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TT300 Centrifugal Compressor

www.turbocor.com

A little history please!

•1993: Turbocor started as an R&D company in Australia with an international team of designers and engineers working to bring high efficiency compressor technology to heating, ventilation, air conditioning and refrigeration's (HVACR) middle market.

•11 years in development.

•$ 50,000,000.00 in research & development costs.

•1999: Turbocor moves to Montreal to become a North American operating business with corporate headquarters, stage-one manufacturing plant, testing and engineering labs, and training facility.

•2004: Danfoss Turbocor form a 50/50 joint venture called

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In 1993,the Turbocor development team was given some simple goals:

To develop a small centrifugal compressor that:h d it i th 60 t 90 t• had a capacity in the 60 to 90 ton range,

• was environmentally friendly,• did not use a lubricant,• was direct drive,• was as small as a matchbox,• was 100% efficient,• was silentwas silent,• had all its component technologies fully integrated,• weighed less than 1lb..

We failed.Not totally, but on a few points:• It is rated at 60 to 90 ton

• It operates on R134a

• It eliminated lubricants by using magnetic bearings

• It uses a high speed synchronous permanent magnet direct drive motor√

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• It is very small compared to its competition (25-30% of the size)

• but is not as small as a matchbox

• It is the most efficient mid-size compressor in the world, (IPLV .406)

• however we have not hit 100% efficiency yet

• It is very quiet (70 dBa at 1.5 meters)

• however it is not silent

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• It has a fully integrated control system including bearing and inverter control

• It is light weight, weighing 265 lbs, which is about 25% the weight of its competition

• however it does weigh more than 1 lb.

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The first Turbocor Compressor

The compressor has undergone extensive life cycle and beta testing

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TurbocorTurbocorAward Winning Technology:

The ASHRAE/AHR Expo’s Energy Innovation Award

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The Canadian Energy Award

The U.S. EPA’s Climate Protection Award

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U S Green Building CouncilU.S. Green Building Council

www.turbocor.com

R134a

R134a was chosen as the refrigerant because of:

• its high efficiency,• Its environmental friendliness,• its proven acceptance in the

market place,• its availability,

d th f t th t it i t• and the fact that it is not a blend,

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Important Aspects of Compressor Selection

• Highly Reliable• Highly Reliable– Simple

• High Efficiency– At Full Load– And Part Load

• Reduced Maintenance Cost C it M d l ti• Capacity Modulation– Infinite Stages of Modulation– Wide Range of Stable Operation

• Quiet

Four Types of Compressors

•Reciprocating•Reciprocating•Scrolls•ScrewsC t if l•Centrifugals

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The Turbocor Compressor at a Glance

Inverter Speed Control

2 Stage, Direct Drive, Hermetic Centrifugal Compressor

Permanent Magnet Motor

Inlet Guide Vanes

Motor and Bearing Control

Reliabilityy

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• It offers highest aerodynamic compression efficiency

Why a centrifugal compressor?

compression efficiency• With variable-speed drive, it

provides best part load efficiency

• The compressor has asingle moving part

• It has high speed capability, thus reducing its overall size

• It has a well-proven long life in central plant applications

Why magnetic 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 eliminationlife through elimination of wear surfaces

• More durable than hydrostatic, foil orair bearings

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• The rotor shaft is held in position with ten separately

Magnetic bearing system

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 who’s signal is fed back to a digital controller.

• Back up bearings are fitted should a catastrophic failure occur.

Direct Drive Centrifugal withMagnetic Bearings

Magnetic bearings and sensors keep the shaft properly centered and positioned at all times.

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What is IPLV? Integrated Part Load Value

IPLV is a rating standard developed by ARI (American Refrigeration Institute) to determine the efficiency of a compressor over a range capacities. The old standard only compared compressor at full load. However, compressors rarely run at full load. This new standard takes that reality into consideration.

Integrated Part Load Value

% load

100

75

1992 standard

17%

39%

1998 standard

1%

42%

Weighted average values

ARI Standard 550/590-98

50

25

33%

11%

45%

12%

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The first intelligent compressor

The TT300 is the world’s first digital compressor, with:

• Digitally controlled bearings,• Digitally controlled power

electronics,• Digitally controlled compressor

control,• Digitally controlled chiller control,• Digitally controlled expansion

valve control

• The shafts position is consistently monitored by

Magnetic bearing system

the 5 axis proximity sensors, these signals are sent to the digital controller which then sends a command to the 5 separate pulse width modulators (PWM), repositioning the shaft on a continual basis. Movements of less thanMovements of less than .00002” are sensed and adjustments are made accordingly

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Accidents happen:• Auto-balance compensation is a

Magnetic bearing system

Auto balance compensation is a unique part of the Turbocor bearing system. In this case, the compressor continued to operate safely even though this hole saw slug was embedded in the 1st stage impellor. 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.

• In the case of a power outage, the TT-300 is fully protected. Within 0 5 of a micro-second the motor

Power outage?

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 enough power to fully support the bearing system during the switch from motor to generator mode.

• After the compressor comes to aAfter the compressor comes to a complete stop, the rotor de-levitates normally onto touchdown bearings.

• Touchdown bearings are used as a back up bearing system as well as to act as a cradle for the rotor during the off-mode

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• The Compressors speed adjusts automatically to match the load

Variable speed drive

and current operating conditions so that optimum efficiency is gained.

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

bcube.– Speed Energy3

Variable speed drive

• The compressors speed varies dependent on thevaries dependent on the conditions. Its operating speed ranges from 18,000 to 48,000 RPM.

• The inverter is built into the compressor as is the rest of the control system

• Another advantage of this system is its low startingsystem is its low starting current, the compressor draws 2 amps to start compared to 500 amps on a conventional compressor

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The motor

The permanent magnet motor has p gmany unique features:

• It is a 140hp motor that is the size of a conventional 1hp induction motor.

• It operates at high speed (18,000 to 48,000 RPM)

• It has a very low startingIt has a very low starting current (2 amps).

• It is refrigerant cooled.• It is fully protected with

thermistors

The working end

It is a centrifugal compressor that:It is a centrifugal compressor that:• is two stage,• uses open shrouded impellors• has an economizer feature• operates on R134a• has infinitely variable capacity

control,• uses guide vanes and variable

diffusers to optimize its performancediffusers to optimize its performance,• is not worried about oil return, and• does not mind the occasional slug of

liquid,

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TT-300 vs. leading screw compressorEnergy Efficiency Performance

TT-300 vs. leading screw compressorEnergy Efficiency Performance

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More about the systems integrationPower electronics:• The line reactor – this is an

optional feature that is not housed within the compressor. The LR is pused for improving the power factor to better than .95

• The rectifier – converts incoming AC supply (50/60hz) to a DC current

• The capacitors – smoothes out the current ripple so that the IGBT is fed with a stable current

• The integrated gate bi-polar transistor (IGBT) – converts thetransistor (IGBT) converts the DC current into a variable frequency of between 0 and 800 hz.

• The synchronous permanent magnet brushless DC motor – is a two pole design and is refrigerant cooled

Compressor controller:• The Soft start module – this

module charges the capacitors

More about the systems integration

module charges the capacitors with a trickle charge preventing a large inrush current when power is first switched onto the compressor, in normal operation, the compressor remains live and is switched on and off by the IGBT.

• The compressor controller – not only controls the compressorsonly controls the compressors performance, but also has features like two stage expansion control, chiller control and remote monitoring.

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Bearing and motor controller:

More about the systems integration

• The bearing and motor control (BMC) – is used to digitally control the speed of the motor as well and to control the position of the shaft.

• The pulse width modulator (PWM) – is an onboard amplifier that is used to provide a fast response signal to the bearing actuators so that the shaft is kept in the correct position.

• The BMC has built in 5 axis proximity sensors which through the processor control the shaft position.

Other features:• Inbuilt pressure and

d

More about the systems integration

temperature transducers• Motor and electronics

cooling circuit• DC/DC power supplies• Communication port• Guide vane control• Mounting vibration

isolators (protects theisolators (protects the compressor from external vibration)

• Lifting lugs

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Training and monitoring

• Monitoring and trouble shooting of the compressor can be performed via the Internet.

• Training modules will also be available shortly on the Internet

Why retrofit?

• Usually when a chiller is replaced, it involves major capital works:

• Structural modifications, expensive crainage, major plumbing and electrical works, permits, power upgrades etc. etc. etc.

• You not only save on the cost of the chiller, the cost of the capital works, putting up with the inconvenience of the system being d f i i d f idown for extensive periods of time, when you retrofit with Turbocor, you end up with the same net effect at a fraction of the cost.

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Retrofit Rack

Why rebuild when you can replace?

From a clients point of view:-• By changing out theBy changing out the

compressor with a Turbocor, rather than rebuilding it for the umpteenth time,

– you add system reliability,– improve energy savings,– upgrade the system with the

latest in technology, – reduce noise and vibration– and save money.

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OEM’s that are using Turbocor

Multistack

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McQuay

Power Pax - Australia

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Axima - Germany

What sizes do they come in?

The Current Offering:• Model - TT300 • Refrigerant - R134a• Capacities - 60, 70, 80 & 90 tonR• Voltage - 400V – 480V 50/60 Hz• Application – Water and evaporative cooled

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What sizes do they come in?

The Current Offering:• Refrigerant – R22g• Capacities – 90, 100, 110 tonR• Voltage 400V – 480V 50/60 Hz

What sizes do they come in?

Next Generation :• Models – TT300 & TT500• Refrigerant R134a• Capacities – 60, 70, 80, 90, 110, 130, 150 tonR• Models - TR200, TR300 & TR400

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TT300 Centrifugal Compressor

www.turbocor.com

Projet Bell CadillacPrésentation

Mohamad Jamous ingMohamad Jamous ing.

Services ImmobiliersAssurance qualité technique