Catalog Cat Templifier-1 Templifier Heat Recovery Water Heaters Model TSC, Centrifugal, 3,000 to 24,000 MBH (880 to 7,000 kw) 1996 McQuay International
Table of Contents Introduction...3 Templifier Description...5 Model TSC Centrifugal...5 Application...10 General...10 Waste Heat Side...10 Water Heating Side...11 Controls...14 Environmental Impact...15 Economic Evaluation...16 Selection Procedure...17 Performance Data...18 Electrical Data...20 Physical Data...21 Dimensional Data...22 Sound Data...23 Options...23 Guide Specifications...25 Document Catalog Templifier-1 Issue Date November 2006 Replaces PM Templifier Manufactured in an ISO Certified Facility Initial Issue April 2000 "McQuay" is registered trademark of McQuay International 1996 McQuay International "Illustrations and information covers McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice" 2 Cat Templifier-1
Introduction What Is It? The Templifier Heat Pump Water Heaters are designed to economically turn waste heat into useful heat. They are nonreversible, water-to-water, Carnot cycle heat pumps utilizing centrifugal compressors and shell and tube heat exchangers. Waste heat is extracted from a fluid stream by cooling it in the evaporator, the compressor amplifies the temperature of the heat and the condenser delivers the heat to heating loads such as space heating and domestic hot water. Model TSC Templifiers are equipped with centrifugal compressors and are available in six different sizes, each with optional pass arrangements. Heating capacities range from 3,000 MBH to 24,000 MBH (880 to 7,000 kw) with hot water temperatures up to 140 F (60 C). How Does It Work? Commercial and institutional buildings throw away untold millions of BTUs of rejected heat from the air conditioning load to the atmosphere through their cooling towers. To obtain maximum efficiency from the chillers, the tower water temperature is maintained as low as possible (within certain operational limitations). The tower water temperature range of about 60 F to 95 F (15 C to 35 C) precludes the use of this warm water for other purposes such as domestic water and space heating. However, this heat can be recovered by cooling the stream of cooling tower waste heat in the Templifier evaporator. The waste heat is transferred to the refrigerant. The compressor increases the temperature and pressure of the refrigerant. This higher temperature heat is then transferred from the refrigerant to water flowing through the condenser and delivered to the heating load. Figure 1, Typical Templifier Flow Diagram COOLING TOWER HEATING LOAD SUPPLE- MENTAL HEATER 125 F (52 C) 135 F (57 C) CONDENSER 85 F (29 C) CONDENSER 95 F (35 C) EVAPORATOR 90 F (32 ) TEMPLIFIER 45 F (7 C) EVAPORATOR 55 F (13 C) CHILLER COOLING LOAD Cat Templifier-1 3
Where to Use Templifiers Building Types Applications Hotels/Motels Schools Space Heating Service Hot Water Health Care Food Service Outside Air Heating Laundries Athletic Facilities Nursing Homes Reheat Kitchens Resorts COP and the Multiplying Effect Coefficient of Performance (COP) is defined as the useful energy output of a Templifier divided by electric energy input, all expressed in the same units of measure. Put another way, 4 units of waste heat in, plus 1 unit of purchased electrical energy input equals 5 units of useful heat out - a COP of 5. Electric resistance heat has a COP of 1, buy 1 unit of electricity and you get one unit of heat out. In this example, the Templifier is 5 times more efficient. Why Consider a Templifier? The primary purpose of a Templifier is to heat water more economically than fossil fired boilers or electric resistance heaters. A secondary benefit is that a Templifier can off-load overloaded boilers and/or cooling towers thereby delaying or eliminating a capital expenditure required to increase their capacity. The Templifier is nothing more than an electric water heater with an attractive, higher COP than resistance heat, but it must be able to pay its own way by providing an acceptable Return On Investment (ROI) for the owner. Advantageous Job Conditions Certain job conditions will contribute to the economic viability of a Templifier: Relatively high fossil fuel costs and low electrical demand and energy costs. High heating and cooling load factors-a high number of hours of use. When recovering rejected heat from an air conditioning system, this means a long cooling season or high cooling internal loads. Heating requirements coincident with cooling load to minimize or eliminate storage requirements. Warm source water temperatures to maximize COP. 4 Cat Templifier-1
Templifier Description Model TSC Centrifugal The McQuay Centrifugal Compressor Templifier is based on the McQuay Distinction Series of water chillers in use around the world for over 40 years. Continuous research and development over this life span have produced one of the most efficient and reliable refrigeration machines available in the market today. Compressor Centrifugal compressor efficiency is a function of impeller design and application to the refrigeration system. McQuay gear drive centrifugal Templifiers provide a variety of tip speed ratios to permit selection of impellers for maximum efficiency over their entire part load to full load range and are ideal for 50 Hz application. Mechanical gear losses are limited by design standards to less than one-half of 1%. The variety of impeller speeds obtained by alternate gear selections make the McQuay compressor uniquely suited to the wide range of operating conditions encountered in heat pump water heating duty. The compressor can be specifically designed for job site conditions. A motor draws locked rotor current until it reaches approximately 80% of its running speed. While drawing locked rotor current the stresses on the motor are over six times that of full load. The McQuay compressors minimize this stress through the unique gear drive and light weight drive train that allows most compressors to reach running speed in less than six seconds. The motors are cooled by liquid refrigerant, a technique particularly well suited to heat pump duty. Lubrication System A separately driven electric oil pump assembly supplies lubrication at controlled temperature and pressure to all bearing surfaces and is the source of hydraulic pressure for the capacity control system. Figure 2, Lubrication System The control system will not allow the compressor to start until oil pressure at the proper temperature is established, and also allows the oil pump to operate after compressor shutdown to assure lubrication during coast down. Lubricant from the pump is supplied to the compressor through an external brazed-plate heat exchanger and internal 5 micron oil filter. All bearing surfaces are pressure lubricated. Drive gears are operated in a controlled lubricated mist atmosphere that efficiently cools and lubricates them. Lubricant is made available under pressure from the compressor oil filter to the unit capacity control system and is used to position the inlet guide vanes in response to changes in leaving condenser water temperature. If a power failure occurs, an emergency oil reservoir provides lubrication flow under pressure and prevents damage that could occur during the spin down period with the oil pump stopped. Cat Templifier-1 5
Shell-and-Tube Heat Exchangers McQuay Templifiers are equipped with new high performance heat exchangers. The unique design greatly increases heat transfer and reduces unit footprint and refrigerant charge compared to previous designs. In many cases vessel length has been reduced by 40 percent. Templifiers are designed, constructed and tested in accordance with ASME Section VIII and ASHRAE Standard 15 requirements. The replaceable water tubes are internally and externally enhanced copper and are mechanically bonded to steel tube sheets. Standard tubes are 0.025 inch wall copper in the evaporator and condenser. Optional tubes include 0.028 inch and 0.035 inch in either vessels and 90/10 cupro-nickel, 304 stainless steel or titanium material. Clad tube sheets and epoxy coated heads are included when other than copper tubes are specified. Both vessels are available for 1, 2 or 3 pass water flow. A 3/4" thick vinyl/nitrate polymer condenser insulation is standard. All seams are glued to form an effective vapor barrier. Pumpdown Pumpout systems provide a means to collect and contain the refrigerant charge with minimum loss, when the access to internal components is required for service. McQuay condensers are sized to hold the entire unit refrigerant charge when not more than 90% full at 90 F (32 C) ambient temperature. They are equipped with a tight-seating check valve at the hot gas inlet and a manual shutoff valve in the liquid outlet. These valves, coupled with the condenser design, satisfy the stringent requirements of the U.S. Department of Transportation for refrigerant shipping containers, as well as ASME vessel codes. When service is required, the refrigerant charge may be pumped down into the condenser by compressor operation and use of a refrigerant transfer unit. Elimination of the cost and space requirements of an external pumpout system is a major McQuay advantage. Templifiers Feature MicroTech II Controls McQuay has incorporated the latest microprocessor technology into the MicroTech II control system to give you the ultimate in unit control. The control includes many energy-saving features to keep your unit running efficiently. day in, day out, for years to come. Figure 3, Unit Controller and Operator Interface Touch Screen The unit controller and operator interface touchscreen mounted on a Templifier unit are shown to the right. The 12-inch VGA touch screen is on an adjustable arm so that it can be positioned comfortably for each operator. The unit control panel contains a USB port from which trend data and manuals can be conveniently downloaded. All-important unit operating data is easily accessed and viewed. Password protected unit setpoints, complete with description and setting range, are available at the touch of a screen. 6 Cat Templifier-1
Figure 4, Compressor Controller A major feature of the MicroTech II controller, as applied to water heaters, is the distributive control scheme. The picture to the right shows the compressor control panel (with cover removed) mounted at the rear of the unit, adjacent to the compressor itself. This panel also contains the oil pump contactor and overload. Also on the plan (control network) is the unit controller and operator interface touch screen. If the interface touch screen and/or unit controller is out of service, the uinit can continue to operate on the compressor controller alone. This feature provides unprecedented reliability in a control system. MicroTech II Features and Benefits FEATURE Easy integration into a building management system via McQuay s exclusive Protocol Selectability feature. Easy to read, adjustable, 12-inch, Super VGA color touchscreen operator interface Historic trend data-can be downloaded from a USB port Precise ± 0.2 F chilled water control Proactive pre-shutdown correction of unusual conditions allows unit to stay online Automatic control of hot water and source water pumps, if desired Twenty-five previous alarm descriptions are stored in memory Multiple language capability Metric or in-lb units of measure BENEFIT Designer can to select any BAS supplier using industry standard protocols and know the MicroTech II control will easily interface directly with it. Operators can observe chiller operation at a glance, easily select various detail screens and change setpoints Water temperatures, refrigerant pressures, and motor load plots can provide valuable unit operation data Provides stability in chilled water system Activates alarm and modifies chiller operation to provide maximum possible cooling Integrated lead/lag and automatic engagement of backup pump Invaluable asset in troubleshooting Great asset for world-wide applications Designed with the System Operator in Mind Reliable, economic use of any unit depends largely on an easy operator interface. That s why operation simplicity was one of the main considerations in the development of the MicroTech II controller. The operator interface with the unit is a 12-inch, Super VGA color touch-screen. The operator can clearly see the entire unit graphically displayed, with key operating parameters viewable on the screen. Other screens, such as alarm history and set points, are easily accessed through touch screen buttons. Cat Templifier-1 7
We have even gone as far as installing the unit operating and maintenance manual, as well as the parts list, in the chiller s microprocessor memory, so that they are viewable on the touchscreen or can be downloaded to a computer through the onboard USB port. Proactive Control By constantly monitoring unit status, the MicroTech II controller will automatically take proactive measures to relieve abnormal conditions or shut the unit down if a fault occurs. For example, if a problem occurs in the source water and suction pressure starts to rise, the controller will automatically hold the load point and activate an alarm signal. A further drop in pressure will initiate compressor unloading in an effort to maintain the setpoint pressure. If the pressure continues to drop, the unit will shut off at the cutout pressure setting. Alarm History for Easy Troubleshooting The MicroTech II controller's memory retains a record of faults and a time/date stamp. The controller's memory (no batteries required) can retain and display the cause of the current fault and the last twenty-five fault conditions. This method for retaining the fault is extremely useful for troubleshooting and maintaining an accurate record of unit performance and history. The MicroTech II controller features a three-level password security system to provide protection against unauthorized use. Figure 5, MicroTech II Controller Home Screen The Home Screen shown above is the primary viewing screen. It gives real time data on unit status, water temperatures, chilled water setpoint and motor amp draw. This display answers the vital question-is the chiller doing what it is supposed to be doing? 8 Cat Templifier-1
If an alarm occurs, a red button appears on the screen (a remote signal is also available). Pressing this button accesses the Active Fault Screen that gives complete fault information. The fault can be quickly and easily cleared at this point. Changing Setpoints Changing setpoints is easy with the McQuay MicroTech II control. For example, to change the hot water set point, press SET from any screen, then press the WATER button and this screen appears, press button #1, Leaving Water Temperature, and you are ready to input a password and then a new value. Trend Logging Ever wonder how your unit performed last week? Were you holding the correct hot water temperature? What kind of heating load did the chiller have? The McQuay MicroTech II controller can provide the answers, thanks to its huge memory, and plot water temperatures, refrigerant pressures, and motor load data. These values can also be downloaded through a convenient USB port, located in the unit control panel, and pasted into a spreadsheet for archiving or further detailed evaluation. MicroTech II Controller Increases Chiller Operating Economy Many standard features have been incorporated into MicroTech II control in order to maintain the operating economy of McQuay Templifiers. In addition to replacing normal relay logic circuits, we ve enhanced the controller's energy saving capabilities with the following features: User-programmable compressor soft loading. Prevents excessive power draw during pull down from high chilled water temperature conditions. Demand limit control. Maximum motor current draw can be set on the panel, or can be adjusted from a remote 4-20ma or 1-5 VDC BAS signal. This feature controls maximum demand charges during high usage periods. Plotting Historic Trends. Past operation of the chiller can be plotted as trend lines and even downloaded to spread sheets for evaluation - a valuable tool for optimizing efficiency. Cat Templifier-1 9
Application General A Templifier unit is controlled by the heating load as sensed at either the entering or leaving hot (condenser) water temperature. The amount of cooling done in the evaporator is uncontrolled and is a result of the amount of cooling required to meet the heating load. If there is insufficient waste heat for the unit to meet the heating load, the Templifier will begin to pull down the waste heat temperature, i.e. the evaporator water temperature will drop. Templifiers are equipped with a low source water temperature over-ride control feature. The control unloads the unit to prevent the leaving evaporator temperature from falling below a predetermined setpoint. This occurrence basically means that there is insufficient waste heat to support the heat load requirements. Consequently the hot water temperature will fall since the heating load is larger than the Templifier's reduced output. Supplementary heat is activated at this point to make up the heat difference. This is an important concept. The heating load requirements over time, the concurrent availability of waste heat, and the size and control of a supplementary heat must be coordinated. Waste Heat Side Cooling Tower Water Most commercial and institutional heat pump applications use condenser outlet water for a heat source. Some points to remember: The condenser water from the air conditioning system (waste heat source) is from an open system using treated water. This water flows through the tube side of the evaporator of a centrifugal Templifier (Model TSC) and is subject to the same fouling (and attendant required maintenance) as a chiller condenser. The Templifier will often utilize only a portion of the entire tower water flow and require a bypass during normal operation. It is recommended that all installations have a tower water bypass around the Templifier evaporator so that the chiller plant can remain operational in the event of Templifier evaporator servicing. (See Figure 1.) Cooling tower systems are usually designed with 95 F (35 C) entering to 85 F (29.4 C) leaving water temperatures. These temperatures will vary somewhat in areas with unusually high or low wet bulb temperatures. Air conditioning chillers are then designed to operate in this environment as the worst or most severe condition. The cooling tower water temperature is allowed to drop as lower wet bulb temperatures become available. This is good practice since chiller efficiency improves. Important Note: These lower than design condenser water temperatures must be accounted for when selecting a Templifier. The Templifier must be selected to operate at the lowest expected water temperature leaving the air conditioning condenser during Templifier operation. However, the COP used for economic evaluations should be based on a weighted average source water temperature. 10 Cat Templifier-1
Geothermal, Warm Ground Water Sufficient quantities of warm ground water are available in some locations to act a heat source. To maximize COP, use as high a quantity of ground water as possible considering the following: Flow capability of the Templifier evaporator. Quantity of water available and disposal considerations. Pump power Ground water may contain: Particulate matter (sand, mud) that should be filtered out Corrosive elements that may require special evaporator materials or an intermediate heat exchanger High mineral content that can cause scaling. This will require a de-scaling maintenance program or an intermediate heat exchanger as shown in Figure 6. Figure 6, Intermediate Heat Exchanger Solar Collectors Templifiers can be mated with solar collector arrays to great advantage. The collectors do not have to be designed to provide the required use temperature. Instead, the collectors provide heat to the Templifier evaporator and the Templifier amplifies the solar heat to the use temperature. This allows utilizing solar heat as low 50 F (10 C) to provide hot water output up to 140 F (60 C) for TSC units. This temperature amplification reduces the number of expensive collectors required and/or allows more BTUs to be collected from an existing array. Water Heating Side General recommendations for the hot water side of the Templifier system: The lowest possible hot water temperature should be selected in order to maximize the unit COP. Booster heaters should be employed for open systems such as laundry or dishwashing water that have temperature requirements higher than the Templifier's capability. Supplementary heaters are usually required in case the heat pump is unavailable or there is insufficient waste heat available. Templifiers can be controlled by either the entering or leaving hot water temperature. Higher COPs and better unloading can be achieved when the entering water temperature is controlled. This method is especially recommended for space heating where it essentially provides hot water reset since the hot water temperature to the heating load decreases as the load decreases. Cat Templifier-1 11
Service Hot Water Service hot water system will invariably use a storage tank due to the large variation in demand. Large buildings will use a recirculating hot water system to provide instant hot water at the point of use. The Templifier can be incorporated into the system as shown in Figure 7. Temperature control should be on the leaving water temperature in order to maintain tank temperature. The tank temperature should be as low as possible, usually 120 F (49 C) for lavatory, tub, and shower use and 140 F (60 C) for kitchen use. Supplementary/standby heat should be provided in case the Templifier is off-line or there is insufficient source heat to maintain the setpoint temperature. A Templifier used for both service water heating and space heating should employ an intermediate heat exchanger between the service water system and the unit. Some local codes may require an additional heat transfer surface (heat exchanger) between the refrigerant and potable water. Figure 7, Service Hot Water T-C 140 F (60 C) HEAT SOURCE CONDENSER EVAPORATOR TEMPLIFIER OUTPUT 140 F (60 C) STORAGE TANK 140 F (60 C) RETURN / MAKEUP STANDBY / AUXILIARY HEAT Space Heating/Reheat A key consideration on space heating applications is the simultaneous occurrence of a heating load and the availability of waste heat presumably from the air conditioning system. This condition usually occurs in buildings with a large core zone and buildings using reheat or multizone air handlers. Water source heat pumps can provide an excellent Templifier environment and are treated in a separate section. Return water control is usually used on space heating applications. By holding the condenser entering temperature constant, the leaving water temperature going to the load will decrease with decreasing heating load. Care must be exercised in placement of the supplemental heater temperature sensor so that the heater does not override the Templifier. See Figure 8. Figure 8, Return Water Control 12 Cat Templifier-1
Outside Air Heating Templifiers are well suited to heating outside air because of the relatively low air temperature requirements. It is imperative that precautions be taken to prevent freezing the coil. Even though mixed air temperatures can be above freezing or even at setpoint shutting off water flow, cold air can stratify at the bottom of the heating coil and freeze the coil. Figure 9, Outside Air Heating Figure 9 illustrates a method of using a continuously running small circulating pump and three-way valve (twoway valve can also be used) to provide full water flow to the coil at all times. The flow switch overrides normal control and throws the control valve to full open preventing freeze-up. Overheating of the air will result. Power failure or operator error can defeat this protective arrangement. Water-Loop Heat Pump Systems Unitary water-source heat pumps (WSHP) in closed water loops have proven to be a flexible and efficient system for many buildings, especially offices, schools, health care facilities and hotels. These systems should be balanced in regard to the disposition of heat, i.e. not throwing away any heat that can be recovered and used somewhere, somehow in the building. Furthermore, when there is truly excess heat, thought should be given to storing it for later use. Typically, excess heat can be generated during the day and used at night when the net building load requires heat input. The Templifier can be used to advantage in WSHP systems by recovering low grade heat that would otherwise be rejected and increasing its temperature to a useful level. This high grade heat can be: Stored up to 140 F (60 C) for TSC units during periods of excess heat, usually daytime hours, and used as a heat source when heat input into the system is required, usually at night. A conventional storage tank in the main loop has to be excessively large since it is limited to the min/max loop temperature, usually 60 F to 90 F (15 C to 32 C). Used instantaneously for other building heating loads such as domestic hot water, reheat, and make-up air heating. Figure 10 illustrates how to place the Templifier Heat Pump in the WSHP system. Controls are usually set so that: The water heater will come on to control a minimum of 60 F (15 C) loop temperature. The heat rejection device will come on to control a maximum of 90 F (32 C) loop temperature. The Templifier will cycle and load in response to its heating load but also have an evaporator leaving water temperature override to prevent cooling the loop below 63 F (17 C). This eliminates the possibility of the Templifier subcooling the loop below the minimum loop temperature. Cat Templifier-1 13
Figure 10, Water Source Heat Pump System Controls Templifiers are controlled by the heating load as sensed by changes in the entering or leaving condenser water temperature. Usually on space heating applications and anywhere else possible, the sensor should be in the entering condenser water. The entering temperature is held constant and the leaving temperature floats with the load. Thus at low loads the leaving condenser water temperature is low and the head imposed on the compressor is minimized. This maximizes the unit COP and provides a more stable environment for centrifugal compressor operation. Templifiers provide heat to a heating load by extracting heat from a waste heat stream by cooling it. If there is insufficient waste heat with respect to the heating load, the temperature of the waste stream will be driven down, perhaps to unacceptable levels. For example, cooling tower water could be lowered to a point where the chillers will not operate properly and the air conditioning compromised. This is not acceptable. To avoid this, Templifiers are equipped with a source water temperature override control feature. The MicroTech control senses the leaving evaporator water temperature and unloads the Templifier when the override setpoint is reached. This decreases the unit's heating capability, the hot water loop temperature will start to drop, and the auxiliary heater will come on to make up the capacity difference. The Templifier is saying, "there is insufficient source heat for me to meet the heating load. I'm doing all I can but will need help from the auxiliary heater". 14 Cat Templifier-1
Environmental Impact The environmental impact of any process or equipment is vitally important today and will continue to be in the future. Templifier Heat Pump Water Heaters have some distinct advantages when it comes to their effect on our environment. Environmental impact is measured in several ways: ODP-Ozone Depletion Potential; measures the impact of a substance on the depletion of the ozone layer in the upper atmosphere. With refrigerants, this action is caused by chlorine. HFC-134a contains no chlorine and has a zero ODP. GWP-Global Warming Potential; measures the contribution of a substance to the greenhouse gas effect which causes global warming. This is a pound to pound comparison, discounting the application of the substance and any other effects caused by its use. The number, relative to CO 2 for a 100 year integration time horizon is HFC- 134a=1300. TEWI-Total Equivalent Warming Impact; is a combination of the refrigerant GWP, unit refrigerant emissions rate, and the refrigeration system s energy efficiency. Science has agreed that a systems approach is necessary to evaluate the real effect of a substance on global warming. This is TEWI. In a Templifier, the contribution of the refrigerant GWP is insignificant when compared to the effect of a unit s power needs translated to power plant CO 2 emissions. The percentages shown on the right will vary slightly depending on unit refrigerant loss and on the efficiency of local power generation. Equipment operators should keep equipment leak free (minimize the 2% segment) and operate as efficiently as possible (minimize the 98% segment). The significant influence in establishing the TEWI of a hot water plant is the system used to produce the heat, as illustrated in the following examples. Compare the fuel burned (products of combustion) to produce one million BTUs of hot water at 120 F. Electrical Resistance Heater 6 6 Heater 293 kw T & D 308 kw Power 3 x 10 BTU 100% Eff. 10 BTU Hot Water Network 95% Eff. Plant 35% Eff. Fuel Use On-Site Fossil-Fired Boiler 6 6 Boiler 1.25 x 10 BTU 10 BTU Hot Water 80% Annual Eff. Fuel Use Templifier 6 Templifier T & D Power 6 42 kw 44 kw.43 x 10 BTU COP = 7 10 BTU Hot Water Waste Heat 6.78 x 10 BTU Network 95% Eff. Plant 35% Eff. Fuel Use Compared to a Templifier, a resistance heater burns seven times the fuel quantity and an on-site boiler consumes three times the amount. The Templifier is a clear winner when it comes to keeping the planet green. Cat Templifier-1 15
Economic Evaluation Introduction Since Templifiers are often purchased on the basis of their economic viability, economic evaluations should be as accurate as possible. The annual heat output of the Templifier depends on the heating load profile and the coincident availability of waste heat, usually from the chilled water plant condenser water. Evaluation Data The following information will assist in making a reliable evaluation: The daily heating load profile. The cooling load profile as far as the availability of waste heat from the air conditioning system's condenser water. The temperature of the condenser water is important. During periods of cool ambient temperatures the cooling tower will supply water colder than design conditions. The Templifier will consequently be operating with source water at lower than design temperature. This will result in a lower COP for the Templifier but a better efficiency for the chiller which usually has the larger electric load. The COP will usually be fluctuating over the course of the day and season. When the cooling load is large compared to the Templifier waste heat requirement, a cursory examination may be sufficient. The cost of fossil fuel used to fire the boiler that the Templifier will be replacing (or electricity if resistant heaters are used). The cost of electricity to operate the Templifier. The Templifier installed cost. If the need for other equipment (such as additional cooling tower or boiler) is eliminated because of the Templifier, the avoided cost saving should be credited against the Templifier cost. Financial information such as actual tax rate, cost of capital, analysis period and the owner's threshold payback or Return on Investment. 16 Cat Templifier-1
Selection Procedure Due to the large number of centrifugal component combinations available, units are selected on a computer program. The selections contained in Table 1 (60 Hertz) and Table 2 (50 Hertz) are for the specific flows and temperatures shown. The indicated performance is correct for these conditions and can also serve as an approximate guide for other conditions of service. The ratings are based on entering evaporator source water temperature, not leaving. Both evaporator and condenser are based on an approximate 10 degree F temperature range. 1. If job conditions have more source water available than the quantity show in the TSC Performance Tables, the evaporator leaving water temperature will be higher than used for the selection and the unit COP will improve. 2. If job conditions have less source water available than the quantity show in the TSC Performance Tables, the evaporator leaving water temperature will be lower than used for the selection and the unit COP will be lower than that shown. 3. If job conditions have hot condenser water flows within about 50% of the quantities shown, the unit performance will be close to that shown. Water pressure drops for the heat exchangers and flows shown in the Performance Tables are all less than 10 psi. Consult the local McQuay sales office for unit performance outside that given in the Performance Tables. Cat Templifier-1 17
Performance Data Table 1, Heating Capacities and Heating COP, 60 Hz Compressor Vessel Flow Gpm Entering Source Temp. F TSC063 75 E2612-CE 800 85 C2212-CN 1100 95 TSC079 75 E3012-BE 1300 85 C2612-DN 1400 95 TSC087 75 E4212-CE 2100 85 C3612-CN 2200 95 TSC100 75 E4212-BE 3000 85 C3612-CN 3400 95 TSC126 75 E4812-CE 3700 85 C3612-BN 4000 95 Heating Capacity Tons Condenser Leaving Hot Water Temperature 110 F 120 F 130 F 140 F Input kwi COP Heating Capacity Tons Input kwi COP Heating Capacity Tons Input kwi COP Heating Capacity Tons MAU 20U (RLA=248 Amps) MAR 35U (RLA=383 Amps) MAP 35U (RLA=439 Amps) JAL 35U (RLA=441 Amps) 333.0 153.0 7.6 397.0 224.5 6.2 386.0 259.5 5.2 314.0 260.9 4.2 MAU 20U (RLA=257 Amps) MAR 35U (RLA=438 Amps) MAQ 35U (RLA=438 Amps) JAL 35U (RLA=441 Amps) 394.0 158.9 8.7 492.0 259.2 6.6 441.0 259.2 5.9 338.0 260.9 4.5 MAU 20U (RLA=251 Amps) MAR 35U (RLA=438 Amps) MAQ 35U (RLA=438 Amps) JAL 35U (RLA=441 Amps) 437.0 155.9 9.8 542.0 259.1 7.3 490.0 259.6 6.6 364.0 261.1 4.9 LBA 35U (RLA=451 Amps) LAY 47U (RLA=560 Amps) LAV 49U (RLA=605 Amps) LAV 49U (RLA=605 Amps) 551.0 266.7 7.2 578.0 335.7 6.0 528.0 368.9 5.0 472.0 369.3 4.4 LBA 35U (R;A=464 Amps) LAY 47U (RLA=590 Amps) LAV 49U (RLA=605 Amps) LAV 49U (RLA=604 Amps) 632.0 274.9 8.0 669.0 354.5 6.6 567.0 369.2 5.4 502.0 369.5 4.7 LBA 35U (RLA=457 Amps) LAY 47U (RLA=578 Amps) LAV 49U (RLA=605 Amps) LAV 49U (RLA=605 Amps) 693.0 270.3 9.0 722.0 347.3 7.3 598.0 369.7 5.6 523.0 370.2 4.9 MBE 49U (RLA=629 Amps) MBC 57U (RLA=701 Amps) MBA 66U (RLA=701 Amps) 841.0 383.4 7.7 799.0 419.2 6.7 670.0 419.2 5.6 Input kwi No Selection MBE 57U (RLA=701 Amps) MBC 57U (RLA=701 Amps) MBA 66U (RLA=700 Amps) MAW 66U (RLA=701 Amps) 996.0 419.0 8.3 903.0 419.7 7.5 743.0 419.3 6.2 446.0 420.0 3.7 MBE 57U (RLA=701 Amps) MBD 57U (RLA=702 Amps) MBA 66U (RLA=700 Amps) MA2 66U (RLA=700 Amps) 1102.0 419.4 9.2 1015.0 420.5 8.4 789.0 419.6 6.6 495.0 420.2 4.1 MBK 73U (RLA=941 Amps) MBH 85U (RLA=1098 Amps) MBG K0U (RLA=1165 Amps) MBE N2U (RLA=1384 Amps) 1225.0 569.5 7.5 1249.0 667.3 6.5 1154.0 714.7 5.6 1122.0 821.6 4.8 MBK 73U (RLA=936 Amps) MBH K0U (RLA=1167 Amps) MBG K0U (RLA=1278 Amps) MBE N2U (RLA=1501 Amps) 1400.0 567.2 8.6 1499.0 716.1 7.3 1405.0 780.7 6.3 1344.0 893.5 5.2 MBK 73U (RLA=913 Amps) MBH K0U (RLA=1214 Amps) MBG K0U (RLA=1246 Amps) MBE N2U (RLA=1500 Amps) 1538.0 554.6 9.7 1709.0 744.0 8.0 1533.0 762.8 7.0 1482.0 893.7 5.8 MBT N2U (RLA=1291 Amps) MBR N3U (RLA=1523 Amps) MBP N3U (RLA=1523 Amps) MBL N3U (RLA=1523 Amps) 1634.0 760.4 7.5 1615.0 890.0 6.3 1365.0 890.9 5.3 1072.0 891.3 4.2 MBT N2U (RLA=1483 Amps) MBR N3U (RLA=1523 Amps) MBP N3U (RLA=1523 Amps) MBL N3U (RLA=1523 Amps) 1988.0 881.2 7.9 1809.0 890.6 7.1 1520.0 891.3 5.9 1088.0 891.9 4.2 MBT N2U (RLA=1501 Amps) MBR N3U (RLA=1523 Amps) MBP N3U (RLA=1523 Amps) MBL N3U (RLA=1523 Amps) 2219.0 892.4 8.7 2004.0 591.3 11.6 1639.0 891.9 6.4 1041.0 892.9 4.0 NOTES: 1. Capacity in condenser tons 2. COP=(condenser tons)(12,000) / (kw)(3415) 3. Evaporator tons=(cop-1 / COP)(condenser tons) 4. Delta-T=(tons)(24) / GPM 5. Alpha characters in table such as MBT N2U are compressor and motor ordering codes. COP 18 Cat Templifier-1
Table 2, Heating Capacities and Heating COP, 50 Hz Compressor Vessel Flow Gpm Evaporator Entering Source Temp. F ( C) TSC063 75 (23.9) E2612-CE 800 85 (29.4) C2212-CN 1100 95 (35.0) TSC079 75 (23.9) E3012-BE 1300 85 (29.4) C2612-DN 1400 95 (35.0) TSC087 75 (23.9) E4212-CE 2100 85 (29.4) C3612-CN 2200 95 (35.0) TSC100 75 (23.9) E4212-BE 3000 85 (29.4) C3612-CN 3400 95 (35.0) TSC126 75 (23.9) E4812-CE 3700 85 (29.4) C3612-BN 4000 95 (35.0) Heating Capacity Tons Condenser Leaving Hot Water Temperature 110 F (43.3 C) 120 F (48.9 C) 130 F (54.4 C) 140 F (60.0 C) Input kwi COP Heating Capacity Tons Input kwi COP Heating Capacity Tons Input kwi COP MAN20F (RLA=265 Amps) MAK31F (RLA=367 Amps) MAH35F (RLA=442 Amps) 349.0 156.0 7.866 390.0 213.8 6.414 386.0 253 5.364 Heating Capacity Tons Input kwi No Selection MAN20F (RLA=272 Amps) MAK31F (RLA=383 Amps) MAH35F (RLA=444 Amps) MAG35F (RLA=417 Amps) 408.0 160.0 8.966 453.0 223.8 7.117 438.0 253.7 6.070 349.0 238.1 5.154 MAN20F (RLA=265 Amps) MAK31F (RLA=375 Amps) MAH35F (RLA=440 Amps) MAG35F (RLA=436 Amps) 453.0 156.4 10.184 496.0 219.1 7.960 478.0 251.6 6.680 400.0 249.5 5.637 LAU41F (RLA=438 Amps) LAR45F (RLA=555 Amps) LAR49F (RLA=582 Amps) LAP49F (RLA=621 Amps) 545.0 253.6 7.556 579.0 331.5 6.141 525.0 332.1 5.558 476.0 357.2 4.685 LAU41F (RLA=490 Amps) LAR49F (RLA=618 Amps) LAR49F (RLA=619 Amps) LAP49F (RLA=622 Amps) 663.0 285.7 8.159 679.0 354.6 6.733 615.0 355.7 6.079 507.0 357.7 4.984 LAU41F (RLA=479 Amps) LAR49F (RLA=620 Amps) LAR49F (RLA=616 Amps) LAP49F (RLA=613 Amps) 728.0 279.2 9.168 744.0 355.9 7.350 668.0 354.3 6.629 516.0 352.1 5.153 MAW57F (RLA=679 Amps) MAW57F (RLA=678 Amps) MAU62F (RLA=681 Amps) 882.0 396.9 7.813 784.0 396.9 6.945 664.0 403.1 5.792 No Selection MAW57F (RLA=679 Amps) MAW57F (RLA=679 Amps) MAU62F (RLA=681 Amps) MAQ62F (RLA=688 Amps) 983.0 397.1 8.704 889.0 397.3 7.867 739.0 403.3 6.443 468.0 407.7 4.036 MAW57F (RLA=679 Amps) MAW57F (RLA=679 Amps) MAU62F (RLA=681 Amps) MAQ62F (RLA=688 Amps) 1074.0 397.2 9.507 981.0 397.4 8.679 795.0 403.4 6.929 458.0 407.6 3.951 MBC85F (RLA=964 Amps) MBCN0F (RLA=1037 Amps) MBAN0F (RLA=1183 Amps) MB2N1F (RLA=1438 Amps) 1273.0 570.9 7.840 1122.0 576.1 6.848 1124.0 669.8 5.900 1139.0 825.5 4.851 MBC85F (RLA=1030 Amps) MBCN0F (RLA=1166 Amps) MBAN0F (RLA=1327 Amps) COP MA2N1F (RLA=1426 Amps) 1510.0 608.5 8.725 1432.0 659.2 7.638 1410.0 756.2 6.556 1256.0 818.5 5.395 MBCN0F (RLA=1155 Amps) MBCN0F (RLA=1233 Amps) MBAN0F (RLA=1302 Amps) MA2N1F (RLA=1387 Amps) 1757.0 652.5 9.468 1685.0 700.3 8.460 1543.0 742.2 7.310 1326.0 796.6 5.853 MBKN2F (RLA=1530 Amps) MBKN2F (RLA=1530 Amps) MBHN2F (RLA=1531 Amps) MBEN2F (RLA=1530 Amps) 1795.0 863.8 7.306 1619.0 863.9 6.589 1370.0 864.8 5.570 1093.0 865 4.443 MBKN2F (RLA=1530 Amps) MBKN2F (RLA=1530 Amps) MBHN2F (RLA=1530 Amps) MBEN2F (RLA=1510 Amps) 1990.0 863.8 8.100 1818.0 864.4 7.395 1537.0 864.9 6.248 1099.0 853.7 4.526 MBKN2F (RLA=1530 Amps) MBKN2F (RLA=1531 Amps) MBHN2F (RLA=1531 Amps) MBEN2F (RLA=1530 Amps) 2215.0 864.4 9.010 2014.0 865 8.186 1668.0 865.4 6.777 1085.0 865.7 4.407 NOTES: 1. Capacity in condenser kw thermal 2. COP=(condenser kw output) / (compressor kw input) 3. Evaporator kw=(cop-1 / COP)(condenser kw) 4. Delta-T=kW / (4.18 x L/s) 5. Alpha characters in table such as MBkN2F are compressor and motor ordering codes. Cat Templifier-1 19
Electrical Data Figure 11, TSC Field Wiring Diagram 20 Cat Templifier-1
Physical Data Table 3, TSC 063 - TSC 126 TSC UNIT SIZE TSC 063 TSC 079 TSC 087 TSC 100 TSC 126 COMPRESSOR Model CE 063 CE 079 CE 087 CE 100 CE126 Number 1 1 1 1 1 Motor Speed 60/50 Hz 3550/2960 3550/2960 3550/2960 3550/2960 3550/2960 CONDENSER Diameter/Length in./ft 22/12 26/12 36/12 36/12 36/12 mm/mm 559/3658 660/3658 914/3658 914/3658 914/3658 Water Volume gal. (l) 76 (290) 111 (419) 234 (884) 234 (884) 234 (884) 2 Pass Connection Size in (mm) 8 (203) 8 (203) 12 (305) 12 (305) 12 (305) Working Press-Water, psi (kpa) 150 (1034) 150 (1034) 150 (1034) 150 (1034) 150 (1034) Working Press-Refrig, psi (kpa) 300 (2070) 300 (2070) 300 (2070) 300 (2070) 300 (2070) EVAPORATOR Diameter/Length in./ft 26/12 30/12 42/12 42/12 48/12 mm/mm 660/3658 762/3658 1067/3658 1067/3658 1219/3658 Water Volume gal. (l) 72 (273) 101 (381) 222 (841) 222 (841) 327 (1237) 2 Pass Connection Size in (mm) 8 (203) 10 (254) 14 (356) 14 (356) 18 (457) Working Press-Water, psi (kpa) 150 (1034) 150 (1034) 150 (1034) 150 (1034) 150 (1034) Working Press-Refrig, psi (kpa) 200 (1380) 200 (1380) 200 (1380) 200 (1380) 200 (1380) DIMENSIONS Length in. (mm) 169 (4293) 175 (4445) 175 (4445) 175 (4445) 175 (4445) Width w/ Starter in. (mm) 61 (1549) 71 (1803) 101 (2565) 107 (2718) Width w/o Starter in. (mm) 46 (1168) 56 (1422) 86 (2184) 86 (2184) 80 (2032) Height in. (mm) 80 (2032) 88 (2235) 111 (2819) 99 (2515) 99 (2515) WEIGHTS (w/ Starter) Shipping lb (kg) 12777 (5796 15835 (7183) 24657 (11170) 27657 (13545) 33224 (15070) Operating lb (kg) 14017 (6358) 17501 (7938) 28460 (12892) 31460 (14270) 38823 (17610) WEIGHTS (w/o Starter) Shipping lb (kg) 11577 (5251) 14635 (6638) 23457 (10626) 26457 (12001) 32024 (14526) Operating lb (kg) 12517 (5678) 16301 (7394) 27260 (12349) 30260 (13726) 37623 (17066) Cat Templifier-1 21
Dimensional Data TSC MODEL TSC063/E2612/C2212 TSC079/E3012/C2612 TSC087/E4212/C3612 TSC100/E4212/C3612 TSC126/E4812/C3612 OVERALL LENGTH WIDTH CONNECTIONS CENTER OF 1&3 2 HEAD CONN HEIGHT W/O FOOTPRINT GRAVITY EVAP COND PASS PASS BOTH ENDS STARTER 2 2 A A A B C X Y Z D E F G PASS PASS 169 164 169 80 48 69 38 21 148 145 48 40 (4293) (4166) (4293) (2032) (1219) (1753) (965) (533) (3759) (3683) (1219) (1016) 8 8 175 168 175 88 56 70 41 25 148 145 56 48 (4445) (4267) (4445) (2235) (1422) (1778) (1041) (635) (3759) (3683) (1422) (1219) 10 8 175 168 175 105 86 69 45 35 148 145 86 78 (4445) (4267) (4445) (2667) (2184) (1753) (1143) (889) (3759) (3683) (2184) (1981) 14 12 175 170 175 99 86 69 46 35 148 145 86 78 (4445) (4318) (4445) (2515) (2184) (1753) (1168) (889) (3759) (3683) (2184) (1981) 14 12 181 175 181 106 104 70 46 46 145 145 104 96 (4597) (4445) (4597) (2692) (2642) (1778) (1168) (1168) (3683) (3683) (2642) (2438) 18 14 22 Cat Templifier-1
Sound Data Within a given size family the sound levels of McQuay Templifiers will vary as a function of impeller speed and other variables. The sound data in Table 4 is representative of the units shown and is the highest sound level expected for the TSC family size. The Range is the difference in sound level between the values shown and the lowest sound level expected for the unit size. Table 4, Sound Pressure at One Meter from Unit Envelope TSC Octave Band Sound Pressure Levels Per ARI Standard 575 (db) Overall "A" Model 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz Weighted Range 063 71 69 71 73 77 78 80 73 85-3 079 71 69 72 76 80 83 83 78 88-4 087 72 76 79 83 87 90 90 86 95-9 100 71 70 73 77 81 84 84 79 89-2 126 71 74 77 81 86 89 89 84 94-6 Options Vessels Marine water boxes Provides tube access for inspection, cleaning, and removal without dismantling water piping. Flanges (victaulic standard) ANSI raised face flanges on either the evaporator or condenser. Mating flanges are by others. 0.028 or 0.035 in. tube wall thickness For applications with aggressive water conditions requiring thicker tube walls. Cupro-nickel or titanium tube material For use with corrosive water conditions, only available with clad tube sheets. Water side vessel construction of 300 psi (150 psi is standard) For high pressure water systems, typically high-rise building construction. Water flow or differential pressure switches A proof of flow device is mandatory in the water system. They can be field supplied, mounted and wired. This option provides them as a factory mounted and wired option. Double insulation, 1 ½ inch, on evaporator, suction piping, and motor barrel For high humidity locations and ice making applications. Electrical Optional starters for factory or field mounting See details in the Motor Starter section of this manual. NEMA 4 watertight enclosure For use where there is a possibility of water intrusion into the control panel. Cat Templifier-1 23
NEMA 12 Dust tight enclosure For use in dusty areas. Controls English or Metric Display Either English or metric units for operator ease of use. Modem for remote monitoring Includes the modem required for remote monitoring one or more units. Requires Monitor software. Monitor software Required for installation in a PC to complete remote monitoring capability. Unit Export packaging Can be either slat or full crate for additional protection during shipment. Units normally shipped in containers. Pumpout Unit Available in 1100 to 4900 pound sizes. Refrigerant monitor For remote mounting including accessories such as 4-20ma signal, strobe light, audible horn, air pick-up filter. Sound attenuation package Consists of acoustical insulation on the discharge line. Extended warranties Extended 1, 2, 3, or 4 year warranties for parts only or for parts and labor are available for the entire unit or compressor/motor only. 24 Cat Templifier-1
Guide Specifications SECTION 15XXX CENTRIFUGAL HEAT PUMP WATER HEATER PART 1 GENERAL 1.1 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for centrifugal heat pump water heater. 1.2 REFERENCES Comply with the following codes and standards Underwriters Laboratory ANSI/ASHRAE 15 1.3 SUBMITTALS Submittals shall include the following: OSHA as adopted by the State ASME Section VIII A. Dimensioned plan and elevation view drawings, including motor starter cabinet, required clearances, and location of all field piping and electrical connections. B. Summaries of all auxiliary utility requirements such as: electricity, water, air, etc. Summary shall indicate quality and quantity of each required utility. C. Diagram of control system indicating points for field interface and field connection. Diagram shall fully depict field and factory wiring. D. Manufacturer s performance data. E F 1.4 QUALITY ASSURANCE Before shipment, submit a certification of satisfactory completion of factory run test signed by a company officer.. Installation and Operating Manuals. A. Qualifications: Equipment manufacturer must specialize in the manufacture of the products specified and have five years experience with the equipment and refrigerant offered. B. Regulatory Requirements: Comply with the codes and standards in Section 1.2. C. Water heater manufacturer plant shall be ISO Registered. 1.5 DELIVERY AND HANDLING A. Units shall be delivered to the job site completely assembled and charged with refrigerant and oil. B. Comply with the manufacturer s instructions for rigging and transporting units. Leave protective covers in place until installation. Cat Templifier-1 25
1.6 WARRANTY The refrigeration equipment manufacturer s warranty shall be for a period of one year from date of equipment start up or 18 months from shipment whichever occurs first. The warranty shall include parts and labor costs for the repair or replacement of defects in material or workmanship excluding refrigerant. 1.7 MAINTENANCE Unit maintenance shall be the responsibility of the owner with the following exceptions: PART 2 PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS A. McQuay International B. (Approved Equal) 2.2 UNIT DESCRIPTION Provide and install as shown on the plans a factory assembled, factory charged, and factory run-tested heat pump water heater. Each unit shall be complete with a single-stage hermetic centrifugal compressor with lubrication and control system, (factory mounted starter), evaporator, condenser, refrigerant control device and any other components necessary for a complete and operable package. 2.3 DESIGN REQUIREMENTS A. General: Provide a complete heat pump water heater as specified herein. Machine shall be provided according to referenced standards Section 1.2. In general, unit shall consist of a compressor, condenser, evaporator, lubrication system, starter and control system. Note: Unit shall be charged with HCFC-134a refrigerant B. Performance: Refer to schedule on the drawings. C. Acoustics: Sound pressure levels for the complete unit shall not exceed the following specified levels. Provide the necessary acoustic treatment to the unit as required. Data shall be in db. Data shall be the highest levels recorded at all load points. Test shall be in accordance with ARI Standard 575. Octave Band 63 125 250 500 1000 2000 4000 8000 dba 26 Cat Templifier-1
2.4 WATER HEATER COMPONENTS A. Compressor: 1. Unit shall have a single-stage hermetic centrifugal compressor. Casing design shall ensure major wearing parts, main bearings, and thrust bearings are accessible for maintenance and replacement. The lubrication system shall protect machine during coast down period resulting from a loss of electrical power. 2. The impeller shall be statically and dynamically balanced. The compressor shall be vibration tested and not exceed a level of 0.14 IPS. 3. Movable inlet guide vanes actuated by an internal oil pressure driven piston shall accomplish unloading. Compressors using an unloading system that requires penetrations through the compressor housing or linkages, or both that must be lubricated and adjusted are acceptable provided the manufacturer provides a five-year inspection agreement consisting of semi-annual inspection, lubrication, and annual change out of any compressor seals. A statement of inclusion must accompany any quotations. B. Lubrication System: The compressor shall have an independent lubrication system to provide lubrication to all parts requiring oil. Provide a heater in the oil sump to maintain oil at sufficient temperature to minimize affinity of refrigerant, and a thermostatically controlled water-cooled oil cooler. Coolers located inside the evaporator or condenser are not acceptable due to inaccessibility. A positive displacement oil pump shall be powered through the unit control transformer. C. Refrigerant Evaporator and Condenser: 1. Evaporator and condenser shall be of the shell-and-tube type, designed, constructed, tested and stamped according to the requirements of the ASME Code, Section VIII. Regardless of the operating pressure, the refrigerant side of each vessel will bear the ASME stamp indicating compliance with the code and indicating a test pressure of 1.3 times the working pressure but not less than 100 psig. Provide intermediate tube supports at a maximum of 24 inch spacing. 2. Tubes shall be enhanced for maximum heat transfer, rolled into steel tube sheets and sealed with Locktite or equal sealer. The tubes shall be individually replaceable. 3. Provide isolation valves and sufficient volume to hold the full refrigerant charge in the condenser or provide a separate pumpout system with storage tank. 4. The water sides shall be designed for a minimum of 150 psig or as specified elsewhere. Vents and drains shall be provided. Cat Templifier-1 27