or steel base and have service clearance at one end
of the unit for possible removal of evaporator and/or condenser tubes. Tube clearance required is
14 feet (4.3 meters) for units with 12-foot (3.7 meters) long shells, and 11 feet (3.3 meters for units
with 9-foot (2.7 meters) long shells. Evaporator and condenser tubes are rolled into the tube sheets
to permit replacement. Service clearance on all other sides is 3 feet (1 meter), although the
National Electric Code (NEC) may require additional clearances and should be consulted.
Vibration Pads
The shipped loose neoprene vibration pads should be located under the corners of the unit (unless
the job specifications state otherwise). They are installed to be flush with the sides and outside
edge of the feet. Most TSC units have six mounting feet, although only the outer four are required.
Six pads are shipped and the installer can place pads under the middle feet, if desired.
Mounting
Make sure that the floor or structural support is adequate to support the full operating weight of the
complete unit.
It will not be necessary to bolt the unit to the mounting slab or framework; but should this be
desirable, 1 1/8" (28.5 mm) mounting holes are provided in the unit support at the four corners.
Note
: Units are shipped with refriger ant and oil valves closed to isolate these f luids for
shipment. Valves must remain closed until start-up by the McQuay technician.
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Water Piping
Water Pumps
Note
: Avoid the use of 3600/3000 rpm (two-pole motor) pump motors. It is not
uncommon for these pumps to 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 compressor motor. McQuay encourages the use of 1750/1460
rpm (four-pole) pump motors whenever possible.
Evaporator and Condenser Water Piping
All evaporators and condensers come standard with groove-type nozzles for Victaulic couplings
(also suitable for welding) or optional flange connections. The installing contractor must provide
matching connections of the size and type required.
CAUTION
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.
The unit must be properly grounded or severe damage to the
MicroTech Controller II can occur.
Water pressure gauge connection taps and gauges must be provided in the field piping at the inlet
and outlet connections of both vessels for measuring the water flow pressure drops. The pressure
drops and flow rates are specific to the unit and job and can be found in the unit submittal
documentation. Refer to the nameplate on the vessel shells for identification.
Evaporator inlet and outlet water connections have been changed over time with design changes
in the vessel. Be sure that water inlet and outlet connections match certified drawings and
factory-stenciled nozzle markings. The condenser is connected with the coolest water entering at
the bottom to maximize subcooling.
The piping must be supported to eliminate any strain on the unit. Piping should also be
adequately insulated. Normally, the condenser hot water piping is insulated and the evaporator
piping may, or may not, be insulated, depending on its operating temperature range. A cleanable
20-mesh water strainer must be installed at the inlets of both vessels. Sufficient shutoff valves
should be installed to permit draining the water from the evaporator or condenser without
draining the complete system.
Flow Switches
A flow switch must be mounted in the leaving water line of both vessels to prove adequate water
flow before the unit can start. They also serve to shut down the unit in the event that water flow
is interrupted.
A flow switch is available from McQuay under Part Number 017503300. It is a "paddle" type
switch and adaptable to any pipe size from 1 inch to 8 inches.
Consult the manufacturer's data for the minimum flow rates required to close the switch.
Installation should be as shown in Figure 3.
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Centrifugal Templifier Units IOMM TSC
Figure 3, Flow Switch Mounti ng
Flow direction marked
on switch
I in. (25mm) NPT flow
switch connection
Tee
Electrical connections in the Unit Control Panel should be made per the field wiring diagram,
Figure 8 on page 16. The normally open contacts of the flow switch should be wired between
these two terminals. Flow switch contact quality must be suitable for 24 VAC, low current
(16ma). Flow switch wiring must be in separate conduit from any high voltage conductors (115V
and higher).
CAUTION
Freeze Notice: The evaporator and condenser are not self-draining; both must be blown
out to avoid possible tube failure if sub-freezing temperatures are possible.
The piping should also include thermometers at the inlet and outlet connections and air vents at
the high points.
The water heads can be interchanged (end for end) so that the water connections can be made at
either end of the unit. If this is done, new head gaskets must be used and the control sensors
relocated.
In cases where the water pump noise can be objectionable, vibration 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.
Physical Data and Weights
Evaporator
The condenser is insulated against heat loss. Optional additional insulation may include the
evaporator and non-connection water head, suction piping, compressor inlet, motor housing, and
motor coolant suction line.
The insulation used is UL recognized (File # E55475). It is 3/4" thick ABS/PVC flexible foam
with a skin. It has a K factor of 0.28 at 75°F. The sheet insulation is fitted and cemented in place
forming a vapor barrier, then painted with a resilient epoxy finish that resists cracking.
The insulation complies to appropriate requirements or has been tested in accordance with the
following:
ASTM-C-177 ASTM-C-534 Type 2 UL 94-5V
ASTM-D-1056-91-2C1 ASTM E 84 MEA 186-86-M Vol. N
CAN/ULC S102-M88
Refrigerant-side design pressure is 200 psi (1380 kPa). Standard water-side design pressure is
150 psi (1034 kPa) with higher pressures available as an option.
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Table 1, Evaporator Physical Data
Evaporator
Code
E1809 434 (197) 37 (138) 75 (7.0) 2734 (1239) 1
E1812 347 (158) 27 (103) 78 (7.2) 2370 (1075) 1
E2009 561 (254) 34 (164) 82 (7.6) 3026 (1371) 1
E2012 420 (190) 37 9139) 84 (7.8) 2713 (1231) 1
E2209 729 (331) 54 (206) 66 (6.1) 3285 (1488) 1
E2212 500 (227) 45 (170) 90 (8.3) 2877 (1305) 1
E2609 531 (249) 54 (295) 76 (7.1) 2730 (1238) 1
E2612 708 (321) 72 (273) 102 (9.4) 3640 (1651) 1
E3009 676 (307) 67 (252) 86 (8.0) 3582 (1625) 1
E3012 901 (409) 89 (336) 115 (10.6) 4776 (2166) 1
E3609 988 (720) 118 (445) 155 14.4) 5314 (2408) 1
E3612 1317 (597) 152 (574) 129 (11.9) 6427 (2915) 1
E4212 1757 (797) 222 (841) 148 (13.7) 8679 (3937) 1
E4812 2278 (1033) 327 (1237) 169 (15.6) 10943 (4964) 2
Notes:
1. Refrigerant charge is approximate since the actual charge will depend on other variables. Actual charge will be shown
on the unit nameplate.
2. Water capacity is based on standard tube configuration and st andard di shed heads.
3. The evaporator charge includes the maximum condenser charge available with t hat evaporator and is therefore the
maximum charge for a t otal unit with the evaporator.
Refrigerant
Charge
lb (kg)
Evaporator
Water Capacity,
gal (L)
Insulation Area
Sq Ft (m
2
)
Vessel Weight
lb (kg)
Number of
Relief
Valves
Condenser
With positive pressure systems, the pressure variance with temperature is always predictable, and
the vessel design and relief protection is based upon pure refrigerant characteristics. HFC-134a
requires ASME vessel design, inspection and testing and uses spring-loaded pressure relief
valves. When an over-pressure condition occurs, spring-loaded relief valves purge only that
amount of refrigerant required to reduce system pressure to a lower level and then close.
Refrigerant-side design pressure is 200 psi (1380 kPa). Standard water side design is 150 psi
(1034 kPa).
Pumpdown
To facilitate unit servicing, all McQuay centrifugal Templifier units are designed to permit
pumpdown and isolation of the entire refrigerant charge in the unit’s condenser.
Table 2, Condenser Physical Data
Condenser
Code
C1609 468 (213) 33 (125) 1645 (746) 2
C1612 677 (307) 33 (123) 1753 (795) 2
C1809 597 (271) 43 (162) 1887 (856) 2
C1812 845 (384) 44 (166) 2050 (930) 2
C2009 728 (330) 47 (147) 1896 (860) 2
C2012 971 (440) 62 (236) 2528 (1147) 2
C2209 822 (372) 73 (278) 2596 (1169) 2
C2212 1183 (537) 76 (290) 2838 (1287) 2
C2609 1242 (563) 83 (314) 2737 (1245) 2
C2612 1656 (751) 111 (419) 3650 (1660) 2
C3009 1611 (731) 108 (409) 3775 (2537) 2
C3012 2148 (975) 144 (545) 5033 (3383) 2
C3612 2963 (1344) 234 (884) 7095 (3219) 2
C4212 3796 (1722) 344 (1302) 9984 (4529) 2
C4812 4912 (2228) 488 (1848) 12843 (5826) 4
Notes:
1. Condenser pumpdown capacity based on 90% full at 90°F.
2. Water capacity based on standard configuration and standard heads and c an be l ess with lower tube counts.
3. See Relief Valves section on page 11 for additional information.
Pumpdown
Capacity lb (kg)
Water
Capacity gal (L)
Vessel Weight
lb (kg)
Number of
Relief Valves
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Centrifugal Templifier Units IOMM TSC
Compressor
Table 3, Compressor Weights
Compressor Size
Weight lb (kg)
⇒
⇒
063 079 087 100 126
3200 (1440) 3200 (1440) 3200 (1440) 6000 (2700) 6000 (2700)
Oil Coolers
McQuay centrifugal Templifier units have a factory-mounted, brazed-plate, water-cooled oil
cooler, temperature controlled water regulating valve and solenoid valve. Cooling water
connections are located near the compressor (see Figure 6) and are shown on the specific unit
certified drawings.
Field water piping to the inlet and outlet connections must be installed according to good piping
practices and should include stop valves to isolate the cooler for servicing. A 1" minimum
cleanable filter (40 mesh maximum), and drain valve or plug should also be field installed.
The water supply for the oil cooler must be clean, treated, closed-loop water such as chilled water
or from a source such as city water and must be 80°F (27°C) or less. Do not use cooling tower
water. If chilled water is used, the oil cooler must be piped across the chilled water pump to
provide sufficient pressure. The water flow through the oil cooler will be adjusted by the unit's
regulating valve so that the temperature of oil leaving the oil cooler and being supplied to the
compressor is between 95°F to 105°F (35°C to 41°C).
Table 4, Oil Cooler Data
Hot Side
POE Lube
TSC 063 - 087
Flow, gpm 9.9 11.9 2.9 2.0 1.54
Inlet Temperature, °F
Outlet Temperature, °F
Pressure Drop, psi - 32.2 2.0 0.9 0.5
TSC 100 - 126
Flow, gpm 15.8 21.9 5.11 3.5 2.7
Inlet Temperature, °F
Outlet Temperature, °F
Pressure Drop, psi - 30.6 1.7 0.8 0.5
Note:
1. Pressure drops include valve on the uni t.
118.0 80.0 65.0 55.0 45.0
100.0 87.3 94.5 98.3 101.4
120.0 80.0 65.0 55.0 45.0
100.0 87.0 95.0 99.0 102.3
Cold Side
Water
Cold Side
Water
Cold Side
Water
Cold Side
Water
When supplied with city water, the oil piping should discharge through a trap into an open drain to
prevent draining the cooler by siphoning. The city water can also be used for cooling tower
makeup by discharging it into the tower sump from a point above the highest possible water level.
OIL COOLER CONNECTION SIZE: All TSCs are 1 in. FPT.
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Figure 4, Oil Cooler Piping Across Evaporator Water Pump
PUMP
CHILLER
R
STOP
VALVE
STRAINER
MAX. 40 MESH
TEMPLIFIER
OIL COOLER
SOLENOID
VALVE
S
DRAIN VALVE
OR PLUG
NOTE: Evaporator water may only be used if i t meets the criteria stated above.
Figure 5, Oil Cooler Piping With City Water
R
OIL COOLER
SOLENOID
S
VALVE
STOP
VALUE
Oil
Reservoir
Solenoid
Valve
Temperature
Control Valve
WATER
SUPPLY
STOP
VALVE
STRAINER
MAX. 40
MESH
DRAIN VALVE
OR PLUG
Figure 6, Oil Cooler Connections, TSC Units
COOLING TOWER
COOLING TOWER MAKEUP
DISCHARGE ABOVE
HIGHEST POSSIBLE
WATER LEVEL
OPEN
DRAIN
Compressor &
Lub Control
Inlet
Connection
Outlet
Connection
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Centrifugal Templifier Units IOMM TSC
Relief Valves
As a safety precaution and to meet code requirements, each Templifer unit is equipped with
pressure relief valves located on the condenser, evaporator, and oil sump vessel for the purpose of
relieving excessive refrigerant pressure (caused by equipment malfunction, fire, etc.) to the
atmosphere. Codes requires that relief valves must be vented to the outside of a building. Relief
piping connections to the relief valves must have flexible connectors.
Note
making pipe connections. W henever vent piping is installed, the lines should be run in
accordance with local code requirements. Where local codes do not apply, the latest issue
of ANSI/ASHRAE Standard 15 code recomm endations should be followed.
Condensers have two relief valves as a set with a three-way valve separating the two valves (large
condensers will have two such sets). One valve remains active at all times and the second valve
acts as a standby.
Remove plastic shipping plugs (if installed) from the inside of the valves prior to
:
Figure 7, Condenser 3-Way Valve
The vent line piping to a dual valve set is sized for one relief valve and piped to both valves. On
large capacity condenser designs, two separate sets of dual relief valves are used. The vent line
must be sized for the total of two valves but piped to all four.
Refrigerant Vent Piping
Relief valve connection sizes are 1-inch FPT and are in the quantity shown in Table 1 and Table 2.
Relief valves must be piped to the outside of the building in accordance with ANSI/ASHRAE 15.
Twin relief valves mounted on a transfer valve are used on the condenser so that one relief valve
can be shut off and removed leaving the other in operation. Only one of the two is in operation at
any time. Where four valves are shown in the table, they consist of two valves each mounted on
two transfer valves. Only two relief valves of the four are active at any time.
Vent piping is sized for only one valve of the set, since only one can be in operation at a time. In
no case would a combination of evaporator and condenser sizes require more refrigerant than the
pumpdown capacity of the condenser. Condenser pumpdown capacities are based on the current
ANSI/ASHRAE Standard 15 which recommendations of 90% full at 90°F (32°C). To convert
values to the older ARI standard, multiply pumpdown capacity by 0.888.
IOMM TSC Centrifugal Templifier units
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