Conociendo La Competencia

Title: Getting to Know the
Competition – Magnetic
Compressors
Date: February 3, 2012
Magnetic Drive Compressor Table of Contents
1. Introduction
2. System Design
3. Operation
4. Components
5. Claimed Features
6. Manufacturers/Suppliers
7. Chiller Comparison
8. Points/Counter Points
2
Property of Carrier Corporation © 2012
Introduction
We are hearing a lot about magnetic

driven, oil free compressor chillers.
With claims like theirs, it seems like a

good idea to utilize this technology every
where possible….
LET’S INVESTIGATE
THIS!
3
Magnetic Drive Compressor Frame Sizes
Turbocor McQuay WME /

York / S2M
(McQuay WMC, MultiStack, Smardt Cooling,
etc.) Synchrony
Nominal Capacity Nominal Capacity Nominal Capacity
Model Model Model
Range (Tons) Range (Tons) Range (Tons)
TT300 71.1 – 91 WME 400 – 700 YMC2 210-400
TT350 85.3 – 113.7
TT400 113.7 – 142.2
TT500 170.6 - 199
4
Magnetic Direct Drive System
Representation of Turbocor Compressor Components
• Magnetic bearings and sensors keep the shaft properly centered

and positioned at all times.
Power is present and driver board is functional at all times?
•The rotor shaft is held in position with ten (10) separately
controlled electro magnetic cushions which continually changes in
strength to keep the shaft centrally positioned.
Ten cushions are controlled separately?
What happens if one cushion fails?
If a circuit board fails?
5
Magnetic Direct Drive System
Representation of Turbocor Compressor Components
•The shafts position is monitored with 10 sensor coils who’s signal

is fed back to a digital controller.
Ten sensor coils are required to properly monitor the compressor?
Does this means that just one (1) sensor failure will require a complete
compressor replacement?
• Shaft is monitored and positioned 100,000 / sec.
Shaft requires monitoring and repositioning 100,000/sec?
6
Magnetic Drive Compressor VFD & IGV Operation
Turbocor Claimed Compressor Features
• “The Compressors speed adjusts automatically to match the load and lift
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 are
reduced, energy consumption is reduced by the cube.”
– Speed Energy3
7
Magnetic Drive Compressor Components
How is this repaired or replaced?
Built-In VFD
Pressure &
Temperature Sensors
Inlet Guide
Vanes (IGV)
Synchronous Brushless Centrifugal

DC Motor Compressor (2 Stage
Design)
Same impeller for
all selections?
What about
different lift
Motor & Bearing characteristics?
Control
8
Magnetic Drive Compressor Claimed Features
• 100% Oil Free

What about the EXV? eliminates oil system
maintenance costs.
• R134a Refrigerant
meets Montreal protocol
and is not subject to
phase-out.
• Magnetic Bearings All mechanical
losses are not
eliminate bearing claimed.
frictional losses.
Is it really
• One moving part one (1)
assures long service life. moving
part?
(2)
• Unmatched Efficiency Impellers,
Never seen as low as .31 kW/ton
(1) Shaft,
IGV & IGV
this published! IPLV. Actuator
• Less than 2 amp Inrush

Current reduces installed
Can you size your wires at <2 A?
cost and peak load.
• Lowest Noise - Only 72
At what % Load? How many compressors? dBa.
(Add 3 dBA per compressor on a chiller) 9
Magnetic Drive Chiller Manufacturers/Suppliers
WMC
WME
AHRI Certified
Not AHRI Certified
If not AHRI
certified, how is
performance
confirmed?
10
North American Manufacturers
Model Capacity 0 500 1,000 1,500 2,000
Range Tons Tons Tons Tons Tons
Capacity Range
120-
Advantage http://
www.advant
WMC 180
Engineering Tons
ageengineer
ing.com/
56.9-
Armstrong http://
www.armstr
Quantum 625.6
Pumps Tons
ongpumps.c
om/
20-
Mammoth http://
www.mamm
WCC 2,000
WEBCO Tons
othwebco.co
m/
145- http://
McQuay WMC 400 www.mcqua
y.com
Tons
400- http://
McQuay WME 700 www.mcqua
y.com
Tons
MS-T 80-600 http://

MultiStack MS-500-
Tons
www.multist
ack.com/
F
60- http://
Smardt Cooling TT 1,200 www.smardt
.com/
Tons
60-180 http://
Thermal Care TC
Tons
thermalcare.
com
210-
York/Johnson http://
www.johnso
YMC 400
Controls Tons
ncontrols.co
m
90-540
Aaon LL
Tons
www.aaonn
et.com
ArcticChill www.arctichi
ll.com
11

Magnetic Drive Chiller Comparison
Attribute Turbocor York/Johnson Controls

(McQuay WMC, MultiStack & McQuay WME
Smardt Cooling) YMC2
Range 60 – 2,000 400 – 700 210 - 400

Efficiency
(FL/IPLV) 0.640 / 0.315*** 0.550 / 0.317 0.570 / 0.390
Magnetic Drive
Type Danfoss Turbocor Synchrony S2M
ASHRAE 90.1-2010 Standard Efficiency (FL/PL)
Compressor Type Capacity Range (Tons) Path A (FL/PL) kW/Ton Path B (FL/PL) kW/Ton
Screw ≥ 300 0.620/0.540 0.639/0.490
Centrifugal < 150 0.634/0.596 0.639/0.450
Centrifugal ≥ 150 & < 300 0.634/0.596 0.639/0.450
Centrifugal ≥ 300 & < 600 0.576/0.549 0.600/0.400
Centrifugal ≥ 600 0.570/0.539 0.590/0.400

*** MISLEADING FOR MULTIPLE CHILLER PLANTS
Turbocor may have difficult 15
meeting ASHRAE 90.1
Turban legends
urban legend
publication
A story, which may have started with a
grain of truth, that has been embroidered
and retold until it has passed into the
realm of myth
16
Turban legends
Turban legend #1
Multiple Compressors
Means “unusual
redundancy safeguards”
17
Multiple Compressor Redundancy
What does this

mean?
18
Multiple Compressor Redundancy
REALLY!?!
What if it is Single Point Power? MOST ARE…
What if there is no isolation valve?
What about the compressor leads?
19
What Does EPA State About This?
EPA Regulations
20
Proper Chiller Redundancy
McQuay WMC &
30HXC & 30XW
Smardt
# of
Refrigeration 1 2
Circuits
# of
Compressors Multiple 2 or 3
Can the Chiller
Still Run if a 50% 33%-66%
Yes Yes
Compressor
Shuts Down?
capacity capacity
Can the system
run if a 0% 33%-66%
No Yes
compressor is
being serviced?
capacity capacity
Can the system 0% 33%-66%
run if there is an No Yes
EXV failure? capacity capacity
Can the system
run if there is 0% 33%-66%
any other No Yes
refrigerant capacity capacity
failure?
Dual compressor & single circuit does not always equate

to dual redundancy.
21
Still a Centrifugal Compressor
Even oil free centrifugal chillers with magnetic bearings will surge if
project requirements exceed the lift capability of the compressor
Design Lift
Lift Reduction
Head
Factor
Maximum Surge Line
Operation
Point
Flow Factor Design Capacity
22
Normal Operation
85F
Cooling
Cooling
Cooling
23
What happens as the temperature rises?
(i.e. Tower Fan Failure)
85F
105F
SURGE
Cooling
Cooling
SURGE
Cooling
SURGE
If one (1) centrifugal chiller surges, they all will surge! 24
System Redundancy
All centrifugal chillers – including oil free type with magnetic
bearings can only reduce speed with a reduction in lift.
What Happens to the Chiller System if there is:
• A Plugged Pump Strainer

• A Cooling Tower Fan Failure
• Dirty/Fouled Tubes
• Lower Condenser Flow Rate?
Redundancy with a common mode

of failure provides no redundancy
at all!
25
Turban legends
Turban legend #1
Multiple Compressors
L S E
A
Means “unusual
F
redundancy safeguards”
Take-Away
EPA requires refrigerant evacuation when equipment is being opened for
service.
Redundancy is about the system, not the chiller!
This is not TRUE if all compressors fail due to the same condition.
Redundancy with a common mode of failure provides no redundancy at
all.
26
Turban legends
Turban legend #2
Turbocor Chillers ARE
“Oil Free”
27
EXV
If the compressor is oil-

free, then why may 8 oz.
of oil be required at start
up?
Answer: To
lubricate the EXV
and prevent the
EXV from sticking.
How do you know to add more?
Does the oil ever need to be changed?
28
Metering Devices
Metering Device
Model Number
Type
McQuay WMC EXV
McQuay WME EXV
MultiStack MS500F EXV
Smardt Cooling WA EXV
York/Johnson
YMC2 Variable Orifice
Controls EXV
Carrier 19XR(V) Variable Orifice

Carrier 23XRV Variable Orifice
EXV Metering Devices Require Oil,

while Variable Orifices Do Not.
29
Oil Maintenance
Maintenance
Schedule
DOES NOT
mention any
requirement for
inspecting or
replacing the
oil.
Does the oil last the life of the chiller?

30
Turban legends
Turban legend #2
L SE
Turbocor Chillers ARE
FA
“Oil Free”
Take-Away
 Chillers with an EXV will require oil.
 What else aren’t they saying?
31
Turban legends
Turban legend #3
Less Than Two Amps
Inrush is This Really
Relevant
32
Remember This Slide?
Soft-Start
(<2amps Inrush)
Why Make This Claim?
• Can I size a generator at less than 2
amps? Generator is kVA. NO
• Can your customer size their wires
based on this? NO
• Can any useful cooling occur for < 2
amps?
NO
Most people discuss Inrush as
Amps to get to @ 100% Load
(LRAD)
Is Turbocor avoiding this

discussion because of poor full
load efficiency?
33
Turban legends
Turban legend #3
LS E
Less Than Two Amps
FA
Inrush is This Really
Relevant
Take-Away
 Is this really a sales feature?
 Is it a way to avoid discussing poor full load efficiency?
 What else aren’t they saying?
34
Turban legends
Turban legend #4
Using Turbocor
compressors provides you
with the most HVAC
energy savings
35
Heat Recovery
6,000,000 Btu/H = 400 Tons

Use 15,000 Btu/H for heat rejection.
Why doesn’t
Turbocor discuss
this as a
requirement?
36
Heat Recovery Benefits
Chillers can transfer heat for as little as 25% of the cost
required to create heat with a boiler.
30XW Heat Recovery Chiller Savings vs. Boilers

80%
70%
60%
50%
40% 71% 75%
30% 50%
20%
10%
Natural Gas Boiler Electric Boiler Fuel Oil Boiler
($12/1,000 ft3) ($0.10/kWh) ($ 3/gal)
37
Heat Recovery Savings Potential
Replace Constant Speed Chiller with Heat Recovery
Replace Constant Speed Chiller with VFD Chiller
Chiller
Existing Constant Speed
Existing Constant Speed
0.550 kW/Ton Chiller IPLV & Boiler 0.550 + 4.0 kW/Ton
Chiller IPLV
Efficiency
New Heat Recovery

New VFD Chiller VFD 0.330 kW/Ton Chiller IPLV & Boiler 1.4 kW/Ton
Efficiency
Savings 0.220 kW/Ton Savings 3.15 kW/Ton
300% More Savings w/ Heat Recovery Chiller
“If just 10% of the cooling ton hours are

simultaneous cooling and heat recovery
ton hours, you can save more energy with
a 30XW chiller than with a variable speed
centrifugal. Just 10%”
38
Confirming Savings
Real World Example
i-Vu® Controls on 30XW Heat Machine at Charlotte Factory
30XW
Over $100,000 per year in energy savings!!

39
Turban legends
Turban legend #4
Using Turbocor
L
compressors provides you S E
energy FA
with the most HVAC
savings
Take-Away
 ASHRAE requires heat recovery for specific applications.
 Heat recovery chillers often provide the highest level of system savings.
 Carrier has proven heat recovery savings!
40
Turban legends
Turban legend #5
Turbocor Compressors
are Perfectly Suited for
Replacement Projects
41
Centrifugal Compressor Design
Ideal Fan Laws Dictate the relationship between speed, flow and lift
Flow ~ V, A
To increase flow, increase flow area Flow
Area
V
or rotor speed
2
Lift ~ V
To increase lift, increase diameter or Diameter
rotor speed
3
Power ~ Flow x Lift ~ V
With constant flow and reduced lift,
reduce speed to reduce power
A reduction in lift allows a speed reduction.

Lift is a function of the speed squared.
Power is related to the speed cubed!
All centrifugal chillers are subject to Ideal Fan Laws…

INCLUDING TURBOCOR!
42
Turbocor Compressor Frame Sizes
Turbocor
(McQuay WMC, MultiStack, Smardt Cooling, etc.)
Impeller Types
Nominal Capacity
Model Offered
Range (Tons)
(#)
TT300 71.1 – 91 1
TT350 85.3 – 113.7 1
TT400 113.7 – 142.2 1
TT500 170.6 - 199 1
• Four (4) discrete sizes (only one (1) impeller per size)
• Cannot mix models
• What happens if the compressor is not optimized for the application?
43
Be wary of any life cycle analysis that uses nominal efficiencies rather than job
specific efficiencies.
Nominal Conditions Actual Conditions
Capacity (Tons) 250 200

Leaving Chilled Water
44 42
Temperature (oF)
Entering Condenser
85 85
Water Temperature (oF)
Condenser Flow Rate
3.00 2.00
(gpm/Ton)
Full Load Efficiency
0.640 ??
(kW/Ton)
IPLV/NPLV (kW/Ton) 0.345 ??
Will these values be the same?

44
Turban legends
Turban legend #5
Turbocor Compressors
L S E
A
are Perfectly Suited for
F
Take-Away
 All centrifugal chillers are subject to Ideal Fan Laws…INCLUDING
TURBOCOR.
 Just installing a Turbocor compressor as a replacement unit, will not
guarantee savings…it is dependent of the site conditions.
45
Turban legends
Turban legend #6
High Pressure Drop
Across the Heat
Exchangers is a
Negligible Efficiency
Loss
46
Pressure Drop Comparison
Carrier 23XRV vs. McQuay WMC Evaporator Pressure
Drop
45 300 Tons @ 54/44oF
40
300 Tons @ 56/44oF
35
30 300 Tons @ 56/42oF

Pressure Drop (ft.)
25
20
Pump Cost Savings
15 $498.60/year
10
0
500 525 550 575 600 625 650 675 700
Flow Rate (gpm)
47
Pressure Drop Comparison
Carrier 23XRV vs. McQuary WMC Condenser Pressure

Drop
35 300 Tons @ 95/87oF
30 300 Tons @ 95/86oF
25
300 Tons @ 95/85oF
Pressure Drop (ft.)
20
15
Pump Cost Savings
$549.40/year
10
0
750 775 800 825 850 875 900 925 950 975 1000 1025 1050 1075 1100
Flow Rate (gpm)
48
How Significant is Pressure Drop?
A pump’s power is more significant than the

difference in kW/Ton at 25% load.
Chiller A Chiller B
Capacity (Tons) 450 450
Capacity at 25% Load (Tons) 112.5 112.5
Efficiency at 25% Load (kW/Ton) 0.296 0.320
kW at 25% Load 33.3 2.7 kW Difference 36.0
Cooler Pump Power (kW) 4.31 2.74 kW 3.10
Condenser Pump Power (kW) 5.28 Difference 3.75
Total Power (kW) 42.89 42.85
Power Difference (kW/%) 0.04 (0.0%)
OH BY THE WAY, HOW OFTEN WILL YOU RUN AT 25%?

49
Is the 25% Load Point Significant?
2,000 Ton Hotel, with (4) 500 Ton chillers

100% 75% 50% 25% 100% 75% 50% 25%
Athens 41.4% 58.6% 0.0% 0.0% New Delhi 48.1% 51.9% 0.0% 0.0%
Bangkok 65.1% 34.9% 0.0% 0.0% Osaka 34.0% 66.0% 0.0% 0.0%
Chicago 36.0% 64.0% 0.0% 0.0% Paris 63.5% 36.5% 0.0% 0.0%
Darwin 36.1% 63.9% 0.0% 0.0% Quito 74.9% 25.1% 0.0% 0.0%
Edmonton 60.5% 39.5% 0.0% 0.0% Rio de-Janiero 52.8% 47.2% 0.0% 0.0%
Frankfurt 64.6% 35.4% 0.0% 0.0% Singapore 24.3% 75.7% 0.0% 0.0%
Guangzhou 36.1% 63.9% 0.0% 0.0% Taipei 35.2% 64.8% 0.0% 0.0%
Hong Kong 28.5% 71.5% 0.0% 0.0% Ulsan 39.3% 60.7% 0.0% 0.0%
Istanbul 67.9% 32.1% 0.0% 0.0% Vienna 67.3% 32.7% 0.0% 0.0%
Jakarta 31.9% 68.1% 0.0% 0.0% Warsaw 62.6% 37.4% 0.0% 0.0%
Kuala Lumpur 41.4% 58.6% 0.0% 0.0% Xiamen 35.2% 64.8% 0.0% 0.0%
London 58.0% 42.0% 0.0% 0.0% Yuma 39.5% 60.5% 0.0% 0.0%
Moscow 59.2% 40.8% 0.0% 0.0% Zurich 60.4% 39.6% 0.0% 0.0%
Where are all the 25% hours?

50
Turban legends
Turban legend #6
High Pressure Drop
L
Across the Heat
S E
FA
Exchangers is a
Negligible Efficiency
Take-Away
Loss
 ∆kW for pump cost may exceed ∆ kW/Chiller at low loads.
 At lower chiller loads, pump savings can be significant.
 Chiller 25% efficiency with a high pressure drop will have no savings at
all.
51
Turban legends
Turban legend #7
Turbocor IPLV will give
you a LEED credit
52
Turbocor & LEEDTM
Efficiency LEED Credit
LEED EA 1 Credits are

based on reducing
ACTUAL energy costs,
not on the IPLV/NPLV of
the chiller!
53
Turbocor & LEEDTM
Efficiency LEED Credit
LEED EA 1 Credit Prerequisites:

Option 1: Whole Building Energy Simulation
Use the ASHRAE 90.1-2007 Appendix G Performance Rating Method to determine the percent improvement in energy cost of the proposed building
to the ASHRAE 90.1 baseline building.
New % Existing % NC / School pts CS pts New % Existing % NC / School pts CS pts
12% 8% 1 3 32% 28% 11 13
14% 10% 2 4 34% 30% 12 14
16% 12% 3 5 36% 32% 13 15
18% 14% 4 6 38% 34% 14 16
20% 16% 5 7 40% 36% 15 17
22% 18% 6 8 42% 38% 16 18
24% 20% 7 9 44% 40% 17 19
26% 22% 8 10 46% 42% 18 20
28% 24% 9 11 48% 44% 19 21
30% 26% 10 12
Option 2: (1 point) Use the prescriptive measures by climate zone from the appropriate ASHRAE Advanced Energy Design Guide. Guides cover
Small Office Buildings – for office occupancy which is less than 20,000 sq ft.
Small Retail Buildings - for retail occupancy which is less than 20,000 sq ft.
Small Warehouses and Self Storage Buildings - for warehouse and storage facilities under 50,000 sq ft
K-12 Schools Buildings - for K-12 school occupancy and under 200,000 sq ft,
Option 3: (1 to 3 points) Advanced Buildings Core Performance Guide
Can be applied to all buildings under 100,000 sq ft which are not health care, warehouse, or laboratory.
Meet all the climate zone prescriptive requirements of Section 1 and 2 of the guide and:
- For offices, schools, public assembly, and retail buildings meet the requirements of Section 1: Design Process Strategies and Section 2: Core
Performance Guide (1 point)
- Up to 2 additional points for implementing performance strategies from Section 3: Enhanced Performance. One point for each 3 strategies
implemented. Sections 3.1: Cool Roofs, 3.8: Night Venting, and 3.13: Additional Commissioning are not eligible for points.
In Short, Building Modeling is required to get the points for this EA-1 Credit.
54
What is a Simulation Procedure?
Proposed Building Baseline Building(s)
0° Rotation (same as
Proposed)
90° Rotation
Table 1 – Annual Costs

Proposed Building
Component ($)
180° Rotation
Air System Fans
Cooling
Heating
Pumps
Cooling Tower Fans
HVAC Sub-Total
270° Rotation
Lights
Electric Equipment
Misc. Electric
Misc. Fuel Use
Non-HVAC Sub-Total
Grand Total
Average Baseline
55
Turbocor & LEEDTM
Refrigerant LEED Credit
You cannot simply receive

a LEED EA 4 point, by just
buying a chiller!
56
Turbocor & LEEDTM
Refrigerant LEED Credit
LEED E4
Refrigerant Calculator
LEED EA 4 Credit Prerequisites:

Option 1 - Use no refrigerants in building HVAC and refrigeration systems with more
than ½ lb of charge. Natural refrigerants (CO 2 , water, and ammonia) also qualify.
Option 2 – Use refrigerant such that the weighted average of the ODP and GWP
impact do not exceed 100. Existing buildings must have a phase-out plan to
eliminate CFC’s before project completion. District plant systems even if not owned
by the building owner must also comply with
this prerequisite.
Alternate compliance can be achieved by 1) a phase out plan within 5 years of
project completion and the leak rate must be 5% or less using the EPA Rule 608
procedure or 2) a third party certifies based on 10 year simple payback that a
replacement is not justified – the 5% leakage rule still applies and leakage over the
chillers remaining life must be under 30%.
57
Turban legends
Turban legend #7
Turbocor IPLV will give
you a LEED credit
L S E
FA Take-Away
 LEED credits cannot be obtained just by buying a chiller.
 Building modeling is required to get an EA-1 credit (not IPLV).
 Performing the proper refrigerant charge calculation is required for an
EA-4 credit.
58
Turban legends
Turban legend #8
Chiller sound level must
be EIGHTY DBA
59
What Does OSHA Require?
OSHA REQUIRES 85
DBA.
60
Low Sound – Do We Really Need to Hear It?
1. What about the sound

level of the pumps in the
room?
2. What about the sound
levels of other machinery
in the room?
Chiller Room
Sound Level Just

Outside Chiller Room:
14 dBA Less Than
Inside the Room
61
What About (3) Chillers vs. (2) Chillers?
Single
Chiller 1 Chiller 1 & 2 Chiller 1, 2
Chiller
dBA dBA & 3 dBA
Capacity
375 Tons 83 86
250 Tons 80 83 86
 All sound source in the room must be taken into

account.
 Two (2) at 83 dBA ≈ (3) at 80 dBA … Case Closed.
62
Turban legends
Turban legend #8
Chiller sound level must

L S E
FA
be EIGHTY DBA
Take-Away
 OSHA requires 85 dBA.
What is important: chiller sound level or room sound level?
 How important is the chiller sound level if the sound level is 70 dBA
outside the room?
 Are three (3) chillers quieter than two (2) chillers?
63
Turban legends
Turban legend #9
Turbocor Chillers provide
state of the art flexibility
64
Quick Response Time
Variable Primary Flow Operation
1000 gpm Flow rate cut by half in less than

58F one minute.
23XRV quickly shed the load and
stabilized at the new condition.
500 gpm
23XRV Operation as
evaporator water
44F
flow reduced by
50% in 30 seconds.
65
Variable Primary Flow – Rate of Change
Carrier Carrier Turbocor

Model 23XRV 19XR(V) Various
Rate of Change Due to
70% 30% 10% EXV
(%/min) limitation.
Minimum Loop Review
450 900 1,800 McQuay O&M
Volume (gal)* Manual for

more details.
* = 300 Tons Comfort

Cooling Application
Industry Best!
Why is this Important?

66
Quick Response Time
In a variable primary flow system, if the evaporator flow to the chiller is
half, you have cut the load in half.
If the chiller does not unload quickly enough, the chilled water
temperature will drop and either result in:
1. Recycle (LCWT too far below setpoint) or

2. Worst Case, a Freeze Trip (LCWT below freeze protection
value).
3. Slower response time means more loop volume will be
required, which equates to more installation cost.
In Variable Primary Flow applications, make sure to get a rate of

change above 10%/minute specified on the cooler.
More Flexibility = Less Nuisance Trips

67
Turban legends
Turban legend #9
L
Turbocor Chillers provide
S E
FA
state of the art flexibility
Take-Away
 23XRV can react to a flow rate of change 7 times faster than Turbocor
and requires 1/7 of the loop volume.
 19XR(V) can react to a flow rate of change 3 times faster than Turbocor
and requires 1/3 of the loop volume.
 The 23XRV and 19XR(V) can give you higher system stability.
68
Turban legends
Turban legend #10

Harmonic Distortion is
not a Big Concern
69
Are You the Harmonics Expert for your Facility?
Harmonics are Hard to Predict & Diagnose

At a university campus, all of the clocks would intermittently reset themselves
to 12:00 throughout the campus…for no apparent reason.
WHY?
The reason for this occurrence was a
chiller. When the chiller would start,
it would produce a harmonic
frequency that was the same
frequency used to reset all of the
clocks on campus.
70
IEEE-519 Compliance
Carrier IEEE-519 Compliant VFD

Voltage Total Harmonic Distortion (THD) shall not exceed 3% and Harmonic
Current Total Demand Distortion (TDD) shall not exceed 5% as calculate per
IEEE-519 using the VFD circuit breaker input terminals as the point of common
coupling (PCC).
Take the recommendation of IEEE and
use an IEEE-519 compliant VFD.
71
Point of Common Coupling
Turbocor will say:

But if Harmonics are measured at the Point of Common
Coupling, which is part of an entire system, the VFD on
the chiller is only a minor part of that system..
This statement is true… HOWEVER…

Using the proper harmonic mitigation at the circuit breaker for
the chiller will guarantee that the chiller will meet IEEE-519
compliance for harmonics, no matter how the entire system
changes down line of the Point of Common Coupling.
This requires a system study that

may cost approximately $20,000.
72
Turban legends
Turban legend #10
S E
Harmonic Distortion is
L
not a Big Concern
FA
Take-Away
 Proper review of IEEE-519 compliance requires a $20,000 system study.
 The LF2 VFD will maintain IEEE-519 compliance.
 Are harmonic filter losses included in kW/Ton?
73
Turban legends
Turban legend #11

Turbocor Chillers are the
Easiest And Cheapest
Chillers to Service
74
Capacitors
Could this be an safety issue?
• Capacitors require periodic
replacement every (3) years? (5)
years? (7) years? (10) years? at an
approx. cost of $1,000/compressor
and approximately 20 minutes to one
(1) hour to replace.
• Most Turbocor chillers have multiple

compressors.
• Most Turbocor chillers are single

circuit, which means the system will
require a shut down or rental chiller
to replace the capacitors.
WMC400D Approximate Cost
• Because most Turbocor chillers are (4) Compressors
single circuit, it would be best practice
to replace the capacitors of all Capacitors - $1,000 x 4 = $4,000
compressors at the same time. Service ($105/Hr) - $105 x 4 = $420
Therefore, premature failure of a
capacitor bank could require
Total Cost = $4,420.00
replacement of all capacitors before
recommended replacement.
75
Control Board
e rvice “From talking to our contractor that

s
m on from installed the chillers, the biggest
t
Com plain d: issue that these machines have is
com he fiel ures control board failure. They are very
t
F ail susceptible to lighting strike power
rd
Boa surge issues” – Director of
Operations, Energy Systems
Company.
Lightning/Surge Arrestors are

STANDARD for Carrier VFD
products.
• How are boards replaced?

• Estimated board replacement…$7,000
76
Check Valve
Turbocor compressor requires a check valve to protect the
carbon sleeve touchdown bearing and prevent damage at
compressor shut down.
Check valve failure can

cause damage to
compressors and
require compressor
replacement.
Check valve
maintenance is not
mentioned in O&M
manual. 77
Schrader Fittings & Thermowells
Carrier utilizes thermowells for heat

exchanger temperature sensors
Carrier utilizes Schrader fittings for heat
exchanger pressure sensors
These devices permit sensor change out
with refrigerant inside chiller
With out these devices the refrigerant charge

must be removed
Hours of service time and money
(10 Hours per 1,000 lb of refrigerant)
78
What Does the Competition Really Say?
Refrigerant cannot be transferred

with onboard compressor.
79
Unit Mounted PumpOut
York
MultiStac MultiStac Smardt
Carrier Carrier McQuay McQuay Johnson
k k Cooling
Controls
Model
19XR 23XRV WMC WME YMC2 MST MS500F WA
Number
Unit
Mounted
Yes Yes No No No No No No
PumpOut
Available
Unit Mounted Freestanding Refrigerant

Recovery Unit
80
Why is the Unit Mounted PumpOut Beneficial?
Freestanding
Unit Mounted
Refrigerant
PumpOut
Recovery Unit
Extra Installation
None Yes
Space Required?
Installation/Set
Minimal High
Up Time
Service Time Minimal High
Unit Mounted PumpOut

Lowers installation and
maintenance costs.
81
Turban legends
Turban legend #11
Turbocor Chillers are the
Easiest And Cheapest
L S E
FA
Chillers to Service
Take-Away
 Most magnetic driven chillers do use some oil.
 Capacitors require replacement.
Magnetic driven chiller manufacturers do not utilize Schrader fittings or
thermowells.
82
Turban legends
Turban legend #12

Numerous two hundred
and fifty ton chillers are
better than single larger
capacity chillers
83
The 250 Ton Trap
Why does Turbocor

specify projects with
multiple chillers at 250
Tons instead of larger
chillers?
Is it better for the

customer?
84
Is It Better for the Customer to Buy Multiple
Chillers?
(B) 23XRV (375

(A) 2 x 23XRV (C) 3 x 250 Ton
Ton) + 30XW
375 Ton Turbocor
(375 Ton)
Annual Energy Cost Details

Chiller Electric Cost ($) $77,817 $94,491 $100,016
Chiller Fuel Cost ($) $0 $0 $0
Heat Rejection Fans ($) $16,971 $14,948 $16,085
Chilled Water Pump ($) $19,762 $18,747 $18,238
Condenser Water Pump ($) $11,171 $11,052 $11,296
Total Energy Cost ($) $125,720 $139,238 $145,634
Total Savings Cost ($) $19,914 $6,396 --
Total Savings Percent (%) 14% 4½%
So if a two (2) 375 Ton chiller system is better for the
customer than three (3) 250 ton chillers, why doesn’t
Turbocor specify 375 ton chillers?
85
ASHRAE 90.1
ASHRAE 90.1-2007 Efficiencies
Could it be because
0.634 kW/Ton
Turbocor is not
ASHRAE compliant
0.576 kW/Ton above 300 tons?
McQuay WMC Selection
86
Turban legends
Turban legend #12
Numerous two hundred
L S E
and fifty ton chillers are
FA
better than single larger
capacity chillers
Take-Away
 Multiple smaller chillers may not be the most efficient HVAC system
solution.
 See Cashman Center Case Study for more details.
87
Turban legends
Turban legend #13

Turbocor’s IPLV
Efficiency Means That It
Is The Most Efficient
Chiller Design For
Chilled Water Systems
88
Turbocor Performance
McQuay Data WMC 290
Entering Condenser Water Temperature
1. FL Efficiency Not ASHRAE
Load % 85 75 65 * 62
90.1 Compliant 300 + tons 100 0.64 0.522 0.425 0.38
2. Not Industry Leading 75 0.568 0.445 0.345 0.297

50 0.538 0.41 0.295 0.244
3. You don’t run chillers at 25 0.524 0.39 0.291 0.235
these loads in multiple IPLV 0.344

chiller plants! 275 ton unit performance, ARI Conditions
Pressure Drop (ft wg) Evap = 22.2, Cond = 13.4
4. IPLV can be misleading and * McQuay WMC chillers require head pressure control to
misapplied. operate < 62F ECdWT
Information supplied on __/__/2008 by _______ .
Major Efficiency Benefits are at 50% & 25%, but these load
points have little impact on multi-chiller plants.
89
The Life Cycle Point
Carrier Worldwide Study
2,000 Ton Hotel, with (4) 500 Ton chillers

100% 75% 50% 25% 100% 75% 50% 25%
Athens 41.4% 58.6% 0.0% 0.0% New Delhi 48.1% 51.9% 0.0% 0.0%
Bangkok 65.1% 34.9% 0.0% 0.0% Osaka 34.0% 66.0% 0.0% 0.0%
Chicago 36.0% 64.0% 0.0% 0.0% Paris 63.5% 36.5% 0.0% 0.0%
Darwin 36.1% 63.9% 0.0% 0.0% Quito 74.9% 25.1% 0.0% 0.0%
Hong Kong 28.5% 71.5% 0.0% 0.0% Ulsan 39.3% 60.7% 0.0% 0.0%
Istanbul 67.9% 32.1% 0.0% 0.0% Vienna 67.3% 32.7% 0.0% 0.0%
Jakarta 31.9% 68.1% 0.0% 0.0% Warsaw 62.6% 37.4% 0.0% 0.0%
London 58.0% 42.0% 0.0% 0.0% Yuma 39.5% 60.5% 0.0% 0.0%
Moscow 59.2% 40.8% 0.0% 0.0% Zurich 60.4% 39.6% 0.0% 0.0%
Where is the 50% or 25% Load?

90
The Life Cycle Point
Carrier Worldwide Study
600 Ton Office, with (2) 300 Ton chillers

100% 75% 50% 25% 100% 75% 50% 25%
Athens 29.8% 59.9% 10.3% 0.0% New Delhi 22.1% 62.4% 15.5% 0.0%
Bangkok 30.2% 66.4% 3.5% 0.0% Osaka 31.8% 54.8% 13.4% 0.0%
Chicago 23.7% 64.7% 11.5% 0.0% Paris 29.7% 49.0% 21.3% 0.0%
Darwin 48.1% 49.5% 2.4% 0.0% Quito 3.2% 53.3% 43.5% 0.0%
Hong Kong 32.9% 56.4% 10.7% 0.0% Ulsan 23.0% 59.7% 17.2% 0.0%
Istanbul 31.5% 52.7% 15.8% 0.0% Vienna 30.9% 48.2% 20.9% 0.0%
Jakarta 33.4% 66.6% 0.0% 0.0% Warsaw 21.6% 53.9% 24.5% 0.0%
London 5.1% 60.2% 34.7% 0.0% Yuma 24.7% 56.0% 19.3% 0.0%
Moscow 20.2% 57.6% 22.2% 0.0% Zurich 20.4% 58.2% 21.4% 0.0%
Where is the 50% or 25% Load?

91
Efficiency Metrics
Industry Part Load metrics are based on single chiller plants
AHRI 550/590 ESEER

(Europe)
% Load Weight Condition Weight Condition
44F/54 F 12 / 7 C
100 1% 3%
85 F, 3 gpm per ton 30 / 35 C
75% 42% 44F / 75F 33% 26 C
50% 45% 44F / 65F 41% 22 C
25% 12% 44F / 65F 23% 18 C
ARI 550/590 section D2 states, “The equation (IPLV) was derived to provide a
representation of the average part load efficiency for a single chiller only. However,
it is best to use a comprehensive analysis that reflects the actual weather data,
building load characteristics, operational hours, economizer capabilities and energy
drawn by auxiliaries such as pumps and cooling towers, when calculating the chiller
and system efficiency. This becomes increasingly important with multiple chiller
systems because individual chillers operating within multiple chiller systems are more
heavily loaded than single chillers within single chiller systems.”
92
Three (3) 500 Ton Chiller Example
Where is the 50% & 25% load in a Multiple Chiller Plant Operation?
Building Load CH-1 CH-2 CH-3

1500 Tons 100% 100% 100%
1250 Tons 83.3% 83.3% 83.3%
1000 Tons 100% 100% Off
750 Tons 75% 75% Off
500 Tons 100% Off Off
250 Tons 50% Off Off
93
Chiller Staging
Honolulu Hotel
3 x 400 Ton Chillers: CH-1 (black), CH-2 (Yellow), CH-3 (Blue)
5 3 1 100% Bin
87.5%
Minimum Building Load
75% Bin
2 62.5%
50% Bin
4 Net Result - SPLV 3
6 Bin Chiller Load Weight ECdWT 37.5%
100% 87.5 - 100% 38% 77.5 F
75% 62.5 - 87.5% 62% 74.9 F
50% 37.5 - 62.5% 0% 25% Bin
25% 0 - 37.5% 0%
94
Do You Really Want To Talk NPLV?
WMC400 23XRV 23XRM
Quantity 2 2 2
System Layout Parallel Parallel Series Counterflow
Total Capacity (Tons) 1,000 (500/Each) 1,000 (500/Each) 1,000 (500/Each)
100% Load Efficiency

0.644 0.585 0.475
(kW/Ton)
23XRV Savings (%) -- 9% 26%
PLV (kW/Ton)* 0.358 0.310 0.302
23XRV Savings (%) -- 13.4% 15.6%

* Values based on the following conditions: CWT = 44/54, CdWT = 85/95
•Robust Design
•No Surge Technology
•Wide Operating Envelope
•Few Movable Parts
•Minimum 500,000 Hour L10
Individual Bearing Life at
AHRI Conditions
95
Turban legends
Turban legend #13
E
Turbocor’s IPLV
L S
Efficiency Means That It
A
F
Is The Most Efficient
Chiller Design For
Take-Away
Chilled Water Systems
 For multiple chiller plant, SPLV is the proper life cycle costs analysis
metric.
 For single chiller plants, items such as pump power should taken into
account during a life cycle analysis.
You may get greater savings with a heat recovery chiller plus true
redundancy.
96
Turban legends
Turban legend #14

Equal Unloading of
Multiple Chillers Is The
Most Efficient Design
97
Turbocor Equal Unloading Position
23XRV WMC290
Quantity 1 2
Percent Load 100% 50%
Capacity (Tons) 300 300 (150/each)
Efficiency at % Load 0.567 0.295
kW 170 88.5 (44.25/each)
Total kW 170 88.5
Claimed Savings (%) 48%
Based on submittal data, why wouldn’t you run two (2)

chillers at 50% load?
Wait…what about the condenser water temperature?
98
23XRV Efficiency at 100% Load
Efficiency of chillers operating at or near 100% load varies significantly with
entering condenser water temperature.
Chiller Efficiency
85F
0.600
0.500
0.400 65F
0.300
0.200
0.100
0.000
60 65 70 75 80 85
Entering Condenser Water Temperature (F)
Chillers running at lower ECdWT, run more efficiently at any load.

99
Equal Unloading Rebuttal – Step 1
23XRV WMC290
Quantity 1 2
Chiller kW 170 88.5 (44.25/each)
Increased Chiller ECdWT (oF) 65 85 65
Revised Efficiency @ % Load

0.337 0.567 0.295
(kW/Ton)
Revised Chiller kW 101.1 170 88.5 (44.25/each)
Total kW 101.1 170 88.5 (44.25/each)
% Savings 12.5% 48%
First, we need to compare efficiency at the same

operating Entering Condenser Water Temperatures
(ECdWT).
100
23XRV WMC290
Quantity 1 2

0.337 0.567 0.295
(kW/Ton)
AHRI Tolerance at % Load 5% 10%

0.354 0.337 0.567 0.325 0.295
(kW/Ton)
97.5 (48.75/each)
Revised Chiller kW 106.2 101.1 170
88.5 (44.25/each)
97.5 (48.75/each)
Total kW 106.2 101.1 170
88.5 (44.25/each)
% Savings 8% 12.5% 48%

* - Tolerances are based on a 10oF ∆T in the evaporator.
Second, we need to review the actual AHRI tolerances

that are taken into at different % loads.
101
23XRV WMC290
Quantity 1 2

0.337 0.567 0.295
(kW/Ton)
AHRI Tolerance at % Load 5% 10%
0.354 0.337 0.567 0.325 0.295
(kW/Ton)
97.5 (48.75/each)
Revised Chiller kW 106.2 101.1 170
88.5 (44.25/each)
Evaporator Pump * - Pump power

3.6 kW 7.2 kW (3.6/each)*
(600 gpm x 20 ft wg) costs are just for the
bundles. No other
losses included,
Condenser Pump such as valves,
6.8 kW 13.6 kW (6.8/each)*
(750 gpm x 30 ft wg) angles, etc.)
118.3 (59.15/each)
Total kW 116.6 106.2 101.1 170 97.5 (48.75/each)
88.5 (44.25/each)
% Savings -1.4% 8% 12.5% 48%
Lastly, we need to add the Power Requirements for Chilled Water &
Condenser Water Pumps. 102
Turban legends
Turban legend #14
Equal Unloading of
Multiple Chillers Is The
L S E
FA
Most Efficient Design
Take-Away
One (1) 23XRV @ Two (2) WMC290 @
Full Load 50% Load
Total Power (kW) 116.6 118.3

 Does the customer want to pay for the actual power consumed or the
claimed power consumed?
103
Summary
1. Turn to the Experts…Turn to Carrier.

2. What else aren’t they saying?
3. EPA requires refrigerant evacuation when equipment is being opened for service.
4. Turbocor chillers may not be completely oil-free.
5. Less than 2 amps is not a real sales benefit.
6. Other options, such as heat recovery that can provide more energy savings than Turbocor.
7. Replacement jobs are dependent on site conditions, not the compressor type.
8. At lower chiller loads (25%), pump savings can be more significant than chiller efficiency.
9. LEED credits cannot be obtained just by buying a chiller.
10. What is more important: chiller sound level or room sound level?
11. 23XRV (7 times) & 19XRV (3 times) can react to a flow rate of change faster than Turbocor.
12. Redundancy with a common mode of failure provides no redundancy at all.
13. Harmonics are hard to predict and diagnose. IEEE-519 compliance is standard with the LF2.
14. Turbocor chillers may not utilize Schrader fittings or thermowells & require capacitor replacements
instead of an oil change.
15. Selecting a chiller size should not be based on manufacturers ASHRAE 90.1 compliance.
16. For multiple chiller plant, SPLV is the proper life cycle costs analysis metric.
17. Does the customer want to pay for the actual power consumed or the claimed power
consumed?
104
Questions
105

Conociendo La Competencia

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Title: Getting to Know the

We are hearing a lot about magnetic

With claims like theirs, it seems like a

Turbocor McQuay WME /

TT300 71.1 – 91 WME 400 – 700 YMC2 210-400

TT350 85.3 – 113.7

TT400 113.7 – 142.2

TT500 170.6 - 199

• Magnetic bearings and sensors keep the shaft properly centered

•The shafts position is monitored with 10 sensor coils who’s signal

Turbocor Claimed Compressor Features

How is this repaired or replaced?

Synchronous Brushless Centrifugal

• 100% Oil Free

• Less than 2 amp Inrush

Not AHRI Certified

MS-T 80-600 http://

Property of Carrier Corporation © 2012

Attribute Turbocor York/Johnson Controls

Range 60 – 2,000 400 – 700 210 - 400

Screw ≥ 300 0.620/0.540 0.639/0.490

Centrifugal < 150 0.634/0.596 0.639/0.450

Centrifugal ≥ 150 & < 300 0.634/0.596 0.639/0.450

Centrifugal ≥ 300 & < 600 0.576/0.549 0.600/0.400

Centrifugal ≥ 600 0.570/0.539 0.590/0.400

What does this

Dual compressor & single circuit does not always equate

Flow Factor Design Capacity

What Happens to the Chiller System if there is:

• A Plugged Pump Strainer

Redundancy with a common mode

If the compressor is oil-

Carrier 19XR(V) Variable Orifice

EXV Metering Devices Require Oil,

Does the oil last the life of the chiller?

Is Turbocor avoiding this

6,000,000 Btu/H = 400 Tons

30XW Heat Recovery Chiller Savings vs. Boilers

40% 71% 75%

New Heat Recovery

Savings 0.220 kW/Ton Savings 3.15 kW/Ton

300% More Savings w/ Heat Recovery Chiller

“If just 10% of the cooling ton hours are

Over $100,000 per year in energy savings!!

A reduction in lift allows a speed reduction.

All centrifugal chillers are subject to Ideal Fan Laws…

TT350 85.3 – 113.7 1

TT400 113.7 – 142.2 1

TT500 170.6 - 199 1

Nominal Conditions Actual Conditions

Capacity (Tons) 250 200

Will these values be the same?

30 300 Tons @ 56/42oF

Carrier 23XRV vs. McQuary WMC Condenser Pressure

30 300 Tons @ 95/86oF

A pump’s power is more significant than the

OH BY THE WAY, HOW OFTEN WILL YOU RUN AT 25%?

2,000 Ton Hotel, with (4) 500 Ton chillers

Where are all the 25% hours?

LEED EA 1 Credits are

LEED EA 1 Credit Prerequisites:

Table 1 – Annual Costs

Cooling Tower Fans