STUDY ON TURBOCOR COMPRESSOR

PRASANTH.M M.E THERMAL ENGG

1

CONTENT

• INTRODUCTION

• DESCRIPTION

• ADVANTAGES

• APPLICATIONS

• CONCLUSION

• REFERENCE

2

INTRODUCTION

• Oil free compressor

• Specifically designed for HVAC-R industry

• This technology includes magnetic bearings,

variable speed centrifugal compressor and digital

electronic controls

• Enable to achieve highest overall efficiency

3

4

OIL COMPRESSOR OIL FREE COMPRESSOR

Energy loss due to lubrication Saves energy

High start up current Low start up current

Reduced COP Increased COP

No digital control Full digital control

DESCRIPTION

Source :Danfoss5

Source : DANFOSS

6

MAGNETIC BEARING

Source : DANFOSS

7

MAGNETIC BEARINGS

Source : DANFOSS

8

9

CROSS-SECTION OF AXIAL BEARING AND RADIAL BEARING

Source :Danfoss Turbocor Compressors

10

MAGNETIC BEARINGS AND BEARING SENSORS

• Composed of both permanent and electromagnets with a

unique, patented design for compact size and reliable high

performance

• Enables precisely controlled frictionless compressor shaft

rotation on a levitated magnetic cushion

• Bearing sensors, located at each magnetic bearing, feed

back rotor orbit and thrust/axial information in real time to

the bearing controller

11

• Powered by PWM (pulse width modulated)

voltage supply

• High-speed variable frequency operation affords

high efficiency, compactness and soft start benefits

PERMANENT-MAGNET SYNCHRONOUS MOTOR

12

• Radially and axially located bearings support the rotor when

the compressor is not energized

• Provides backup, preventing contact between rotor/impeller

assembly and other metal surfaces

TOUCHDOWN BEARINGS

13

• Only one major moving compressor component

• Acts as rotor for permanent-magnet synchronous

motor

• Impellers are keyed directly to the shaft

SHAFT AND IMPELLERS

14

• IGBT (Insulated Gate Bipolar Transistor) is an inverter that

converts a DC voltage into an adjustable three-phase AC

voltage

• Signals from the motor/bearing controller determine the

inverter output frequency, voltage and phase, thereby

regulating the motor speed

• In case of power failure, this patented control scheme

allows for a normal de-levitation and shutdown

VARIABLE FREQUENCY DRIVE

15

• Significantly reduces high in-rush current at start-

up, providing advantages to line power systems and

reducing thermal stress on the stator

• The start-up in-rush current is only 2 amps vs.

typically up to 250-350 amps experienced by

conventional compressors in this tonnage range —

truly redefining soft starts

SOFT START MODULE

16

• Single point connection to primary power supply

• Rectifier converts AC line power into a high voltage DC power

source

Capacitors for smooth DC voltage supply

• DC-DC converters for supply and isolation of high and low DC

voltages

• Network connection for external control and monitoring

• PWM amplifier for power to electromagnetic bearings

• Compressor bearing and motor controller microprocessor

ELECTRONIC PACKAGE

CONTROL SYSTEMS

17

Source : DANFOSS

MOTOR

Source : DANFOSS

18

Source : DANFOSS 19

PERFORMANCE COMPARISON

20

ADVANTAGES

• Noise Level Is Less Than 72db

• Frictionless Compressor

• Small Foot Print

• Smaller Size

• Less Vibration

• Energy Efficient

• Reliability

21

APPLICATION

• Industrial Facilities

• Schools

• Hotels

• Office buildings

• Hospitals

22

REFERENCE

• Danfoss Turbocor Compressor Inc

• Danfoss

http://refrigerationandairconditioning.danfoss.in

• Turbocor® Compressor Retrofit of a 260 Ton Screw

Chiller for Seattle-Based Hi-Tech Company