McQuay International WMC New Water Cooled Chiller with oil free centrifugal compressors

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Bruce Burke
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1 McQuay International WMC New Water Cooled Chiller with oil free centrifugal compressors Applied Systems - Strategic Marketing

2 Contents 1. Introducing WMC 1.1 Product Overview Range 2. Technical Features 2.1 Features & benefits 2.2 Range 2.3 Oil-free compressor with magnetic bearings 2.4 Electronic expansion valve 2.5 P & I diagram example: 1 compressor case 2.6 Control Panel 3. Focus on the Range 3.1 Product line-up 3.2 Selection Software 3.3 Operating Limits 3.4 Dimensions & Weights 3.5 Sound Levels 3.6 Standard Options 3.7 Options on request 2

3 Chapter Introducing WMC 3

1.1 Product Overview 2010 kw Cooling Capacity 50 100 250 500 750 1000 1250 1500 Ecoplus SE / XE 165 604 1

WMC (Frictionless Centrifugal Chiller) 333 1510 362 1134 317 (WMC up to 1.

4 1.1 Product Overview 2010 kw Cooling Capacity Ecoplus SE / XE circuit 2 circuits circuits 4 circuits PFS (Flooded Technology) R-134a WHS-E SE WHS E XE WMC (Frictionless Centrifugal Chiller) (WMC up to kw) WSC/WDC (Centrifugal Chiller) 300 (WSC up to kw) (WDC up to kw) 388 R-410A Proximus Evolution SE / XE (up to 2196 kw) 4

5 1.2 Range Product Refrigerant Series name Water cooled chiller with oil free centrifugal compressor R-134a WMC Cooling Capacity Circuits From 317 kw to kw (nominal cooling capacity) - 6 sizes (Referred to: water evaporator 12/7 C --- water condenser 30/35 C) 1 refrigerant circuit (1 or 2 compressors) Efficiency versions XE High efficiency Sound Versions ST Standard sound 5

6 Chapter Technical Features 6

7 2.1 Features & benefits Breakthrough energy efficiency (especially at partial loads), resulting in great energy savings and fast payback Totally oil-free operation, resulting in reduced maintenance and increased reliability Compact design and Light Weight, for example to ease retrofit applications Low Noise Level, ideal for sound sensitive environments as libraries, schools, Onboard sophisticated digital electronics to provide smart control Extensive option list to meet Customer requirements Easy integration with BMS (Building Management Systems) 7

8 2.2 Nomenclature WMC -A XE 100 S ST Machine type WMC = Oil Free Centrifugal Chiller Model series Letter A,B, : major modification Efficiency level XE = Standard Efficiency Unit size Always 3-digit code Number of compressors S = 1 D = 2 Noise configuration ST = Standard Noise 8

9 2.3 Oil-free compressor with magnetic bearings The compressor, specifically designed for HVACR industry, is a compact FULLY INTEGRATED SYSTEM including: - Dual stage Centrifugal compressor - Magnetic bearing system (instead of conventional bearings) - Variable Speed Permanent Magnet Direct Drive Motor 9

2.3 Oil-free compressor with magnetic bearings The compressor s one moving part (rotor shaft and impellers) is directly put in rotation by the permanent magnet direct drive motor and kept levitated

10 2.3 Oil-free compressor with magnetic bearings The compressor s one moving part (rotor shaft and impellers) is directly put in rotation by the permanent magnet direct drive motor and kept levitated by a digitally controlled magnetic bearing system; the speed of rotation reduces as the condensing temperature and/or cooling load reduces. Movable inlet guide vanes (activated by a step motor) redirect gas flow into the first stage after the compressor has reached minimum speed. Inverter speed control 2 stage centrifugal compressor Permanent Magnet Direct Drive Motor Pressure and temperature sensors Inlet Guide Vanes Motor and bearing control (the electronics) 10

11 2.3 Oil-free compressor with magnetic bearings The shaft / impeller Different types for different compressor sizes It is the only moving part of the compressor TT300 TT TT400

2.3 Oil-free compressor with magnetic bearings How the magnetic bearing system works: The rotor shaft s position is held by front and rear electro-magnetic bearings The shafts position is monitored

12 2.3 Oil-free compressor with magnetic bearings How the magnetic bearing system works: The rotor shaft s position is held by front and rear electro-magnetic bearings The shafts position is monitored with 10 sensors that send a signal to a digital controller which then sends a command to the 5 separate pulse width modulators (PWM), for a proper shaft repositioning In case of power failure, within 0.5 micro-seconds, the motor becomes a generator for the magnetic bearings and the compressor comes gradually to a complete stop; the rotor delevitates normally unto backup bearings. Onboard capacitors have enough power to fully support the bearing system during the coast down 12

2.3 Oil-free compressor with magnetic bearings Variable Speed Permanent Magnet Direct Drive Motor Permanent magnet, placed onto the rotor, generate the magnetic flux that is necessary to provide

13 2.3 Oil-free compressor with magnetic bearings Variable Speed Permanent Magnet Direct Drive Motor Permanent magnet, placed onto the rotor, generate the magnetic flux that is necessary to provide torque; VFD (Variable Speed Drive) is required to allow a soft start (2 amps starting current) and the variability of speed (high speed, from 18,000 to 48,000 RPM). This motor, also known as brushless, is synchronous and is more efficient than the asynchronous because there are no losses into the rotor (as happens in the asynchronous motor to slip the frequency) The motor is refrigerant cooled and fully protected with thermistors. Compressor cabinet Efficiency versions available 13

14 2.3 Oil-free compressor with magnetic bearings Case 1 : Asynchronous Case 2 : Synchronous with permanent magnets 14

2.3 Oil-free compressor with magnetic bearings The Magnetic bearings The magnetic bearings (180W - 300V dc supply) are used in place of traditional cushions with below

hardware) Long lifetime Modern magnetic bearing system along with the integrated VFD enables outstanding energy efficiency especially at partial loads where

15 2.3 Oil-free compressor with magnetic bearings The Magnetic bearings The magnetic bearings (180W - 300V dc supply) are used in place of traditional cushions with below purposes/advantages: Avoid high mechanical friction losses Avoid heat transfer losses due to oil Eliminate the issues due to oil management systems (controls and hardware) Long lifetime Modern magnetic bearing system along with the integrated VFD enables outstanding energy efficiency especially at partial loads where significant gains can be realized. Also the inrush current is strongly reduced thanks to the use of VFD, resulting in an advantageous down-sizing of electrical protection devices. 15

16 2.3 Oil-free compressor with magnetic bearings The electronics Inbuilt sophisticated electronics guarantee self-diagnostics on Motor, bearings, compressor, expansion valve, performance, events, faults, and allow the exchange and visibility of data with the chiller controller 16

17 2.3 Oil-free compressor with magnetic bearings The electronics Line reactor Rectifier DC-link capacitors IGBT Motor Supply 3 Phases V 50-60HZ Controller Compressor controller DC-DC converter PWM output Power - Motor Power - Generator Control Magnetic bearings 17

2.4 Electronic expansion valve The unit is equipped with the most advanced electronic expansion valves to achieve precise control of refrigerant mass flow.

operating range without any refrigerant flow problems with a perfect chilled water leaving temperature Finally this type of valve allows the double

18 2.4 Electronic expansion valve The unit is equipped with the most advanced electronic expansion valves to achieve precise control of refrigerant mass flow. These valves, that typically work with a lower Δp between high and low pressure side than a thermostatic valve, allow the system to work within a wide operating range without any refrigerant flow problems with a perfect chilled water leaving temperature Finally this type of valve allows the double set-point and generally the application as heat pump: this last point is not true for the WMC due to the envelope of the compressor (see also slide on Operating limits ) 18

19 2.5 P & I diagram example: 1 compressor case 19

20 2.6 Control Panel Control and Power are located in two sections of the main panel. Panel is IP54 internally protected against accidental contact (IP20) Control Power The power panel (high voltage side) is fitted with main switch interlocked door Power section includes compressor fuses and control circuit transformer Low Voltage side High Voltage side 20

21 Chapter Focus on the range 21

22 3.1 Product line-up Oil free centrifugal chillers provide (at fixed evaporator and condenser water conditions) different cooling capacities, EER s, sound levels, pressure drops, etc. this depending on the compressor speed of rotation. WMC range 300D 250D 200D 150S 125S 100S Cooling capacity (kw) TECHNICAL SPECIFICATIONS Version XE - ST 100S 125S 150S 200D 250D 300D Cooling Capacity kw EER up to ESEER up to ) The indicated CC intervals refer to the full load cooling capacity at: - minimum and maximum compressor speed - standard working conditions (12/7 C evaporator - 30/35 C condenser) 2) For dual compressor units the minimum capacity is related to the condition with only one compressor running 3) Maximum EER at standard conditions and a specific compressor speed 4) Maximum ESEER at specific compressor speed 22

23 3.2 Selection Software The WMC selection software is basically a excel-based tool, very easy and intuitive. To access the software the user is required to enter username and password (provided by Strategic Marketing) Calculations of IPLV, ESEER and NPLV are allowed, providing for each point all the most important technical parameters as water flow, pressure drops, capacity, power input, etc Once generated, selections can be easily saved, archived and/or sent by . A dedicated selection software short guide is available to show how to use the tool. 23

24 3.3 Operating Limits Condenser Leaving Water Temp. ( C) Operation with Glycol (below 4 C Evap LWT) Evaporator Leaving Water Temp. ( C) Above diagram is indicative: for the operating limits of the specific models please refer to the WMC selection software. Note - The operation with Glycol influences the unit performance: the WMC selection software is able to adjust the calculations keeping this into account 24

25 3.3 Operating Limits Max saturated discharge temperature: 56 C Max saturated discharge temperature: 45 C 25

3.4 Dimensions & Weights Weight & dimensions 100S 125S 150S 200D 250D 300D Shipping weight kg 2360 2416 2546 3709 4095 4765 Operating weight kg 2520 2634

26 3.4 Dimensions & Weights Weight & dimensions 100S 125S 150S 200D 250D 300D Shipping weight kg Operating weight kg (A) Length mm (B) Width mm (C) Height mm

27 3.5 Sound Levels The WMC chillers are very quiet, this mainly thanks to the use of oil-free Centrifugal compressor with magnetic bearings; additional reduction of sound level is possible through the sound proof cabinet (on request) Sound pressure level at 1 m from the unit in semispheric free field (rif. 2 x 10-5 Pa) Power Unit size 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz db(a) db(a) 100S S S D D D Figures in the table are related to standard working conditions (evaporator water 12/7 C and condenser water 30/35 C) and maximum cooling capacity Sound pressure level correction for different distances Unit size Distance 1m 5m 10m 15m 20m 25m 50m 100S S S D D D Reduction to be applied to standard sound levels 27

28 3.6 Standard Options Following accessories are supplied as Standard on basic unit: Evaporator 2 passes configuration Evaporator Victaulic kit Hydraulic joint with gasket for an easy and quick water connection Evaporator water side design pressure 10 bar 20mm evaporator insulation Condenser 2 passes configuration Condenser Victaulic kit Hydraulic joint with gasket for an easy and quick water connection Condenser water side design pressure 10 bar Electronic expansion valve High pressure side manometers on evaporator and condneser Water pressure differential switch on evaporator and condenser Factory mounted, differential switch is available to detect evaporator and condenser loss of flow Inverter compressor starter For low inrush current and reduced starting torque Double pressure relief valve with diverter Current limit To limit maximum absorbed current of the unit whenever is required Hour run meter General fault contactorset-point reset The leaving water temperature set-point can be overwritten with the following options: 4-20mA from external source (by user); outside ambient temperature; evaporator wate temperature Δt Demand limit User can limit the load of the unit by 4-20mA signal or by network system Alarm from external device Microprocessor is able to receive an alarm signal from an external device (pump etc ). User can decide if this alarm signal will stop or not the unit 28

29 3.7 Options on request Following options are available on request: Evaporator and condenser 1/3 passes availability of these configurations must be checked on the selection software Evaporator and condenser flange kit in place of the standard victaulic connections Evaporator and condenser double flange kit Evaporator and condenser marine water box (with victaulic or flanged connections). To save time and work marine water boxes cover can be easily removed to clean internal tubes without the disconnection of water pipes. Evaporator and condenser water side design pressure 21 bar 20mm condenser insulation Cu-Ni condenser tubes - To work with sea water the heat exchangers are fitted with Cu-Ni tubes and special protection inside the end covers Evaporator/Condenser Flow switch Supplied separately to be wired and installed on the evaporator water piping (by the customer) Suction line shut off valve Installed on the suction port of the compressor to facilitate maintenance operation Energy Meter installed inside the control box, this accessory shows on a digital display: Line-to- Line Voltage, Phase and Average Current, Active and Reactive Power, Active Energy, Frequency Rubber type antivibration mounts Supplied separately, these are positioned under the base of the unit during installation. Ideal to reduce the vibrations when the unit is floor mounted Sound proof system - "integral kind cabinet to reach the best performance in noise reduction Witness test at customer s presence, in accordance with the procedures indicated on the test form 29

30 Thank You 30

A little history please!

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