Arctic Cool Oil-Free Chillers

The Arctic Chiller Group

Remarkable Turbocor Compressor

• 100% Oil Free eliminates oil system maintenance costs.

• R134a Refrigerant meets Montreal protocol and is not subject to phase-out.

• Magnetic Bearings eliminate frictional losses.

• One moving part assures long service life.

• Unmatched Efficiency as low as .30 kw/ton IPLV.

• Low 2-amp In-Rush Current reduces installed cost and peak load.

• Lowest Noise - Only 70 dBa.

The Turbocor Compressor

Pressure and temperature

sensors

Inverter speed control

Synchronous brushless DC motor

Motor and

bearing control

Inlet Guide Vanes

2 stage centrifugal compressor

Soft-Start

(<2amps Inrush)

VFD and Inlet Guide Vane Operation• The Compressors speed adjusts

automatically to match the load and current operating conditions so that optimum efficiency is gained.

• Primary capacity control is done using the onboard VFD and only use the Inlet Guide Vanes to supplement VFD controls. IGVs prevent surge conditions at low turndown. IGVs normally operate at the 110% position.

• The slower the compressors, the greater the efficiency. As speeds is reduced, energy consumption is reduced by the cube of the energy

The Magnetic Direct-Drive System

Magnetic bearings and sensors keep the shaft properly centered and positioned at all times. The rotor shaft is held in position with ten separately controlled electro magnetic cushions which continually changes in strength to keep the shaft centrally positioned.

The shafts position is monitored with 10 sensor coils whose signal is fed back to a digital controller. Movements of less than .00002”are sensed and adjustments are made accordingly.

Shaft is monitored and positioned 100,000 / sec.

The Magnetic Bearing System

• Permanently magnetized shaft does not require electrical power.

• 97% energy efficient

• Uses 0.5% of the energy required for conventional bearings.

• Eliminate high mechanical friction losses• Eliminate oil-related heat transfer losses• Eliminate cost of oil management systems (controls and hardware)• Increase equipment life through elimination of wear surfaces

Leveraging Affinity Laws

8

Energy Used is Proportional to the Cube of the Speed of the MotorTwo pumps at 50% speed use 25% of the power of one pump at 100% speed

Optimizing the System involves leveraging Affinity Laws and Real-Time Tracking and Tuning of Components to shift Load to where total PLANT ENERGY across all related components is reduced.This is not simple PID loop feedback, but Dynamic Optimized kW Input

Variable Speed Factors

• Power is proportional to the speed cubed

• To achieve power reduction, the speed of fans, pumps and compressors should be reduced at lower loads.

• Emerging VFD plant controllers optimize the technology.

• Flooded designs with water in tubes can limit flow range due to velocity and laminar flow issues. DX can be better solution in some applications, but with efficiency loss.

• Cooling tower selections optimized for lower temp and flow. Can increase installed cost yet reduce operation costs.

Load Profile Reveals Dollars

Why Is Turbocor So Compelling?

Compressor Sizes and Uses

TT300 90 tons .375 17 tons

TT350 125 tons .359 28 tons

TT400 150 tons .336 35 tons

TT500 190 tons .342 55 tons

Model Capacity IPLV Turndown

Chilled Water Range – 28F to 60F – 134a limited

Condenser Water Range – 50F to 90F

Ambient Range – 10F to 108-110F

Rule of thumb – 12 degrees minimum between LWT and ECT

Compact Size - Easy to Service

125 HP motor is in the foreground.

150 HP Turbocor permanent magnet motor behind.

Variable-speed, magnetic bearing and cooling controls.

High Capacity – Smaller Size

Oil-Free Eliminates Piping Complexity

No need for elaborate piping designs compared with oil management systems. • No traps and risers• Lower installed costs• Eliminates leak sources

• Enables centrifugal chiller with remote condenser to be placed at greater distance.

Lowest Cost of Service

•Annually check electronics for tight connections

•No oil service or oil disposal - EVER.

•Replace capacitors every ten years

Lowest Noise and Vibration Levels• “Best in Class” low sound levels. No moving mechanical part touches any part of the housing or frame to transmit acoustic energy.

• Tested at 70 dBa at 1 meter with no sound attenuation. Other compressors, by comparison, are approximately 80 dBa and higher.

• Vibration is essentially non-existent.

• The chiller with 5 compressors operating at full speed only produces 75 DB of sound at 10 feet., about the sound level of your television.

What Happens with a Power Outage?

• In the case of a power outage, the compressor is fully protected.

• Within 0.5 of a micro-second, the motor becomes a generator which then feeds power to the various controls and bearing actuators during a controlled coast-down. The onboard capacitors have adequate power to fully support the bearing system during the switch. Capacitors are replaced every ten years.

•After the compressor comes to a complete stop, the rotor de-levitates normally onto touchdown bearings. Carbon or roller touchdown bearings are also used as a back up bearing system to act as a cradle for the rotor during the off-mode.

• The system then determines if normal power is restored, if YES, the shaft levitates. If there is a call for cooling, the rotor will then begin to rotate. The entire cycle from loss of power to normal operation takes about 3-5 minutes.

Automatic Bearing CompensationThis compressor continued to operate even though this hole saw slug was embedded in the 1st stage impeller.

The compressor is not designed to pump hole saw slugs, however when faced with this problem, the auto-balance feature was robust enough to handle the challenge.

The compressor continued to operate at 35,000 rpm with this imbalance.

Turbocor Monitoring Software

Turbocor Monitoring Software

Oil causes 50% of downtime and cost

The Dramatic Effects of Oil

Oil in Evaporator Performance Loss

1-2% 2-4% loss3-4% 5-8% loss5-6% 9-11% loss7-8% 13-15% loss

ASHRAE 601-TRP - Oil contamination can be caused by several factors, including gasket failure, but

the most common cause of oil migration in comfort chillers is the continued use of a chiller at low loads

during the beginning or end of the cooling season. How much does excess oil in the evaporator

degrade performance? Table 1 gives typical ranges.

ASHRAE study reached the same conclusion: “Flow boiling results have been obtained for newer enhanced

boiling tubes with R-134a. This enhanced tube shows a decrease in heat transfer with the addition of even a

small amount of oil throughout various heat loadings. Even at 1 percent (by weight) oil, the heat transfer

coefficient is reduced by 25 percent from its no oil baseline. At higher oil content, a 30 percent reduction has

been typically measured.”

Percent Oil

The Dramatic Effects of Oil

ASHRAE study shows average percentages of oil present in chillers

Percent Oil

Percent OilEfficiency loss in heat exchangers account for substantial operation costs

The Dramatic Effects of Oil

In the ten chillers tested in the ASHRAE study, the average overcharge of oil in the system was 12.88%, this equated to an average energy loss of about 21%Percent of oil

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%

High Cost of Chiller Maintenance

Procedure Daily Weekly Quarterly Yearly

Record operating conditions (log) X

Check oil levels X

Check refrigerant levels X

Check oil return system X

Check operation of motor starter X

Check sump heater and thermostat operation X

Inspect and adjust safety controls X

Leak check and repair leaks X

Lubricate motor X

Check and tighten all electrical connections X

Megohm motor windings X

Perform oil analysis on compressor lube oil X

Replace oil filter and oil return filter/dryers X

Replace or clean starter air filters X

High Cost of Oil - Bearings

Stop Operation & provide backup chiller (rental)

Open the compressor and hermetic motor for inspection

In addition to normal annual maintenance, inspection occurs every 40,000 hrs of operation or every 5 years, whichever occurs first. 5 times during a 30 year service life.

Shutdown, disassemble motor, replace bearings, replace seals.

Cost approximately $25,000 each time 5 times over 30 year service life $125,000 over life of equipment.Burnout & oil induced acid eliminated.

ArcticCool Chillers vs Screws

Conclusion – The Arctic Cool Chiller using the Turbocor TT300 compressor is 45% more efficient than the leading screw compressor

ARI 550/590-1998 Conditions

Leading ScrewWATER COOLED

ArcticCool Chiller with TT300WATER COOLED

Load ECWF/C

LCHWF/C

SSTF/C

SCTF/C

COP kW/Ton SSTF/C

SCTF/C

COP kW/Ton

100% 85/29.5 44/6.7 42/5.6 98/36.7 5.33 0.64 42/5.6 98/36.7 5.56 0.63

75% 75/23.9 44/6.7 42.3/5.8 89.6/32 5. 73 0.6 42.3/5.8 85/29.5 7.31 0.48

50% 65/18.3 44/6.7 42.5/5.9 89.6/32 5.49 0.64 42.5/5.9 72.2/2.2 11.38 0.30

25% 65/18.3 44/6.7 42.8/6. 89.6/32 4.11 0.845 42.8/6 70/21.1 10.86 0.32

IPLV COP kW/Ton 5.4 .65 9.55 0.36

ArcticCool Chillers vs Screws

Conclusion – The Air Cooled Chiller using the Turbocor TT300 compressor is 29% more efficient than the leading screw compressor

ARI 550/590-1998 Conditions

Leading ScrewAIR COOLED

ArcticCool with TT300AIR COOLED

Load AirF/C

LCHWF/C

SSTF/C

SCTF/C

COP kW/Ton SSTF/C

SCTF/C

COP kW/Ton

100% 95/35 44/6.7 35.5/2 122/50 3.19 1.10 35.5/2 122/50 3.08 1.13

75% 80/26.7 44/6.7 36.5/2.5 104/40 4.20 0. 83 36.5/2.5 104/40 4.44 0.79

50% 65/18.3 44/6.7 37.5/3 86/30 5.26 0.69 37.5/3 82.5/28 7.23 0. 48

25% 55/12.8 44/6.7 38/3.5 86/30 3.98 0.88 38/3.5 66.2/19 9.77 0.35

IPLV COP kW/Ton 4.6 0.76 6.32 0. 55

Standard Stacked Design

• Oil-Free design eliminates frictional losses and high cost.

• Lowest IPLV in the industry.

• Variable-speed Drive.

• Flooded evaporator for thermal buffer and approach.

• Cleanable condensers.

• NEMA 1 Panels Standard.

• Danfoss Controls Standard

• Marine Water Box Option.

Compact 90 Ton Low Profile

• Sub-cooled Inter-stage and condensed liquid can increase both Capacity and Efficiency

• Compact Low Profile Design Allows for difficult rigging under existing piping.

Standard Low Profile Design

Standard designs include stacked, offset and low profile.

Air Cooled systems to 400 tons.

Split systems are available.

Multiple Circuits available.

Condenser-less and Condensing Units available.

Water Cooled Chillers

• Up to four compressors per circuit

• Provides the ability to use the entire heat transfer surface even when using few compressors, thereby ensuring close approach temperatures.

•Water cooled products from 60 to 1,500 tons.

Low Profile Water Cooled Chillers

• Low Profile Design• 60 to 1,500 tons• Removable

Controls Option• Evap-Condensed

Options

Air Cooled Chillers

• Single Turbocor compressor per circuit to 420 tons.

• Assures that refrigerant is properly managed during staging and load variations.

•Eliminates the known issues of refrigerant migration with single circuited centrifugal compressors.

Modular Chillers

• Modules with Scroll, Screw or Turbocor Compressors. Any size.

• Air cooled, water cooled, free-cooling and VFD pumping systems are available.

Air Cooled Evap Condensed ChillersNew Advances in Evap Condensing• Microchannel Coils• No Carry-Over• Far Less Make-Up• Far Less Charge• Microprocessor• VFD Fan Option• Short Payback

Advantages of High-Side Float

• High-Side Float provides enhanced performance, reliable operation and system protection.

• Assures sub-cooling section in the condenser with slightly better efficiency.

• Any leak over time could result in suction pressure fault, but expensive compressors always receive critical motor cooling.

Training and Certification

• Conducted by most knowledgeable in Turbocor technologies and application nuances.• Classes in Toronto, Florida and California• Includes Compressor, Controls and Chillers

Application Notes

• Heat Recovery – 120 °F maximum. Special high-lift compressor required. Only works with TT300, no TT400s.

•120 ton TT350 high-lift compressor is now available.

• Controller has settable minimum flows to avoid laminar conditions.

•Operating Envelope. 28°F min at 25% max PG. Glycol applications above 25% may require DX, not flooded design.

• Staging relief valves required for process applications to increase temperature stability. Also needed for most glycol and low unloading.

•Differential temp for TT300 is @ 7-8 °F. 10-12°F for TT400. This is the difference between the entering condenser and leaving chilled water

Practical Application Constraints

• Capital Cost – Premium cost, less competitive with multiple compressors, new high capacity models to reduce cost-per-ton. Better pay-back with higher utility rates. DOE 23% prediction.

• Energy Only Emphasis – Lifecycle cost should contain annual maintenance, U-value, rebuilds, green and LEED compelling story.

• Quality of Utility – Fluctuations of 10% of voltage and 3% of phase can reset compressors. No harm done. Will not apply where power is poor. 460/3/60 only – NO 208 Volt compressors.

• Local Remote Service – DTC mandate. No service, no sale. USA fine.

• Temperatures – Less than 25°F and 25% PG. Less than 110° ambient. Process temp stability need staging valves.

• Rebates – many success stories include utility rebates to reduce pay-back gap. Retrofit versus new chiller analysis.

Condenser

Evaporator

Condenser

Evaporator

56°F50°F

90°F 85°F

50°F

90°F 95°F

44°F

Series Counter-flow Advantages

Where Parallel flow requires each chiller to produce the entire system Lift, Series-Counter-Flow reduces the total work for each chiller resulting in reduced total system energy.

In series-series arrangements, both evaporator and condenser circuits are in series and counter current flow, so the downstream chiller producing the coldest chilled water temperature rejects heat to the coldest condenser water temperature.

Lowest Total Cost of Ownership

• Lowest Energy Consumption – low as .30 IPLV

• Lowest Noise Levels – 70 dB compressor

• NO Oil Maintenance Costs

• NO Degradation of Tubing U-Value, Min 8%

• NO Compressor Rebuild Cycles - High MTBF

• Advanced Danfoss Controls, EnergyMonitor.NET

• Qualifies for Deepest Rebates, LEED Points.

• Fuel Cell Project – DC to DC lowest cost

•Reverse flow generator powers compressors.

Questions or Comments…

Questions…

Contacting Arctic Cool

The Arctic Chiller Group

2100 Steeles Avenue

Brampton, ON L6T 1A7

Phone: (905) 789-9988

www.arcticchillergroup.com

Patrick Legare, Vice President, Arctic Cool - 514-702-0600

Mark Rogan, Group VP Sales and Marketing - 540-855-8110

Barry Werts, VP ArctiChill - 800-849-7778