TABLE OF CONTENTS ! DANGER. Dangers indicate a hazardous situation which will result in death or serious injury if not avoided. !

Transcription

1 Installation Manual IM 1137 Group: Chiller REV Part Number: IM1137 Effective: October 2011 Supersedes: New Templifier Heat Recovery Water Heaters TGZ040B to TGZ190B, Packaged Water Heater 0 to 3100 MBH R134a Hz 00

2 TABLE OF CONTENTS Introduction... 3 General Description... 3 Nomenclature... 3 Inspection... 3 Installation... 4 Handling... 4 Moving the Unit... 4 Location... 5 Vibration Isolators... 6 Water Piping... 8 General... 8 Source Water Piping... 9 Source/Hot Water Thermostat Flow Switch Glycol Solutions Condenser Water Piping Heating and Cooling Units Water Pressure Drop Pressure Drop Data TGZ Scroll TGZ Dimensions Pass Condenser Dimensions Weights Physical Data TGZ Scroll Unit Components Electrical Notes Electrical Data Start-Up and Shutdown Pre Start-up Start-up Extended Shutdown Start-up after Extended Shutdown General Electrical Terminals Operating Limits Compressor Oil Sightglass and Moisture Indicator Troubleshooting Chart Maintenance Schedule HAZARD IDENTIFICATION INFORMATION! DANGER Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.! WARNING Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.! CAUTION Cautions indicate potentially hazardous situations that can result in personal injury or equipment damage if not avoided. Manufactured in an ISO Certified facility 2011 McQuay International. Illustrations and data cover the McQuay International product at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; LONMARK, LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK International under a license granted by Echelon Corporation; Modbus from Schneider Electric; MicroTech II and Open Choices from McQuay International 2 TGZ040B - TGZ190B IM 1137

3 Introduction General Description McQuay TGZ water heaters are scroll compressor refrigeration units that recover heat from warm fluid streams in the evaporator and deliver hot water, at a useful temperature, from the condenser to a heating load. They are designed for indoor installations only and are completely assembled, wired, charged and tested. Each unit consists of four or six (depending on unit size) scroll compressors, evaporator (brazed-plate on models 040 through 120 and shell-and-tube evaporators on models 150 to 190), shell-and-tube condenser/heater, and complete refrigerant piping. There are two refrigerant circuits, each with manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sightglass/moisture indicators, and expansion valves. The electrical control center includes a MicroTech II control system and other components necessary for dependable automatic operation. Complete operating and maintenance information is in OMM Nomenclature T G Z 100 B Templifier Global Vintage Scroll Compressor Nominal Evaporator Tons Inspection When the equipment is received, all items should be carefully checked against the bill of lading to provide a complete shipment. All units must be carefully inspected for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. The unit serial plate should be checked before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of McQuay. Note: Unit shipping and operating weights are given in the Physical Data Tables beginning on page 22. IM 1137 TGZ040B - TGZ190B A 3

4 Installation Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.! WARNING Avoid contact with sharp edges. Personal injury can result. Handling Every model TGZ water heater is shipped with a full refrigerant charge that is isolated in the condenser by the manual condenser liquid valve and the compressor discharge service valve. If the unit has been damaged, allowing the refrigerant to escape, there can be danger of suffocation in the equipment area since the refrigerant will displace the air. Be sure to review Environmental Protection Agency (EPA) requirements if damage has occurred. Avoid exposing an open flame to the refrigerant. Moving the Unit The skid option is strongly recommended for ease of handling and to help prevent damage if a crane is not available for rigging at site. Figure 1, Lifting the Unit TGZ / WGZ RIGGING INSTRUCTIONS SPREADER BARS MUST BE USED FOR STABILITY DURING LIFTING OF ALL SIZE UNITS WGZ UNIT SHOWN REV. 0B It is recommended that all moving and handling be performed with skids under the unit when possible and that the skids not be removed until the unit is in the final location. When moving the unit, dollies or simple rollers can be used under the skids. Never put the weight of the unit against the control box. When moving, always apply pressure to the base on the skids only and not to the piping or shells. A long bar will help move the unit easily. Avoid dropping the unit at the end of the roll. 4 TGZ040B - TGZ190B IM 1137

5 If the unit must be hoisted, it is necessary to lift the unit by attaching cables or chains at the lifting holes located on the disposable lifting bars. Spreader bars must be used to protect the control cabinet and other areas of the unit (see Figure 1) Do not attach slings to piping or equipment. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the trucks or rollers. Location The unit is designed for indoor application and must be located in an area where the ambient temperature is above 40 F (4 C). Because of the electronic control devices, the units should not be exposed to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the unit. If necessary, additional structural members should be provided to transfer the weight of the unit to the nearest beams. Note: Unit shipping and operating weights are available in the Weights section beginning on page 22. Space Requirements for Connections and Servicing Allow a minimum of 4-foot clearance in front of the control panel. The source (evaporator) water and hot water (condenser) piping enters and leaves the unit from the right side when looking at the control panel. Left-hand condenser connections are an option. A clearance of at least 3 feet (1219 mm), or more if codes require, should be provided beyond this piping and on all other sides and ends of the unit for general servicing or for changing the compressors, if it ever becomes necessary. Clearance should also be provided for cleaning or removal of condenser tubes, and evaporator tubes on models 150 to 190, on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (can be up to 12 feet, 36 mm). Tube replacement requires the tube length plus two feet of workspace. This space can often be provided through a doorway or other opening. Moving the Unit The packaged unit skid option is strongly recommended for ease of handling and to help prevent damage if a crane is not available for rigging at site. Properly designed field supplied skids or dollies are acceptable. Do not push unit along a floor without them. All moving and handling of packaged units (illustrated above) must be performed with skids or dollies under the unit and they should not be removed until the unit is in the final location. Never put the weight of the unit against the control box. In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit easily. Avoid dropping the unit at the end of the roll. If the unit must be hoisted, lift the unit from the removable lifting arms factory-bolted to each end of the unit adjacent to the tube sheet by attaching cables or chains to the end of the arms. A spreader bar must be used to protect the piping, control panel and other areas of the chiller (see Figure 1). The arms should be removed and discarded after use. Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers. Placing the Unit The small amount of vibration normally encountered with the water chiller makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure. IM 1137 TGZ040B - TGZ190B A 5

6 Vibration Isolators It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration. Figure 2, Isolator Locations 4 1 LB LF Control Panel RB FRF 3 2 Water Connections Transfer the unit as indicated under Moving the Unit. In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports. The unit should be set initially on shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims that are then removed. A rubber anti-skid pad should be used under isolators if hold-down bolts are not used. Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining the piping and transmitting vibration and noise. Table 1, Vibration Mounting Location and Kit Number TGZ MODEL 040B M1 (LEFT- FRONT) RP-3 Gray-WR R-I-S MOUNTING LOCATION M2 M3 M4 (RIGHT- (RIGHT- (LEFT- FRONT) REAR) REAR) RP-3 Gray-WR RP-3 Gray-WR RP-3 Gray-WR KIT PART NUMBER M1 (LEFT- FRONT) CP1E- ID-900 Dk. Green SPRING-FLEX MOUNTING LOCATION M2 M3 M4 (RIGHT- (RIGHT- (LEFT- FRONT) REAR) REAR) CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green KIT PART NUMBER B RP-3 Gray-WR RP-3 Gray-WR RP-3 Gray-WR RP-3 Gray-WR CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green B RP-3 Gray-WR RP-3 Gray-WR RP-3 Gray-WR RP-3 Gray-WR CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green CP1E- ID-900 Dk. Green B RP-4 Brown-WR RP-4 Brown-WR RP-4 Brown-WR RP-4 Brown-WR ID-1350 Dk. Purple ID-1350 Dk. Purple ID-1350 Dk. Purple ID-1350 Dk. Purple B RP-4 Brown-WR RP-4 Brown-WR RP-4 Brown-WR RP-4 Brown-WR ID-1800 Dk. Green ID-1800 Dk. Green ID-1800 Dk. Green ID-1800 Dk. Green B RP-4 Red-WR RP-4 Red-WR RP-4 Red-WR RP-4 Red-WR ID-1800 Dk. Green ID-1800 Dk. Green ID-1800 Dk. Green ID-1800 Dk. Green B RP-4 Red-WR RP-4 Red-WR RP-4 Red-WR RP-4 Red-WR ID-1800 Dk. Green ID-1800 Dk. Green ID-1800 Dk. Green ID-1800 Dk. Green B RP-4 Lime- WR RP-4 Lime- WR RP-4 Lime- RP-4 Lime- WR WR ID-2400 Gray ID-2400 Gray ID-2400 Gray ID-2400 Gray B RP-4 Lime- WR RP-4 Lime- WR RP-4 Lime- RP-4 Lime- WR WR ID-2400 Gray ID-2400 Gray ID-2400 Gray ID-2400 Gray B RP-4 Lime- WR RP-4 Lime- WR RP-4 Lime- RP-4 Lime- WR WR ID-2400 Gray ID-2400 Gray ID-2400 Gray ID-2400 Gray NOTE: For Spring-flex mountings, CP2E have two springs per isolator housing, CP1E have one spring per housing. 6 TGZ040B - TGZ190B IM 1137

7 Figure 3, Isolator Dimensions Spring Flex Mounting. CP-2 Spring Flex Mounting, CP-1 Rubber-in-Shear Mounting, RP-3 1/2-13 TAP ø.56 2 HO Rubber-in-Shear, RP ø nc-2b ø3.38 R4 LOCATING PIN TO BE INSTALLED HERE TYP. VM&C VM&C R.28 TYP MOUNTING MOLDED IN DURULENE. WEATHER RESISTANT (WR) 2.50 R4 RECESSED GRIP RIBS R.250 TYP. R.750 TYP (R) DURULENE MATERIAL 1.13 ±.25 APPROX..25 DRAWING NUMBER ALL DIMENSIONS ARE IN DECIMAL INCH NOTES: RAISED GRIP RIBS 1. MOUNT MATERIAL TO BE DURULENE RUBBER. 2. MOLDED STEEL AND ELASTOMER MOUNT FOR OUTDOOR SERVICE CONDITIONS. 3. RP-4 MOUNT VERSION WITH STUD IN PLACE. DRAWING NUMBER ALL DIMENSIONS ARE IN DECIMAL INCHES IM 1137 TGZ040B - TGZ190B A 7

8 Water Piping General Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities. They can supply the installer with the proper building and safety codes required for a safe and proper installation. Note: Since the Templifier evaporator and/or condenser may have to be valved off for cleaning or repair, it may be desirable to pipe a bypass around them so that system source and hot water flow is not interrupted. The piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. It should contain: 1. For combination heating and cooling systems, the piping and valving must be designed to prevent cross-contamination of evaporator and condenser water during change over. 2. All piping should be installed and supported to prevent the unit connections from bearing any strain or weight of the system piping. 3. Vibration eliminators to reduce vibration and noise transmission to the building. 4. Shutoff valves to isolate the unit from the piping system during unit servicing. 5. Manual or automatic air vents at the high points of the system. Drains should be placed at the lowest points in the system. 6. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve). 7. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of the vessels to aid in unit servicing. 8. A strainer or some means of removing foreign matter from the water before it enters the pump is recommended. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). The use of a strainer will prolong pump life and thus keep system performance up. 9. A cleanable strainer must also be placed in the water lines just prior to the inlets of the evaporator and condenser, 40-mesh on models TGZ 040 to 120 evaporators and 20-mesh on all other vessels. This will aid in preventing foreign material from entering and decreasing the performance of the evaporator and condenser. 10. Any water piping to the unit must be protected to prevent freezing. Consult the ASHRAE handbook for standard industry practice. 11. If the unit is used in an existing piping system, the system should be thoroughly flushed prior to unit installation. When job conditions permit, regular water analysis and chemical water treatment on the evaporator and condenser is recommended commencing at equipment start-up. 12. The total quantity of water in the evaporator and condenser systems should be sufficient to prevent frequent on-off cycling. For closed loop applications where the cooling load changes relatively slowly, a minimum system volume of two to three minutes times the flow rate (GPM) is recommended. For example, if the design evaporator fluid flow rate is 120 gpm, we recommend a system volume of 240 to 3 gallons. 13. In the event glycol is added to the water system, as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling and heating performance lower, and water side pressure drop will be greater. If the percentage of glycol is large, or if propylene is employed instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 36 F (2.2 C). Reset the freezestat setting to approximately 4 to 5 F (2.3 to 2.8 C) below the leaving chilled water setpoint temperature. See the section titled Glycol Solutions on page 11 for additional information concerning glycol. 14. A preliminary leak check of the water piping should be made before filling the system.! CAUTION A flow switch must be installed in the horizontal piping of the evaporator and condenser outlet piping to prove water flow.. 8 TGZ040B - TGZ190B IM 1137

9 Victaulic Coupling/Flow Switch Warning On units with shell-and-tube vessels and with factory-mounted flow switches and where flange connections (Victaulic-to-flange adaptors or weld-on flanges) are to be used, relocating the flow switch is required to allow for possible future replacement. The flange will interfere with unscrewing the switch. The following procedure is recommended before installing a flange to avoid interference: 1. Remove the flow switch and plug the switch opening in the nozzle. 2. Install the Victaulic-to-flange adaptor or weld on flange. 3. Relocate the flow switch in the water piping outside the flange, close enough to it that the wire leads will reach and the switch can still be unscrewed. Source Water Piping The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. Lay out the water piping so the source water circulating pump discharges into the evaporator inlet.! CAUTION A cleanable strainer must be placed in the water lines just prior to the inlets of the evaporator and condenser, 40-mesh on models 040 to 120 evaporators and 20-mesh on all other vessels. Failure to do so will cause damage to the equipment.! CAUTION Templifier Models TGZ 040 through TGZ 120 must have clean source water from a closed and treated loop going to the brazed-plate evaporator. For open water loop applications, an intermediate heat exchanger between the source water and evaporator is required. Failure to provide a clean, closed water loop can cause equipment failure and possible revocation of the unit warranty. Templifier evaporator water can come from various sources and care must be exercised to avoid sources that can cause corrosion, fouling, or accumulation of debris in the heat exchanger. Borderline cases will require a careful and rigorously performed maintenance schedule. Table 2, Evaporator Characteristics TGZ UNIT SIZE EVAPORATOR MATERIALS STRAINER CLEANING 040B 120B Brazed Plate Stainless Steel, Copper 40-Mesh Chemical 150B 190B Shell-and-Tube Carbon Steel, Copper 20-Mesh Chemical Inlet and outlet connections are clearly marked on the unit and also appear on the dimension drawings, beginning on page 17. Drain connections should be provided at all low points in the system to permit complete drainage. Air vents should be located at the high points in the system to purge out air. A vent connection, located on top of the evaporator vessel, permits the purging of air out of the evaporator. Air purged from the water system prior to unit start-up provides adequate flow through the vessel and prevents safety cutouts on the freeze protection. System pressures can be maintained by using an expansion tank as a combination pressure relief and reducing valve. Pressure gauges should be installed in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator should be measured to calculate proper gpm (L/s) as specified in the Physical Data section tables, beginning on page 22. Vibration eliminators are recommended in both the supply and return water lines. IM 1137 TGZ040B - TGZ190B A 9

10 Source water piping may have to be insulated (depending on its temperature) to reduce heat loss and prevent condensation if cold water is used. If cooling tower water is used, insulation is not necessary. Complete unit and system leak tests should be performed prior to insulating the water piping. Insulation with a vapor barrier is recommended. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility. If the unit operates year-round, or if the system is not drained for the winter, the chilled water piping exposed to outdoor ambient should be protected against freezing by wrapping the lines with a heater cable. Source/Hot Water Thermostat The source water temperature sensor is factory installed in the leaving water connection on the evaporator. The controlling hot water sensor is in the leaving condenser connection. A sensor is also located in the entering water connection in order to measure the condenser Delta-T. Care should be taken not to damage the sensor cable or lead wires when working around the unit. It is also advisable to check the lead wire before running the unit to be sure that it is firmly anchored and not rubbing on the frame or any other component. If the sensor is ever removed from the well for servicing, care must be taken as not to wipe off the heat conducting compound supplied in the well. The units can be switched from heating to cooling. In the cooling mode they are controlled by a thermostat in the leaving evaporator connection, in the heating mode by the condenser thermostat. Flow Switch A water flow switch must be mounted in the evaporator and condenser leaving water lines to prove adequate water flow to the vessels before the unit can start. This will safeguard against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up. A flow switch is available from McQuay under ordering number It is a paddle type switch and adaptable to any pipe size from 1 (25mm) to 6 (152mm) nominal. Certain minimum flow rates are required to close the switch and are listed in Table 3. Installation should be as shown on page 10. See the Field Wiring Diagram on page 31 for terminal locations. The normally open contacts of the flow switch should be wired between these two terminals. There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a no flow condition exists. 1. Apply pipe sealing compound to only the threads of the switch and screw unit into D x D x 1 (25mm) reducing tee (see Figure 4). 2. The flow arrow must be pointed in the correct direction. 3. Provide a straight length of pipe before and after the flow switch of at least five times the pipe diameter. 4. Trim flow switch paddle if needed to fit the pipe diameter. Make sure paddle does not hang up in pipe.! CAUTION Make sure the arrow on the side of the switch is pointed in the direction of flow. Install per manufacturer s instructions. Incorrect installation will cause improper operation and possible evaporator damage. Table 3, Flow Switch Minimum Flow Rates Nominal Pipe Size Inches (mm) Minimum Required Flow to Activate Switch GPM (l/s) 2 (50.8) 18.8 (1.2) 2 1/2 (63.5) 24.3 (1.5) 3 (76.2) 30.0 (1.9) 4 (101.6) 39.7 (2.5) 5 (127.0) 58.7 (3.7) 6 (152.4) 79.2 (5.0) 10 TGZ040B - TGZ190B IM 1137

11 Figure 4, Flow Switch Flow Switch View From End of Cooler Glycol Solutions The use of glycol in Templifier systems is rare but if used, the system glycol capacity, glycol solution flow rate in gpm (Lps), pressure drop through the cooler, and system pressure drop can be calculated using the following formulas and table. 1. Capacity Capacity is reduced from that with plain water. To find the reduced value multiply the unit s water system capacity by the capacity correction factor C, as shown in Table 4 and Table 5, to find the unit s capacity in the glycol system. 2. GPM To determine evaporator gpm (or T) knowing T (or gpm) and capacity: x Glycol Capacity Glycol GPM 24 x G FromTables T 3. Pressure Drop To determine glycol pressure drop through the cooler, enter the proper water pressure drop curve, beginning on page 12, at the water flow. Multiply the water pressure drop found there by P to obtain corrected glycol pressure drop. 4. To determine glycol system kw, multiply the water system kw by factor K. Test coolant with a clean, accurate glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point table below. McQuay encourages a minimum glycol concentration of 25% be provided on all glycol applications. Glycol concentrations below 25% have too little inhibitor content for long-term corrosion protection of ferrous metals. Note: The effect of glycol in the condenser is negligible and there is no capacity derate. There is a significant increase in pressure drop. Table 4, Ethylene Glycol Percent Freezing Point P (Pressure C (Capacity) K (Power) G (Flow) Glycol F C Drop) Table 5, Propylene Glycol Percent Glycol Flow Switch Paddle 1 (25) 2 (51) 3 (76) Pipe Section D x 5D From Evaporator Flow Direction Freezing Point C (Capacity) K (Power) G (Flow) P (Pressure Drop) F C Flow Tee D x D x 1 Straight Pipe for at Least 5D IM 1137 TGZ040B - TGZ190B A 11

12 ! CAUTION Do not use automotive grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors which all cause plating on the copper within the unit evaporator. The type and handling of glycol used must be consistent with local codes. Condenser Water Piping Arrange the condenser water so the water enters the bottom connection of the condenser. The condenser water will discharge the condenser from the top connection. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency. Note that the condensers are shipped as either two-pass (10 to 20-degree F Delta-T) or four-pass (20 to 40-degree F Delta-T). For 2-pass, the connections are on the vertical centerline of the condenser. For 4-pass, they are off to one side. Pressure gauges should be installed in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine gpm (L/s) from pressure drop curves on page 12. Vibration eliminators are recommended in both the supply and return water lines. Templifier hot water systems usually have a supplementary heater located after (downstream) of the Templifier condenser to either boost the hot water temperature or to function as a standby heater. Care should be exercised to avoid overly warm water coming back to the Templifier from the system and causing a relief valve discharge. This is true whether the unit is running or off. Maximum temperature is 165 F Some jurisdictions require double heat exchange walls between refrigerant and potable water. Potable water run directly through a condenser has only one heat exchange wall (the condenser tube) and these jurisdictions may require an intermediate heat exchanger. Heating and Cooling Units Templifiers can be arranged and controlled to act as either a water chiller or a water heater. These systems vary considerably in the specifics of the piping arrangement. Care must be exercised when changeover occurs to avoid mixing water streams that could possibly contaminate a water system. For example a unit can have chilled water in the evaporator and tower water in the condenser when in the cooling mode. Changeover to heating could put tower water through the evaporator and hot water (possibly potable water) through the condenser. This could introduce tower water into the chilled water system and into the hot water system and should be avoided. Water Pressure Drop The vessel flow rates must fall between the minimum and maximum values shown on the appropriate evaporator and condenser curves on pages 13 to 15. Flow rates below the minimum values shown will result in laminar flow that will reduce efficiency, cause erratic operation of the expansion valve and could cause low temperature cutoffs. On the other hand, flow rates exceeding the maximum values shown can cause erosion on the evaporator water connections and tubes. Measure the water pressure drop through the vessels at field installed pressure taps. It is important not to include valves or strainers in these readings. The condenser flow rate will determine whether 2-pass or 4-pass condensers are used, according to the following table: CONDENSER DELTA-T PASSES FLOW 10- to 20 Degrees F 2-Pass High Flow Rate 20 to 40 Degrees F 4-Pass Low Flow Rate The entering water should be piped to the bottom connection of the condenser and out the top. 12 TGZ040B - TGZ190B IM 1137

13 Pressure Drop Data TGZ Scroll Figure 5, Evaporator Pressure Drop 100 A B C Dp (ft) 10 D E F G H I J A B C EF G D I H J 1 D A B C J I EFG H Flow Rate (gpm) Model Evap. Model Curve Ref Minimum Flow & Pr. Drop Nominal Flow & Pr. Drop Maximum Flow & Pr. Drop Inch-Pound S.I. Inch-Pound S.I. Inch-Pound S.I. GPM Ft L/S kpa GPM Ft L/S kpa GPM Ft L/S kpa TGZ040B AC-500DQ-62H A TGZ050B AC-500DQ-82H B TGZ0B AC-500DQ-102H C TGZ080B AC-500DQ-122H D TGZ100B AC-500DQ-142H E TGZ110B AC-500DQ-162H F TGZ120B AC-500DQ-182H G TGZ150B EV /9 H TGZ170B EV /7 I TGZ190B EV /7 J Note: Nominal Flow Rate is gpm for 10ºF Delta-T at unit operating conditions of evaporator at 75/65ºF water temp and condenser at 110/30º F water temp. IM 1137 TGZ040B - TGZ190B A 13

14 Figure 6, Standard Four-pass Condenser Pressure Drop TGZ 4-Pass Condenser Water Pressure Drop Dp (ft) TGZ040 TGZ050 TGZ0 TGZ080 TGZ100 TGZ110 TGZ120 TGZ150 TGZ170 TGZ190 TGZ0 TGZ100 TGZ150 TGZ190 TGZ170 TGZ050 TGZ080 TGZ110 TGZ120 TGZ Flow Rate (gpm) UNIT MODEL COND. MODEL MINIMUM FLOW RATE NOMINAL FLOW RATE MAXIMUM FLOW RATE INCH-POUND S.I. INCH-POUND S.I. INCH-POUND S.I. gpm ft L/S kpa gpm ft L/S kpa gpm ft L/S kpa TGZ040 C TGZ050 C TGZ0 C TGZ080 C TGZ100 C TGZ110 C TGZ120 C TGZ150 C TGZ170 C TGZ190 C TGZ040B - TGZ190B IM 1137

15 Figure 7, Optional Two-pass Condenser 100 TGZ 2-Pass Condenser Water Pressure Drop Dp (ft) 10 TGZ040 TGZ050 TGZ0 TGZ080 TGZ100 TGZ110 TGZ120 TGZ150 TGZ170 TGZ190 TGZ0 TGZ100 TGZ150 TGZ190 TGZ170 TGZ050 TGZ080 TGZ110 TGZ120 TGZ Flow Rate (gpm) TGZ UNIT MODEL COND. MODEL. MINIMUM FLOW RATE NOMINAL FLOW RATE MAXIMUM FLOW RATE INCH-POUND S.I. INCH- POUND S.I. INCH-POUND S.I. gpm ft L/S kpa gpm ft L/S kpa gpm ft lps kpa TGZ040 C TGZ050 C TGZ0 C TGZ080 C TGZ100 C TGZ110 C TGZ120 C TGZ150 C TGZ170 C TGZ190 C IM 1137 TGZ040B - TGZ190B A 15

16 Relief Valve Piping The current ANSI/ASHRAE Standard 15 specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-134a) shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 20 feet (6.1 meters) from any window, ventilation opening or exit in any building. The piping must be provided with a rain cap at the outside terminating point and a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. In addition, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s). The size of the discharge pipe from the pressure relief valve shall not be less than the size of the pressure relief outlet. When two or more vessels are piped together, the common header and piping to the atmosphere shall not be less than the sum of the area of the relief valve outlets connected to the header. Fittings should be provided to permit vent piping to be easily disconnected for inspection or replacement of the relief valve. NOTE: Provide adequate fittings in piping to permit repair or replacement of relief valve. Figure 8, Relief Valve Piping 16 TGZ040B - TGZ190B IM 1137

17 TGZ Dimensions Figure 9, Dimensions, TGZ040B TGZ0B, Standard 4-pass Condenser NOTE 1) See Weights on page 22 for lifting and corner weights. NOTE 2 Left-hand condenser connections are an available option. IM 1137 TGZ040B - TGZ190B A 17

18 Figure 10, Dimensions, TGZ080B TGZ100B, Standard 4-Pass Condenser "A" L4 / M4 L3 / M3 CONDENSER INLET/OUTLET CONTROL BOX EVAP WATER CONNECTIONS L1 / M1 L2 / M2 MICROTECHII USERINTERFACE CIRCUIT 2 CIRCUIT1 VENT OUTLET CONDENSER INLET DRAIN RELIEF S "X" PASSCONDENSER 4"/(102) NOM. WATER CONNECTIONS "T" "L" CONTROL CONNECTION.88 KNOCKOUTS ON OPPOSITE SIDE INLET EVAPORATOR REMOVABLE DISC. HANDLE POWER CONNECTIONS OUTLET REMOVE BRKT. FOR SHIPPING ONLY "Y" KNOCKOUTS "Z" DIA MOUNTING HOLES (4) NOTES: Lifting and corner weights are in the Weights section on page 22. Left-hand condenser connections are an available option. 18 TGZ040B - TGZ190B IM 1137

19 Figure 11, Dimensions, TGZ110B TGZ120B, Standard 4-Pass Condenser L4 / M4 L3 / M3 (4 PASS CONDENSER) CONDENSER INLET/OUTLET CONTROL BOX EVAP WATER CONNECTIONS L1 / M1 L2 / M2 MICROTECHII USERINTERFACE CIRCUIT 2 CIRCUIT 1 A VENT OUTLET CONDENSER INLET DRAIN RELIEF S "X" PASS CONDENSER 4 IN. (102 MM) NOM. WATER CONNECTION VICTAULIC CONTROL CONNECTION.88 KNOCKOUTS ON OPPOSITE SIDE INLET EVAPORATOR REMOVABLE DISC. HANDLE OUTLET REMOVE BRKT. FOR SHIPPING ONLY POWER CONNECTIONS "Y" KNOCKOUTS NOTE: 4 PASS CONDENSER SHOWN ON THIS SHEET. SHEET 2 SHOWS 2 PASS CONDENSER. "Z" DIA MOUNTING HOLES (4) NOTES: Lifting and corner weights are in the Weights section on page 22. Left-hand condenser connections are an available option. IM 1137 TGZ040B - TGZ190B A 19

20 Figure 12, Dimensions, TGZ150B TGZ190B, Standard 4-Pass Condenser EVAPORATOR OUTLET EVAPORATOR INLET CIRCUIT 2 CIRCUIT 1 VENT MICROTECH II USER INTERFACE VENT "Y" OUTLET CONDENSER INLET DRAIN DRAIN RELIEF S "X" PASSCONDENSER 4" / (102) NOM. WATER CONNECTIONS CONTROL CONNECTION.88 KNOCKOUTS ON OPPOSITE SIDE REMOVABLE DISC HANDLE REMOVE BRKT. FOR SHIPPING ONLY POWER CONNECTIONS EVAP INLET/ OUTLET "Z" KNOCKOUT TGZ B CERTIFIED DWG DIA MOUNTING HOLES (4) NOTES: Lifting and corner weights are in the Weights section on page 22. Left-hand condenser connections are an available option. 20 TGZ040B - TGZ190B IM 1137

21 2-Pass Condenser Dimensions Figure 13, TGZ040B 0B, Optional 2-Pass condenser Note: For optional left-hand connections, reverse the images below. OPTIONAL2PASS CONDENSER 4" / (102) NOMINAL WATER CONNECTIONS * A2* TGZ040-0B CERTIFIED DWG Figure 14, Dimensions, TGZ080B - TGZ100B, Optional 2-Pass Condenser OPTIONAL 2 PASS CONDENSER 4"/ (102) NOMINAL WATER CONNECTIONS Figure 15, Dimensions, TGZ110B - TGZ120B, Optional 2-Pass Condenser OPTIONAL2PASS CONDENSER 5" / (127) NOMINAL WATER CONNECTIONS Figure 16, Dimensions, TGZ150B - TGZ190B, Optional 2-Pass Condenser OPTIONAL2PASS CONDENSER 5" / (127) NOMINAL WATER CONNECTIONS IM 1137 TGZ040B - TGZ190B A 21

22 Weights NOTE: Refer to the unit dimension drawing for lifting and mounting point s physical location. Table 6, TGZ Lifting, Mounting, and Total Weights, Inch-Lbs Units MODEL LIFTING WEIGHT FOR EACH POINT (LBS) MOUNTING LOADS FOR EACH POINT (LBS) L1 L2 L3 L4 M1 M2 M3 M4 SHIPPING WEIGHT (LBS) OPERATING WEIGHT (LBS) TGZ040B TGZ050B TGZ0B TGZ080B TGZ100B TGZ110B TGZ120B TGZ150B TGZ170B TGZ190B Table 7, TGZ Lifting, Mounting, and Total Weights, SI Units MODEL LIFTING WEIGHT FOR EACH POINT (KG) MOUNTING LOADS FOR EACH POINT (KG) L1 L2 L3 L4 M1 M2 M3 M4 SHIPPING WEIGHT (KG) OPERATING WEIGHT (KG) TGZ040B TGZ050B TGZ0B TGZ080B TGZ100B TGZ110B TGZ120B TGZ150B TGZ170B TGZ190B Figure 17, Lifting and Mounting Points Location 4 LB RB 3 Water Connections 1 LF FRF 2 Control Panel 22 TGZ040B - TGZ190B IM 1137

23 Physical Data TGZ Scroll Table 8, TGZ 040B 0B TGZ Unit Model TGZ040B TGZ050B TGZ0B No. Of Circuits COMPRESSORS Nominal Horsepower Number per Circuit Unloading Steps, % 25 / 50 / 75 / / 50 / 75 / / 50 / 75 / 100 Oil Charge per compressor. oz (l) 110 (3.3) 110 (3.3) 110 (3.3) CONDENSER Number No. Refrigerant Circuits Diameter, in. (mm) (273) (273) (273) Tube Length, in (mm) 122 (3099) 122 (3099) 122 (3099) Design Water Pressure, psig (kpa): Refrigerant Side 500 (3447) 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) 232 (1599) Relief Valve Setting, psig (kpa) 500 (3447) 500 (3447) 500 (3447) No. Of Water Passes - Standard No. Of Water Passes - Optional Water Volume, gallons (l) 13.6 (51.5) 13.6 (51.5) 16.3 (61.8) Pump-Down Capacity lb., (kg) (55.2) (55.2) (55.2) (55.2) (48.7) (48.7) Connections: Water In & Out, in., (mm) (4 Pass) 3 (76) 3 (76) 3 (76) Water In & Out, in., (mm) (2 Pass) 4 (102) 4 (102) 4 (102) Relief Valve, Flare in., (mm) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) Purge Valve, Flare in., (mm) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) Vent & Drain, in (mm) FPT 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) Liquid Sub-cooling Integral Integral Integral EVAPORATOR, BRAZED-PLATE Number No. Refrigerant Circuits Water Volume, gallons (l) 3.7 (14.0) 5.0 (18.9) 5.0 (18.9) Refrigerant Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) 450 (3102) Relief Valve Setting, psig (kpa) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig (kpa) 450 (3102) 450 (3102) 450 (3102) Water Connections: In & Out, in. (mm) Victaulic 3 (76) 3 (76) 3 (76) Drain & Vent Field Supplied Field Supplied Field Supplied UNIT DIMENSIONS Length, in. (mm) 138 (3506) 138 (3506) 138 (3506) Width, in. (mm) 33 (838) 33 (838) 33 (838) Height, in. (mm) 63.4 (1610) 63.4 (1610) 63.4 (1610) UNIT WEIGHTS Operating weight, lb. (kg) 24 (1181) 2644 (1199) 2699 (1224) Shipping weight, lb. (kg) 2434 (1104) 2464 (1118) 2496 (1132) R-134a Ref. Charge, lb. (kg) 45 (20.4) 45 (20.4) 45 (20.4) 45 (20.4) 50 (22.7) 50 (22.7) IM 1137 TGZ040B - TGZ190B A 23

24 Table 9, TGZ080B 100B TGZ Unit Model TGZ080B TGZ100B No. Of Circuits 2 2 COMPRESSORS Nominal Horsepower Number per Circuit Staging Steps, % 25 / 50 / 75 / / 50 / 75/ 100 Oil Charge per compressor. oz (l) 158 (4.7) 200 (5.9) CONDENSER Number 1 1 No. Refrigerant Circuits 2 2 Diameter, in. (mm) 14 (356) 14 (356) Tube Length, in (mm) 122 (3099) 122 (3099) Design Water Pressure, psig (kpa): Refrigerant Side 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) Relief Valve Setting, psig (kpa) 500 (3447) 500 (3447) No. Of Water Passes - Standard 4 4 No. Of Water Passes - Optional 2 2 Water Volume, gallons (l) 27.5 (104) 27.5 (104) Pump-Down Capacity, lb. (kg) 186 (84) 186 (84) 186 (84) 186 (84) Connections: Water In & Out (4 Pass), in. (mm) 4 (102) 4 (102) Water In & Out (2 Pass), in. (mm) 4 (102) 4 (102) Relief Valve- Flare, in. (mm) 5/8 (15.9) 5/8 (15.9) Purge Valve- Flare, in. (mm) 5/8 (15.9) 5/8 (15.9) Vent & Drain, in (mm) FPT 1/2 (12.7) 1/2 (12.7) Liquid Sub-cooling Integral Integral EVAPORATOR, BRAZED PLATE Number 1 1 No. Refrigerant Circuits 2 2 Water Volume, gallons (l) 8.7 (32.9) 8.7 (32.9) Refrigerant Side D.W.P., psig (kpa) 450 (3102) 450 (3102) Relief Valve Setting, psig (kpa) 450 (3102) 450 (3102) Water Side D.W.P., psig (kpa) 450 (3102) 450 (3102) Water Connections: In & Out- Victaulic, in. (mm) 3 (76) 3 (76) Drain & Vent Field Supplied Field Supplied UNIT DIMENSIONS Length, in. (mm) (3787) (3828) Width, in. (mm) 35.2 (894) 35.2 (894) Height, in. (mm) 65.5 (1664) 65.5 (1664) UNIT WEIGHTS Operating WT., lb., (kg) 4422 (2006) 4749 (2154) Shipping WT., lb. (kg) 4116 (1867) 4418 (2004) R-134a Ref. Charge, lb. (kg) 85 (38.6) 85 (38.6) 90 (40.8) 90 (40.8) 24 TGZ040B - TGZ190B IM 1137

25 Table 10, TGZ 110B 120B TGZ Unit Model TGZ110B TGZ120B No. Of Circuits 2 2 COMPRESSORS Nominal Horsepower Number per Circuit Staging, 4 Stages, Circuit #1 in Lead 23 / 50 / 73 / / 50 / 75 / 100 Staging, 4 Stages, Circuit #2 in Lead 27 / 50 / 77 / / 50 / 75 / 100 Oil Charge per compressor. oz (l) 200 (5.9) 213 (6.3) 213 (6.3) CONDENSER Number 1 1 No. Refrigerant Circuits 2 2 Diameter, in. (mm) 16.0 (406.4) 16.0 (406.4) Tube Length, in (mm) 120 (3048) 120 (3048) Design Water Pressure, psig (kpa): Refrigerant Side 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) Relief Valve Setting, psig (kpa) 500 (3447) 500 (3447) No. Of Water Passes - Standard 4 4 No. Of Water Passes - Optional 2 2 Water Volume, gallons (l) 35.4 (134) 35.4 (134) Pump-Down Refrigerant Capacity, lb. (kg 252 (114) 252 (114) 252 (114) 252 (114) Connections: Water In & Out, in., (mm) (4 Pass) 4 (102) 4 (102) Water In & Out, in., (mm) (2 Pass) 5 (127) 5 (127) Relief Valve, Flare in., (mm) 5/8 (15.9) 5/8 (15.9) Purge Valve, Flare in., (mm) 5/8 (15.9) 5/8 (15.9) Vent & Drain, in (mm) FPT 1/2 (12.7) 1/2 (12.7) Liquid Sub-cooling Integral Integral EVAPORATOR, BRAZED-PLATE Number 1 1 No. Refrigerant Circuits 2 2 Water Volume, gallons (l) 9.7 (36.7) 9.7 (36.7) Refrigerant Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) Relief Valve Setting, psig (kpa) 450 (3102) 450 (3102) Water Side D.W.P., psig, (kpa) 450 (3102) 450 (3102) Water Connections: In & Out, in. (mm) Victaulic 3 (76) 3 (76) Drain & Vent Field Supplied Field Supplied UNIT DIMENSIONS Length, in. (mm) (3780) (3780) Width, in. (mm) 35.2 (894) 35.2 (894) Height, in. (mm) 67 (1702) 67 (1702) UNIT WEIGHTS Operating WT., lb., (kg) 5373 (2437) 5319 (2413) Shipping WT., lb. (kg) 4967 (2253) 4913 (2229) R-134a Ref. Charge, lb. (kg) 110 (49.9) 110 (49.9) 110 (49.9) 110 (49.9) IM 1137 TGZ040B - TGZ190B A 25

26 Table 11, TGZ 150B 190B TGZ Unit Model TGZ150B TGZ170B TGZ190B No. Of Circuits COMPRESSORS Nominal Horsepower Number per Circuit Staging, 6 Stages, Circuit #1 in Lead 17 / 33 / 50 / 67 / 83 / / 33 / 48 / 67 / 81 / / 33 / 50 / 67 / 83 / 100 Staging, 6 Stages, Circuit #2in Lead 17 / 33 / 50 / 67 / 83 / / 33 / 52 / 67 / 85 / / 33 / 50 / 67 / 83 / 100 Oil Charge per compressor. oz (l) 200 (5.9) 200 (5.9) 213 (6.3) 213 (6.3) CONDENSER Number No. Refrigerant Circuits Diameter, in. (mm) 16 (406.4) 16 (406.4) 16 (406.4) Tube Length, in. (mm) 144 (3658) 144 (3658) 144 (3658) Design Water Pressure, psig (kpa): Refrigerant Side 500 (3447) 500 (3447) 500 (3447) Water Side 232 (1599) 232 (1599) 232 (1599) Relief Valve Setting, psig (kpa) 500 (3447) 500 (3447) 500 (3447) No. Of Water Passes - Standard No. Of Water Passes - Optional Water Volume, gallons (l) 42.5 (1.9) 47.1 (178.4) 47.1 (178.4) Pump-Down Refrigerant Capacity, lb. (kg) 302 (137) 302 (137) 277 (126) 277 (126) 277 (126) 277 (126) Connections: Water In & Out, in., (mm) (4 Pass) 4 (102) 4 (102) 4 (102) Water In & Out, in., (mm) (2 Pass) 5 (127) 5 (127) 5 (127) Relief Valve- Flare, in. (mm) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) Purge Valve- Flare, in. (mm) 5/8 (15.9) 5/8 (15.9) 5/8 (15.9) Vent & Drain, in. (mm) FPT 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) Liquid Sub-cooling Integral Integral Integral EVAPORATOR, SHELL-and-TUBE Number No. Refrigerant Circuits Water Volume, gallons (l) 57.6 (218) 56.9 (215.4) 56.9 (215.4) Refrigerant Side D.W.P., psig (kpa) 450 (3102) 450 (3102) 450 (3102) Water Side D.W.P., psig (kpa) 150 (1034) 150 (1034) 150 (1034) Relief Valve Setting, psig (kpa) 450 (3102) 450 (3102) 450 (3102) Water Connections: In & Out- Victaulic, in. (mm) 8 (203) 8 (203) 8 (203) Drain & Vent, in. (mm) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) UNIT DIMENSIONS Length, in. (mm) (4321) (4321) (4321) Width, in. (mm) 36.8 (935) 36.8 (935) 36.8 (935) Height, in. (mm) 77.7 (1974) 77.7 (1974) 77.7 (1974) UNIT WEIGHTS Operating WT., lb. (kg) 7877 (3573) 7991 (3625) 7972 (3616) Shipping WT., lb. (kg) 7019 (3184) 7101 (3221) 7082 (3212) R-134a Refrigerant Charge, lb. (kg) 140 (63.5) 140 (63.5) 150 (68) 150 (68) 150 (68) 150 (68) 26 TGZ040B - TGZ190B IM 1137

27 Unit Components Figure 18, Compressor Locations Evaporator Evaporator and Condenser Connections Circuit 2 Circuit 1 Control Panel NOTE: Models TGZ150 to TGZ190 add a #5 compressor to circuit #1 and a #6 compressor to circuit #2 and substitute an underslung shell-and-tube evaporator for the brazed-plate evaporator. Figure 19, Electric Panel Components MT II Controller Expansion Board Heat/Cool Switch T3, T4, 110V/24V Transformers (Note) Trans. Secondary Fuse (On Panel Side) S1, System Switch PS1, Pumpdown Switch PS2, Pumpdown Switch Trans. Primary Fuses SR1, SR2, Solenoid Relays Optional Compressor Circuit Breakers HPR1, HPR2, High Pressure Relays Contactors Optional Disconnect Switch Optional Compressor Overloads Grounding Lug Note: Models TGZ have additional T5 for electronic expansion valves. IM 1137 TGZ040B - TGZ190B A 27

28 FLOW FLOW Figure 20, Piping Schematic, Models TGZ R Rev.00 Package Templifier (Sheet 1) CHECK DISCHARGE TRANSDUCER RELIEF(S03, S04) SCHRADER HIGH PRESSURE SWITCH RELIEF CHARGING SCHRADER SUCTION TRANSDUCER (S01, S02) DISCHARGE TUBING SCROLL COMPRESSOR (TANDEM) SUCTION TUBING LEAVING WATER TEMP. SENSOR (S10) DISCHARGE SHUT-OFF CONDENSER ASSEMBLY RELIEF CHARGING OIL SIGHT GLASS HOT GAS BYPASS TUBING (OPTIONAL) SUCTION TEMP. SENSOR (S12, S13) ENTERING WATER TEMP. SENSOR (S08) SUCTION CIR. 1 WATER IN WATER OUT WATER IN R rev.00 Package Templifier ENTERING WATER TEMP. SENSOR (S09) LIQUID SHUT-OFF SYSTEM #1 SYSTEM #2 ACCESS FITTING LIQUID TUBING LIQUID TEMP. SENSOR (S14, S15) FILTER DRIER Figure 21, Models TGZ DISCHARGE CHECK RELIEF SCHRADER SOLENOID (SV1, SV2) DISCHARGE TRANSDUCER (S03, S04) SIGHT GLASS SCHRADER HGBP (SV5, SV6) SCHRADER THERMAL EXPANSION HIGH PRESSURE SWITCH LIQUID CIR. 1 LEAVING WATER TEMP. SENSOR (S00) WATER OUT PLATE TYPE EVAPORATOR DISCHARGE TUBING SCROLL COMPRESSOR (TRIO) SCHRADER SOLENOID (SV1, SV2) SIGHT GLASS SCHRADER SUCTION TUBING ELECTRONIC EXPANSION RELIEF SCHRADER S SUCTION TRANSDUCER (S01, S02) SUCTION TEMP. SENSOR (S12, S13) HGBP (SV5, SV6) LIQUID SUCTION CHARGING WATER IN ENTERING WATER TEMP. SENSOR (S08) OIL SIGHT GLASS (OPPOSITE SIDE) TUBE AND SHELL EVAPORATOR WATER OUT LEAVING WATER TEMP. SENSOR (S00) HOT GAS BYPASS TUBING (OPTIONAL) LEAVING WATER TEMP. SENSOR (S10) FILTER DRIER DISCHARGE SHUT-OFF CHARGING RELIEF WATER OUT WATER IN SYSTEM #1 SYSTEM #2 ENTERING WATER TEMP. SENSOR (S09) LIQUID SHUT-OFF CONDENSER ASSEMBLY LIQUID TEMP. SENSOR (S14, S15) LIQUID TUBING ACCESS FITTING 28 TGZ040B - TGZ190B IM 1137

29 Electrical Notes Field Wiring The TGZ units are supplied as standard with compressor contactors and power terminal block, designed for multipoint power supply to the unit, no compressor circuit breakers. Available options are: Single-point connection to power block with compressor circuit breakers Single-point connection to disconnect switch with compressor circuit breakers High short circuit current rating with single-point disconnect switch (exluding V units) Multi-point connection to disconnect switch, no compressor circuit breakers A factory-installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit. Wiring and conduit selections must comply with the National Electrical Code and/or local requirements. An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 32) give specific information on recommended wire sizes. Unit power inlet wiring must enter the control box through the right side. A 7/8-inch pilot knockout is provided. (Refer to the unit dimension drawings beginning on page 17 for the location of power (and control) connections.)! CAUTION To avoid equipment damage, use only copper conductors in main terminal block. Notes for Electrical Data Single Point Power: 1. If a separate 115V power supply is used for the control circuit, then the wire sizing amps is 10 amps for all unit sizes. 2. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Voltage drop has not been included. Therefore, it is recommended that power leads be kept short. All terminal block connections must be made with copper wire. 3. The recommended power lead wire sizes are based on an ambient temperature of 86 F (30 C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook. 4. Must be electrically grounded according to national and local electrical codes. Voltage Limitations: 1. Within 10 percent of nameplate rating 2. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction that must be adhered to. Notes for Field Wiring Data 1. Requires a single disconnect to supply electrical power to the unit. This power supply must either be fused or use a circuit breaker. 2. All field wiring to unit power block or optional non-fused disconnect switch must be copper. 3. All field wire size values given in table apply to 75 C rated wire per NEC. IM 1137 TGZ040B - TGZ190B A 29

30 Supplemental Overloads Option The supplemental overloads option is used to reduce the required electrical service size and wire sizing for units under 140 F leaving condenser water temperature. Standard Panel Ratings (ka) Voltage WGZ-C Model Size WGZ WGZ WGZ Optional Panel Ratings (ka) Voltage Options, Single-Point Power Connection Only High Short Circuit Current High Interrupt Rating Disconnect Switch Not Available Nor Available NOTE High Short Circuit Current Rating (HSCCR) provides all panel components rated per above table and is so labeled. High Interrupt Disconnect Switch provides for only a disconnect switch with the rating, and the panel has no special labeling. Circuit Breakers The circuit breaker used in the High Short Circuit panel option may have a higher trip rating than the unit Maximum Overload Protection (MOP) value shown on the unit nameplate. The circuit breaker is installed as a service disconnect switch and does not function as branch circuit protection, mainly that the protection device must be installed at the point of origin of the power wiring. The breaker (disconnect switch) is oversized to avoid nuisance trips at high ambient temperature conditions 30 TGZ040B - TGZ190B IM 1137

31 Figure 22, Field Wiring Diagram IM 1137 TGZ040B - TGZ190B A 31

32 Electrical Data Table 12, Compressor Amp Draw TGZ UNIT SIZE VOLTS STANDARD UNIT W/O EXT. OL'S RATED LOAD AMPS PER COMPRESSOR OPTIONAL UNIT WITH EXT. OL'S RATED LOAD AMPS (SEE NOTE 1) PER COMPRESSOR LOCKED ROTOR AMPS COMPRESSORS ACROSS-THE-LINE STARTING CIRCUIT #1 CIRCUIT #2 CIRCUIT #1 CIRCUIT #2 CIRCUIT #1 CIRCUIT #2 No.1 No.3 No.5 No.2 No.4 No.6 No.1 No.3 No.5 No.2 No.4 No.6 No.1 No.3 No.5 No.2 No.4 No NOTES: 1. External overloads only available on Templifier Units with 140 F maximum condenser leaving water temperature. 2. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of RLA of all other loads in the circuit including control transformer. 3. Single point power supply requires a single fused disconnect to supply electrical power to the unit. 4. Compressor RLA values are for wire sizing purposes only and do not reflect normal operating current draw. 32 TGZ040B - TGZ190B IM 1137

33 Table 13, Wire Sizing Amps, Standard Multi-Point Power Supply TGZ UNIT SIZE VOLTS FREQ. (HERTZ) MINIMUM CIRCUIT AMPACITY (MCA) WITHOUT EXTERNAL WITH EXTERNAL OVERLOADS OVERLOADS CIRCUIT #1 MULTIPLE POINT POWER SUPPLY CIRCUIT #2 CIRCUIT #1 CIRCUIT #2 WITHOUT EXTERNAL OVERLOADS FIELD WIRE QTY. WIRE GAUGE 75 C CIRCUIT #1 POWER SUPPLY CIRCUIT #2 FIELD WIRE QTY. WITH EXTERNAL OVERLOADS WIRE GAUGE 75 C CIRCUIT #1 CIRCUIT # #4 #4 3 #4 # #4 #4 3 #6 # #8 #8 3 #10 # #10 #10 3 #10 # #2 #2 3 #3 # #2 #2 3 #3 # #8 #8 3 #8 # #8 #8 3 #10 # #1 #1 3 #1 # #1 #1 3 #2 # #6 #6 3 #6 # #8 #8 3 #8 # /0 2/0 3 1/0 1/ /0 2/0 3 #1 # #4 #4 3 #6 # #6 #6 3 #8 # /0 2/0 3 2/0 2/ /0 2/0 3 1/0 1/ #4 #4 3 #4 # #6 #6 3 #6 # /0 4/0 3 2/0 3/ /0 4/0 3 1/0 3/ #4 #2 3 #4 # #6 #4 3 #6 # /0 4/0 3 3/0 3/ /0 4/0 3 3/0 3/ #2 #2 3 #3 # #4 #4 3 #4 # /0 4/ /0 4/ #2 #2 3 #2 # #3 #3 3 #4 # / / #2 1/0 3 #2 # #3 #1 3 #4 # /0 1/0 3 #1 # #1 #1 3 #2 #2 NOTES: 1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other compressor RLAs. 2. Multiple point power supply requires a separate fused disconnect for each circuit to supply electrical power to the unit. 3. External compressor overload option is only available for units with 140 F maximum leaving condenser water temperature. 4. Wire sizes shown above are for standard ambient temperature and short runs of wire. IM 1137 TGZ040B - TGZ190B A 33

34 Table 14, Wire Sizing Amps, Optional Single Point Power Supply TGZ UNIT SIZE VOLTS FREQ. (HERTZ) MINIMUM CIRCUIT AMPACITY (MCA) SINGLE POINT POWER SUPPLY ) WITHOUT EXT OL'S SINGLE POINT POWER SUPPLY WITH EXT OL'S POWER SUPPLY WITHOUT EXTERNAL OL'S WITH EXTERNAL OL S FIELD WIRE QUANTITY WIRE GAUGE 75 C FIELD WIRE QUANTITY WIRE GAUGE 75 C /0 3 1/ /0 3 # #4 3 # #8 3 # /0 3 3/ /0 3 2/ #3 3 # #4 3 # /0 3 4/ /0 3 4/ #2 3 # #3 3 # / #1 3 # #2 3 # /0 3 1/ #1 3 # (2) 3/0 6 (2) 2/ (2) 3/ /0 3 2/ /0 3 # (2) 3/0 6 (2) 3/ (2) 3/0 6 (2) 2/ /0 3 2/ /0 3 1/ (2) 4/0 6 (2) 4/ (2) 4/0 6 (2) 3/ /0 3 3/ /0 3 2/ (2) (2) (2) (2) 4/ / /0 3 3/ (2) (2) (2) (2) /0 3 3/0 NOTES:. 1. Unit wire sizing amps are equal to 125% of the largest compressor-motor RLA plus 100% of the other compressor RLAs. 2. Single point power supply requires a single fused disconnect to supply electrical power to the unit. 3. External compressor overload option is only available for units with 140 F maximum leaving condenser water temperature. 4. Wire sizes shown above are for standard ambient temperature and short runs of wire. 34 TGZ040B - TGZ190B IM 1137

35 Table 15, Maximum Fuse Sizing TGZ UNIT SIZE VOLTAGE PHASE FREQ. (HERTZ) SINGLE POINT POWER SUPPLY WITHOUT EXTERNAL. OL'S TOTAL UNIT MULTIPLE POINT POWER SUPPLY WITH WITHOUT EXTERNAL. OL'S WITH EXTERNAL OL'S EXTERNAL. OL'S TOTAL UNIT CIRC.#1 CIRC.#2 CIRC.#1 CIRC.# NOTE: "Maximum Fuse Sizes" are selected at approximately 225% of the largest compressor RLA plus 100% of other compressor RLA values. IM 1137 TGZ040B - TGZ190B A 35

36 Table 16, Connection Sizes, Single Point Power Supply, Without External Overloads TGZ UNIT SIZE VOLTS FREQ. (HERTZ) POWER BLOCK TERMINAL POWER BLOCK OR BUS BAR LUGS SIZE (1) CONNECTION (2) SWITCH WIRE RANGE - CU SIZE (1) FACTORY INSTALLED DISCONNECT DISCONNECT SWITCH MOLDED CASE CONNECTION (2) WIRE RANGE - CU FACTORY INSTALLED HSCCR DISCONNECT SWITCH (CIRCUIT BREAKER ) CIRC. BRKR SIZE (1) CONNECTION (2) WIRE RANGE - CU #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 100 #10-1/0 150 #6-350 kcmil 175 #14-2/0 100 #10-1/0 90 #10-1/ #4-500 kcmil 250 #6-350 kcmil 350 (2) 3/0-500 kcmil #4-500 kcmil 250 #6-350 kcmil 350 (2) 3/0-500 kcmil #14-2/0 125 #3-3/0 175 #6-350 kcmil 175 #14-2/0 100 #10-1/0 150 #6-350 kcmil #4-500 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil #14-2/0 125 #3-3/0 200 #6-350 kcmil 175 #14-2/0 100 #10-1/0 150 #6-350 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 250 #6-350 kcmil 225 #6-350 kcmil 175 #14-2/0 125 #3-3/0 175 #6-350 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil 175 #14-2/0 250 #6-350 kcmil 200 #6-350 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #4-500 kcmil 250 #6-350 kcmil 300 (2) 3/0-500 kcmil 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 700 (2) 3/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 700 (2) 3/0-500 kcmil #4-500 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil 175 #14-2/0 250 #6-350 kcmil 300 (2) 3/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 800 (3) 1/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 800 (3) 1/0-500 kcmil #4-500 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 300 (2) 3/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 1000 (3) 1/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 1000 (3) 1/0-500 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 450 (2) 3/0-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 350 (2) 3/0-500 kcmil (2) #2-500 kcmil 800 (3) 1/0-500 kcmil 1000 (3) 1/0-500 kcmil (2) #2-500 kcmil 800 (3) 1/0-500 kcmil 1000 (3) 1/0-500 kcmil #4-500 kcmil 400 (2) 3/0-500 kcmil 500 (2) 3/0-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil NOTES:. 1. "Size" is the maximum amperage rating for the terminals or the main electrical device. 2. "Connection" is the range of wire sizes that the terminals on the electrical device will accept. 36 TGZ040B - TGZ190B IM 1137

37 Table 17, Connection Sizes, Single Point Power Supply with External Overloads TGZ UNIT SIZE VOLTS FREQ. (HERTZ) POWER BLOCK TERMINAL SIZE (1) POWER BLOCK OR BUS BAR LUGS CONNECTION (2) WIRE RANGE - CU FACTORY INSTALLED DISCONNECT DISCONNECT SWITCH MOLDED CASE SWITCH SIZE (1) CONNECTION (2) WIRE RANGE - CU FACTORY INSTALLED HSCCR DISCONNECT SWITCH (CIRCUIT BREAKER ) CIRC. BRKR SIZE (1) CONNECTION (2) WIRE RANGE - CU #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 100 #3-3/0 150 #4-350 kcmil 175 #14-2/0 100 #3-3/0 150 #4-350 kcmil #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 125 #3-3/0 125 #3-3/0 175 #14-2/0 100 #3-3/0 100 #3-3/ #6-400 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil #6-400 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil #14-2/0 125 #3-3/0 125 #3-3/0 175 #14-2/0 100 #3-3/0 125 #3-3/ (2) #2-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil (2) #2-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil 335 #6-400 kcmil 125 #3-3/0 125 #3-3/ (2) #2-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil (2) #2-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil 335 #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil (2) #2-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil (2) #2-500 kcmil 400 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil 335 #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 0 (2) 3/0-500 kcmil #6-400 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil 335 #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 800 (3) 1/0-500 kcmil (2) #2-500 kcmil 0 (2) 3/0-500 kcmil 800 (3) 1/0-500 kcmil #6-400 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil 335 #6-400 kcmil 250 #6-350 kcmil 250 #6-350 kcmil (2) #2-500 kcmil 800 (3) 1/0-500 kcmil 800 (3) 1/0-500 kcmil (2) #2-500 kcmil 800 (3) 1/0-500 kcmil 800 (3) 1/0-500 kcmil #6-400 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil 335 #6-400 kcmil 250 #6-350 kcmil 400 (2) 3/0-500 kcmil (2) #2-500 kcmil 800 (3) 1/0-500 kcmil 800 (3) 1/0-500 kcmil (2) #2-500 kcmil 800 (3) 1/0-500 kcmil 800 (3) 1/0-500 kcmil #6-400 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil 335 #6-400 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil NOTES: 1. "Size" is the maximum amperage rating for the terminals or the main electrical device. 2. "Connection" is the range of wire sizes that the terminals on the electrical device will accept. IM 1137 TGZ040B - TGZ190B A 37

38 Table 18, Connection Sizes, Multi-Point Power Connection, without External Overloads POWER TERMINAL BLOCK FACTORY INSTALLED DISCONNECT TGZ UNIT SIZE 040 VOLT S POWER BLOCK OR BUS BAR LUGS SIZE (1) CIRCUIT #1 CIRCUIT #2 CIRCUIT.#1 CIRCUIT.#2 CONNECTION WIRE RANGE (2) POWER BLOCK/ BUS BAR LUGS SIZE (1) CONNECTION (2) WIRE RANGE MOLDED CASE SWITCH CONNECTION (2) SWITCH CONNECTION (2) SIZE (1) WIRE RANGE SIZE (1) WIRE RANGE #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 100 #10-1/0 125 #3-3/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/0 175 #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil 175 #14-2/0 175 #14-2/0 125 #3-3/0 250 #6-350 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil 175 #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil NOTES: 1. "Size" is the maximum amperage rating for the terminals or the main electrical device. 2. "Connection" is the range of wire sizes that the terminals on the electrical device will accept. 38 TGZ040B - TGZ190B IM 1137

39 Table 19, Connection Sizes, Multi-Point Power Connection, with External Overloads TGZ UNIT SIZE VOLT S POWER BLOCK OR BUS BAR LUGS SIZE POWER TERMINAL BLOCK FACTORY INSTALLED DISCONNECT CIRCUIT #1 CIRCUIT #2 CIRCUIT.#1 CIRCUIT.#2 CONN. WIRE RANGE POWER BLOCK OR BUS BAR LUGS SIZE CONN. WIRE RANGE SWITCH SIZE CONNECTION WIRE RANGE MOLDED CASE SWITCH SIZE CONNECTION WIRE RANGE #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 100 #10-1/0 125 #3-3/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #4-500 kcmil 380 #4-500 kcmil 250 #6-350 kcmil 250 #6-350 kcmil #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/0 175 #14-2/0 175 #14-2/0 100 #10-1/0 100 #10-1/ #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/0 175 #14-2/0 175 #14-2/0 125 #3-3/0 125 #3-3/ #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil 175 #14-2/0 175 #14-2/0 125 #3-3/0 250 #6-350 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #4-500 kcmil 380 #4-500 kcmil 400 (2) 3/0-500 kcmil 400 (2) 3/0-500 kcmil #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil 175 #14-2/0 175 #14-2/0 250 #6-350 kcmil 250 #6-350 kcmil NOTES: 1. "Size" is the maximum amperage rating for the terminals or the main electrical device. 2. "Connection" is the range of wire sizes that the terminals on the electrical device will accept. IM 1137 TGZ040B - TGZ190B A 39

40 Start-Up and Shutdown Note: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. Pre Start-up 1. With main disconnect open, check all electrical connections in control panel and starter to be sure they are tight and provide good electrical contact. Use only copper wire to connection points. 2. Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser. 3. Open all water flow valves to the condenser and evaporator. 4. Flush the cooling tower (if there is one used) and system piping to be sure the system is clean. Start source water pump and manually start hot water pump. Check all piping for leaks. Vent the air from the evaporator and condenser water circuit as well as from the entire water system. The cooler circuit should contain clean, non-corrosive water. 5. Check to see that the water temperature thermostat sensor is installed in the correct water line. 6. Making sure control stop switch S1 is open (off) and pumpdown switch(es) PS1 and PS2 are on manual pumpdown, throw the main power and control disconnect switches to on. This will energize the crankcase heaters. Wait a minimum of 12 hours before starting up unit. 7. Check compressor oil level. Prior to start-up, the oil level should cover at least one-third of the sightglass. 8. Check pressure drop across evaporator and condenser, and see that water flow is correct per the design flow rates and data on pages 13 through Check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate within + 10% and that phase voltage unbalance does not exceed 2%. Verify that adequate power supply and capacity is available to handle load. 10. Check that the panel-mounted Heat/Cool switch is in the correct position 11. Make sure all wiring and fuses are of the proper size. Also make sure all interlock wiring is completed per McQuay diagrams. Use only copper wire. 12. Verify that all mechanical and electrical inspections by code authorities have been completed. 13. Make sure all auxiliary load and control equipment is operative and that adequate cooling heat is available for initial start-up. Start-up 1. Open the compressor suction and discharge shutoff valves until backseated. Always replace valve seal caps. 2. Open the manual liquid line shutoff valve and leak test the unit. 3. Check to see that the unit circuit breakers are in the off position. 4. Check to see that the pumpdown switchs PS1 and PS2 are in the manual pumpdown position and the control system switch S1 is in the off position. 5. Place the main power and control circuit disconnects to the on position. 6. Verify crankcase heaters have operated for at least 12 hours prior to start-up. Crankcase should be warm. 7. Adjust the setpoint on the MicroTech II controller to the desired hot water temperature. 8. Start the auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch and chilled water pump. 9. Check resets of all equipment protection controls. 10. Switch the unit circuit breakers to on. 11. Place pumpdown switches PS1 and PS2 to auto for restart and normal operation. 12. Start the system by pushing the system switch S1 to on. 13. After running the unit for a short time, check the oil level in each compressor crankcase and check for flashing in the refrigerant sightglass. 14. After system performance has stabilized, completet the Compressorized Equipment Warranty Form (Form No. 2036A) to obtain full warranty benefits. List the pressure drop across both vessels. This form is shipped with the unit. After completion return to McQuay Factory Service through the McQuay sales representative. 15. Verify all control settings appropriate to the application. 40 TGZ040B - TGZ190B IM 1137

41 Extended Shutdown 1. Close the manual liquid line shutoff valves. 2. After the compressors have pumped down, stop or bypass the source water and hot water flow. 3. Turn off all power to the unit. 4. Move the control service switch S1 to the off position. 5. Close the suction and discharge shutoff valves on the compressor(s) and the liquid outlet valves at the condenser(s) or receiver(s). 6. Tag all opened disconnect switches to warn against start-up before opening the compressor suction and discharge valves and heating the oil. 7. Drain all water from the unit evaporator, condenser, pumps and water piping if the unit is to be shut down during the winter and exposed to below freezing temperatures. Do not leave the vessels or piping open to the atmosphere over the shutdown period. Start-up after Extended Shutdown 1. Inspect all equipment to see that it is in satisfactory operating condition. 2. Open the compressor suction and discharge valves until backseated. Always replace valve seal caps. 3. Open the manual liquid line shutoff valves. 4. Check circuit breakers. They must be in the off position. 5. Check to see that the pumpdown switch(es) PS1 and PS2 are in the manual shutdown position and the control system switch S1 is in the off position. 6. Throw the main power and control circuit disconnects to the on position. 7. Allow the crankcase heaters to operate for at least 12 hours prior to start-up. 8. Start the source water flow and purge the water piping as well as the evaporator in the unit. 9. Start the auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch. 10. Adjust the setpoint on the MicroTech II controller to the desired hot water temperature. 11. Check resets of all equipment protection controls. 12. Switch the unit circuit breakers to on. 13. Start the system by pushing the system switch S1 to on.! WARNING Most relays and terminals in the control center are powered when S1 is closed and the control circuit disconnect is on. Therefore, do not close S1 until ready for start-up or serious equipment damage can occur. 14. Place pumpdown switch(es) PS1 and PS2 to the auto pumpdown position for restart and normal operation. 15. After running the unit for a short time, check the oil level in each compressor crankcase and for flashing in the refrigerant sightglass (see Maintenance section). General The liquid line sightglass/moisture indicator on all circuits must be checked to be sure the glass is full and clear and the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed. Water supplies in some areas can tend to foul the TGZ heat exchangers to the point where cleaning is necessary. The fouled vessel will be indicated by an abnormally high condensing pressure or low evaporating pressures and can result in nuisance trip-outs. To clean the vessels, a chemical descaling solution should be used according to the manufacturer s directions. IM 1137 TGZ040B - TGZ190B A 41

42 ! WARNING Warranty is voided if wiring is not in accordance with specifications. A blown fuse or tripped protector indicates a short ground or overload. Before replacing fuse or restarting compressor, the trouble must be found and corrected. It is important to have a qualified control panel electrician service this panel. Unqualified tampering with the controls can cause serious damage to equipment and void the warranty. The following steps should be taken prior to attempting any service on the control center: 1. Study the wiring diagram furnished with the unit so that you understand the operation of the unit. 2. Before investigating trouble in the control center, check for burned out light bulbs by testing across the appropriate terminals.! DANGER The panel is always energized to ground even though the system switch is off. If it is necessary to de-energize the complete panel including crankcase heaters, pull the main unit disconnect. Failure to do so will result in serious personal injury or death. If motor or compressor damage is suspected, do not restart until qualified service personnel have checked the unit. Electrical Terminals! DANGER To avoid injury from electric shock hazard, turn off all power before continuing with the following service. All power electrical terminals should be checked for tightness every six months, as they tend to loosen in service due to normal heating and cooling of the wire. Operating Limits Maximum allowable condenser water pressure is 225 a psig (1552 kpa). Maximum allowable evaporator water pressure is 175 psig (1207 kpa). Maximum leaving condenser water temperature is 1 F (71.1 F). Maximum allowable water temperature to evaporator in a non-operating cycle is 105 F (40.5 C). Maximum entering water temperature for operating cycle is 90 F (32.2 C) (during system changeover from heating to cooling cycle). Minimum evaporator leaving water temperature without freeze protection is 40 F (4.4 C). Minimum entering condenser water temperature is F (15.6 C). It may become desirable or necessary to change the operating conditions of the Templifier sometime during its lifetime. The figure below gives the range the unit can operate at based on leaving evaporator and condenser water temperatures. Figure 23, TGZ Operating Envelope Evap Condenser Leaving Water Temperature, F LWT Temp; n/a n/a n/a n/a OK OK 70 n/a n/a n/a OK OK n/a n/a OK OK 50 n/a OK OK 45 n/a OK 40 OK OK 35 OK OK n/a 30 OK OK n/a n/a 25 OK OK n/a n/a n/a 20 OK OK n/a n/a n/a n/a 42 TGZ040B - TGZ190B IM 1137

43 Table 20, TGZ Temperature Limits Cooling Cycle Min. Evaporator Leaving Water Temp. 40 F Condenser Leaving Water Temp Max. Temp. Temp. Evaporator Water Delta-T 6 F 16 F With Glycol in Evap - Evap LWT 15 F F F In Cooling Cycle controlling Evap LWT - The Maximum Setpoint temp is F 70 F 1 F With Evap LWT above 50 F, the Cond LWT must be 30degrees F above Evap. LWT With Evap LWT below 40 F, the Cond EWT must not exceed 120 degrees F above the Evap LWT. Example: Evap LWT = 20 F Cond LWT must not exceed 140 F Heating Cycle Evaporator Leaving Water Temp 40 F 85 F With Evap LWT above 70 F, the Cond LWT must be 30 degrees F above Evap LWT Condenser Leaving Water Temp 110 F 1 F Evaporator Water Delta-T 6 F 16 F Condenser Water Delta - T with 2 Pass Condenser 10 F 15 F Cond Water Delta-T should be 10 degrees F minimum for good condenser subcooling with 4 Pass Condenser 15 F 40 F Table 21, TGZ Flow Limits Unit Nominal Tons Evaporator GPM Range 10 F Water Temp Delta-T, 65 ELWT/130 CLWT Water Temp Delta-T, 65 ELWT/130 LWT Water Temp Delta-T, Full Unit Range Condenser GPM Range - 4 Pass Condenser 20 F Water Temp Delta-T, 65 ELWT/130 CLWT F Water Temp Delta-T, 65 ELWT/130 CLWT Condenser GPM Range - 2 Pass Condenser 10 F Water Temp Delta-T, 65 ELWT/130 CLWT F Water Temp Delta-T, 65 ELWT/130 CLWT NOTE: ELWT=Evaporator Leaving Water Temperature, CLWT=Condenser Water Leaving Temperature. Compressor Oil The oil level should be watched carefully upon initial start-up and for sometime thereafter. Compressor oil must be ICI RL68HP, McQuay Part Number in a 1-gallon container, or ICI RL68H, Part Number in a 1-gallon size. This is synthetic polyolester oil with anti-wear additives and is highly hygroscopic. Care must be taken to minimize exposure of the oil to air when charging oil into the system. Oil can be added to the compressor through the oil fill hole in the compressor. To add oil, pump in the necessary oil. If the system contains no refrigerant, no special precautions are necessary other than keeping the oil clean and dry. Sightglass and Moisture Indicator A clear glass of liquid indicates that there is adequate refrigerant charge in the system to provide proper feed through the expansion valve. Bubbling refrigerant in the sightglass indicates that the system is short of refrigerant charge. Refrigerant gas flashing in the sightglass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. An element inside the sightglass indicates what moisture condition corresponds to a given element color. If the sightglass does not indicate a dry condition after about 12 hours of operation, the unit should be pumped down and the filter-driers changed. IM 1137 TGZ040B - TGZ190B A 43

44 Troubleshooting Chart PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS 1. Main switch, circuit breakers open. 2. Fuse blown. Compressor Will Not Run Compressor Noisy or Vibrating High Discharge Pressure Low Discharge Pressure 3. Thermal overloads tripped or fuses blown. 4. Defective contactor or coil. 5. System shut down by equipment protection devices. 6. No heating required. 7. Liquid line solenoid will not open. 8. Motor electrical trouble. 9. Loose wiring. 1. Improper piping support on suction or liquid line. 2. Worn compressor. 1. Condenser water insufficient or temperature too high. 2. Fouled condenser tubes 3. Noncondensables in system. 4. System overcharge with refrigerant. 5. Discharge shutoff valve partially closed. 1. Suction shutoff valve partially closed. 2. Insufficient refrigerant in system. 3. Low suction pressure. 4. Compressor floodback 5. Condenser too large High Suction 1. Excessive load. Pressure 2. Expansion valve overfeeding. Low Suction Pressure 1. Lack of refrigerant. 2. Evaporator dirty. 3. Clogged liquid line filter-drier. 4. Clogged suction line or compressor suction gas strainers. 5. Expansion valve malfunctioning. 6. Gasket failure in evaporator head ring. 7. Condensing temperature too low. 8. Insufficient water flow. 1. Close switch 2. Check electrical circuits and motor winding for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected. 3. Overloads are auto reset. Check unit closely when unit comes back on lines. 4. Repair or replace. 5. Determine type and cause of shutdown and correct it before resetting safety switch. 6. None. Wait until unit calls for heating. 7. Repair or replace coil. 8. Check motor for opens, short circuit, or burnout. 9. Check all wire junctions. Tighten all screws. 1. Relocate, add or remove hangers. 2. Replace. 1. Investigate ways to increase hot water supply or lower the temperature of the hot water. Check operation of the supplementary heater. 2. Clean. 3. Purge the noncondensables. 4. Remove excess refrigerant. 5. Open valve. 1. Open valve. 2. Check for leaks. Repair and add charge. 3. See corrective steps for low Suction pressure below. 4. Check suction superheat 5. Check condenser operation against rating 1. Reduce load or add additional equipment. 2. Check remote bulb. Regulate superheat. 1. Check for leaks. Repair and add charge. 2. Clean chemically. 3. Replace cartridge(s). 4. Clean strainers. 5. Check and reset for proper superheat. Replace if necessary. 6. Check P across evaporator. 7. Check means for regulating condensing temperature. 8. Adjust flow. Compressor Loading/Unloading Intervals Too Short Motor Overload Relays or Circuit Breakers Open 1. Erratic water thermostat. 2. Insufficient water flow. 1. Low voltage during high load conditions. 2. Defective or grounded wiring in motor or power circuits. 3. Loose power wiring. 4. High condensing temperature. 5. Power line fault causing unbalanced voltage. 6. High ambient temperature around the overload relay. 1. Replace 2. Adjust flow. 1. Check supply voltage for excessive line drop. 2. Replace compressor motor. 3. Check all connections and tighten. 4. See corrective steps for high discharge pressure. 5. Check Supply voltage. Notify power company. Do not start until fault is corrected. 6. Provide ventilation to reduce heat. Compr. Thermal Switch Open 1. Operating beyond design conditions. 1. Add facilities so that conditions are within allowable limits. Freeze Protection Opens 1. Thermostat set too low. 2. Low water flow. 3. Low suction pressure. 1. Reset to 42 F (6 C) or above. 2. Adjust flow. 3. See Low Suction Pressure. 44 TGZ040B - TGZ190B IM 1137

45 Maintenance Schedule I. Compressor A. Performance Evaluation (Log & Analysis) * O B. Motor Meg. Windings X Ampere Balance (within 10%) X Terminal Check (tight connections, porcelain clean) X Motor Cooling (check temperature) X C. Lubrication System Oil Level O X Oil Appearance (clear color, quantity) O Oil change if indicated by oil analysis X II. Controls A. Operating Controls Check Settings and Operation X B. Protective Controls Test Operation of: Alarm Relay X Pump Interlocks X High and Low Pressure Cutouts X III. Condenser B. Test Water Quality X C. Clean Condenser Tubes (or as required) X D. Eddycurrent Test - Tube Wall Thickness X E. Seasonal Protection X IV. Evaporator B. Test Water Quality X C. Clean Evaporator Tubes or plates ( as required) X D. Eddycurrent Test - Tube Wall thickness (shell & tube vessels) X E. Seasonal Protection X V. Expansion Valves A. Performance Evaluation (Superheat Control) X VI. Compressor - Chiller Unit A. Performance Evaluation O B. Leak Test: Compressor Fittings and Terminal X Piping Fittings X Vessel Relief Valves X C. Vibration Isolation Test X D. General Appearance: Paint X Insulation X VII. Starter(s) A. Examine Contactors (hardware and operation) X B. Verify Overload Setting and Trip X C. Test Electrical Connections X VIII. Optional Controls A. Hot Gas Bypass (verify operation) X Key: O = Performed by in-house personnel X = Performed by service personnel IM 1137 TGZ040B - TGZ190B A 45

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48 This document contains the most current product information as of this printing. For the most up-to-date product information, please go to All McQuay equipment is sold pursuant to McQuay s Standard Terms and Conditions of Sale and Limited Product Warranty. Consult your local McQuay Representative for warranty details. Refer to form Y. To find your local representative, go to (800) IM 1137 (10/11)