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Magnitude® Magnetic Bearing Chiller
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Daikin Magnitude Chillers
Two models, from 100 to 700 tons Magnetic bearing compressor system eliminates the efficiency losses inherent with traditional compressors First in the chiller industry to utilize magnetic bearing technology, in 2004 Magnitude is the family name for Daikin’s line of water-cooled magnetic-bearing frictionless compressor centrifugal chillers which is now available in sizes up to 700 tons. Like other centrifugal compressors, the Magnitude compressor utilizes centrifugal energy, imparted on refrigerant gas by a rotating impeller, to increase pressure. However, unlike a standard centrifugal chiller in which the compressor shaft/impeller assembly rides on conventional bearings, in all Magnitude products, a magnetic bearing system levitates the shaft/impeller assembly inside of the compressor body. This frictionless system has multiple benefits which we will discuss throughout this presentation. Magnetic bearing technology has successfully been in use for over 60 years. The first magnetic bearing technology patents were issued in the 1940s to a University of Virginia professor who was developing the technology for use in ultracentrifuges. Since that time magnetic bearing technology has successfully implemented in many products such as industrial machinery, maglev trains, and even artificial hearts. Daikin pioneered the usage of the technology in the commercial HVACR industry, and in 2004 launched its first magnetic bearing chiller product – the WMC. Since that time, Daikin has continued to lead the magnetic bearing chiller industry – both in technology and in sales, dominating the magnetic bearing chiller market as well as having a majority share in the low tonnage centrifugal chiller market. Magnitude WMC 100 to 400 tons Magnitude WME 400 to 700 tons 2
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Magnitude Product Line Chart
The Magnitude line comes in a variety of sizes to meet the needs of the low-medium tonnage chiller market. The original Daikin series of magnetic bearing chillers is known as WMC. With the exception of the smallest unit, the WMC-145S – a single compressor model, the WMC utilizes dual compressor technology. The WMC offers industry-leading performance in the 100 – 400 tonnage range. One WMC compressor is capable of handling up to 60% of the full load requirement. In the event of a compressor failure, the inoperable compressor can be isolated and removed, and the chiller operated as usual. A quick examination of the IPLV (Integrated Part Load Value) equation, shows that over 57% of operating hours are spent operating at 60% full load or less. Therefore, there is a significant likelihood that the customer’s capacity demands can still be met with one compressor. After proven success with the WMC line, and to meet the needs of the larger tonnage market, we introduced the WME models available. The WME units utilizes a single compressor and similar magnetic bearing technology to that of the WMC. The WME offers world-class performance in the tonnage range. The one-compressor design offers cost-savings and allows the customer to offer fully system redundancy with multiple chillers, a typical practice in this size range. If asked… Currently the WME is offered in 460 V/ 60 phase. The WMC is factory offered in 460V / 60 Hz and 500 V / 50 Hz. We recognize a need for this product in lower and higher voltage markets and is working to develop these options. In the meantime, field supplied transformers have been applied to the product in successful implementations across the globe. 3
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Innovative Compressor Design
Magnetic bearings No contact = No friction = Greater efficiency Oil-free design No contact surfaces = No oil or oil handling equipment Integrated variable frequency drive VFD VFD The key to the outstanding performance of the Magnitude line lies in the unique and innovative design of its compressors. Regardless of model, each Magnitude compressor utilizes magnetic bearing technology, an oil-free design, and an integrated variable frequency drive – all of which contribute to the unit’s longevity and industry-leading and sustainable performance. Unlike a standard centrifugal chiller which utilizes conventional touch bearings, there are no moving contact surfaces within the Magnitude compressor. This frictionless compressor design contributes significantly to the efficiency of the chiller. Additionally, because there are no moving contact surfaces, mechanical wear issues are non-existent and oil, and an associated oil management system, are not required nor used in the Magnitude chiller. The oil-free design enhances efficiency and promotes sustainable performance. Magnitude chillers have integrated variable frequency drives. The VFD is integral to the compressor body on the WMC, whereas the VFD is housed in a separate panel on the WME. The integrated VFD is a significant contributor to the industry-leading efficiency of the Magnitude line. Magnitude compressors have excellent unloading capabilities and do not require the utilization of inefficient hot gas bypass. ---- NOTE TO PRESENTER: Unloading capabilities are always dependent on conditions. At 450, 500, and 570 tons (AHRI Standard Rating Conditions and utilizing condenser relief), the machines will unload to 10%. However, always verify job-specific performance characteristics by using Daikin software to generating product ratings. Magnitude™ WME Compressor Magnitude™ WMC Compressor 4
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WMC Compressor Design Discharge Port Suction gas Integral VFD
Magnetic bearings and sensors Permanent magnet brushless DC motor Inlet Guide Vanes Heat exchanger for motor cooling (refrigerant cooled motor/VFD) Let’s take a closer look at the compressor in its entirety. Here is a diagram of the WMC compressor. Point out: Semi-hermetic, direct drive motor Suction gas inlet and inlet guide vanes (IGV work in conjunction with the VFD to react to load requirements – open as more load required, close with unloading) Shaft assembly - Two stage compression (two impellers) for WMC; WME has single stage (one impeller) compression Show discharge port WMC utilizes integral VFD built into compressor. WME also comes with an integrated VFD, however it is housed outside of the compressor body in a separate panel and will be seen in subsequent slides. Black box on front of the Magnitude WMC compressor is the compressor control module. This is the “brains” of the compressor. Communicates with and monitors conditions in the chiller, the VFD, inlet guide vanes, motor, magnetic bearings and sensors. All Magnitude compressor motors and VFDs are refrigerant-cooled. Refrigerant is supplied via the liquid refrigerant line. The amount of refrigerant supplied is controlled by the compressor control module. IMPORTANT – Discuss what happens in the event of an unplanned power failure - On this compressor, point out bay of capacitors across back of compressor. (Note: WME utilizes similar regenerative power for controlled coast-down) - Capacitors are charged at start-up. In the event of a power outage and unit shutdown, the energy stored in the capacitors will be fed back into system to allow for the shaft to spin down gently while still remaining levitated. Finally, when the capacitors are discharged and there is not enough power to keep the shaft levitated, it will gently sit down into the touchdown bearing system. Coast down from 100% load, takes approximately 30 seconds. The touchdown bearings, which theoretically should never see rotational motion, have still been tested for full system failure and it would take several full-rotation crashes to damage the touchdown bearings. As a safety, Magnitude compressors will not start without capacitors. Magnitude compressors are intelligent, reliable, and are typically field serviceble. --- NOTES TO PRESENTER: Serviceability – WMC: Capacitors, access to VFD card and cards in the compressor control module. Else, must be sent to the factory for servicing. WME: Capacitors, front-end aerodynamics, and VFD are fully field-servicable Can not share a similar cut-away of the WME compressor yet due to patent-pending issues. This presentation will be updated when graphics are allowed for release. IGVs actuated by a stepper motor/worm gear assembly. Sometimes people are skeptical of a compressor with such complicated controls. In our history with the WMC, we have found the compressor to be highly reliable. In fact, if one were to try to pinpoint the biggest point of failure on the chiller, it wouldn’t be the compressor – it would be a check valve on the condenser. The compressor used in the WMC is purchased by Daikin for use in our Magnitude WMC chillers whereas the WME has a Daikin proprietary design compressor. Suction gas Compressor control module Shaft & impeller 5
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R-134a Refrigerant No phase-out schedule, no ozone depletion potential
Positive pressure refrigerant = reduced contaminant risk On-board refrigerant containment Simpler, more cost-effective solution No purge system required Units ship with refrigerant No recovery system required Many Magnitude units earn 2 LEED® points for Category EAC 4, Enhanced Refrigerant Management All Daikin centrifugal chillers, including all in the Magnitude line, utilize environmentally responsible R-134a refrigerant. Unlike R-123a, which is still being used by a competitor, R-134a is not subject to phase-out per the Montreal Protocol and, with a ozone depletion potential of zero, shows Daikin’s commitment to the environment. Given that R-134a is a positive pressure refrigerant, Daikin chillers have a reduced risk of contamination compared to a negative pressure machine, such as those utilizing R-123a. All Magnitude condensers are designed, and DOT approved, to isolate and store the entire refrigerant charge. This allows Magnitude chillers to be shipped from the factory fully assembled and charged, arriving on site ready for installation and operation. Overall, the Daikin design offers a simpler, more cost-effective solution than many of its competitors with regards to refrigerant handling. Daikin chillers do not require purge systems, separate pump out or refrigerant recovery units. Additionally, many Magnitude models qualify for LEED EA Credit 4, Enhanced Refrigerant Management.
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The Simplicity of Being Oil-Free
Standard Centrifugal Magnetic Bearing Centrifugal Oil YES NO + Oil Heater + Oil Cooler + Oil Pump/Starter + Oil Reservoir + Oil Filter + Oil Piping/Valving + Oil Sensors/Controls = More things to break, more maintenance, more $ No concerns, no cost An important feature of the Magnitude magnetic bearing chiller is that it is designed to be oil-free. As there is no physical contact of the shaft/impeller assembly with any other components while the system is in motion, oil – and a subsequent oil maintenance system – is not used. Most technicians with centrifugal chiller experience will say that their most troublesome chiller maintenance issue pertains to the oil system. Even if the oil system is working correctly, a strict maintenance regiment is required to insure that it keeps working correctly. We avoid this burden with the Magnitude – it is simply something we don’t have to think about. Not to mention, just as Daikin opted to use R-134a, going oil-free is just another example of Daikin’s commitment to the environment. 7
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Oil-Free Magnitude® Chiller Offers Sustainable Performance
Positive pressure, oil-free design eliminates the performance degradation due to non-condensables and oil contamination of the refrigerant Recent studies have shown that oil can have drastic effects on more than just maintenance obligations and costs. Articles published in the RSES Journal and the Air-Conditioning, Heating, Refrigeration NEWS have highlighted the effects of oil buildup in the chiller on capacity and performance. The table, published in the NEWS, shows that oil accumulation in the evaporator can have devastating effects on performance. Magnitude compressors offer sustainable performance – the capacity and efficiency you achieve on the last day you run the chiller should be the same as the day you started it up. ----- NOTE TO PRESENTER: RSES = Refrigeration Service Engineers Society Source: The News, 04/15/04, by Jack Sine 8
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Industry-Leading Performance
Model Capacity tons Full load, kW/ton IPLV WME700S 700 0.532 0.306 WME500S 570 0.570 0.335 500 0.312 WMC400D 390 0.604 0.329 360 0.571 0.327 WMC290D 290 0.545 0.326 WMC250D 250 0.614 0.350 WMC150D 150 0.611 0.355 WMC145D 145 0.629 0.367 WMC145S 0.661 0.360 14% Energy Savings Over Comparable Standard Centrifugal Chiller w/ VFD 39% Energy Fixed Speed Chiller The entire Magnitude line offers outstanding competitive performance, particularly in part-load operation. What separates the WME from the WMC is that it is an industry-leader in both full and part load conditions – truly world-class and making it suitable for a variety of applications where unbeatable performance is required at all loads. Magnitude offers substantial performance benefits over competitive standard centrifugal chillers. Notice that a 500 ton WME offers a 14% energy savings over a comparable traditional centrifugal chiller with VFD and 39% energy savings over a fixed speed chiller. NOTE: With the exception of the 390 tons, all data reflects ASHRAE compliance at AHRI Std. Rating Conditions. REFERENCE: ASHRAE Compliant at ARI Std. Rating Conditions For <150 tons: Full Load ≤ 0.703, IPLV ≤ 0.669 For 150 ≤ x < 300 tons: Full Load ≤ 0.634, IPLV ≤ 0.596 For 300 ≤ x < 600 tons: Full Load ≤ 0.576, IPLV ≤ 0.549 Selections verified 5/6/10 9
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Industry-Leading Performance
Up to 40% more energy efficient than standard centrifugal chillers Saving more than $2 million over the life of the chiller!
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Industry-Leading Performance
What this means for owners... Energy savings at non-peak loads LEED Energy and Atmosphere Credit 1 (EAc1), Optimize Energy Efficiency, for 1 to 19 possible points Potential qualification for rebate programs Stellar performance boils down to more dollars in the owner’s pocket. Magnitude offers energy savings opportunities all-around, with a particularly substantial savings opportunity during non-peak load hours. Efficient Magnitude chillers contribute to a building’s overall efficiency, and hence contribute to an owner’s ability to qualify for more points towards LEED EAC Credit 1. Magnitude may also help owners qualify for energy incentives and rebate programs. 11
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Real Savings in Real Jobs
One Crawford Condominiums Portsmouth, Virginia We saved 3,000 a month in electrical costs after replacing our old chillers with two Daikin magnetic bearing chillers. And the units are so quiet, the residents living directly below the chillers cannot hear them operate. Charles Twine, Vice President of the Crawford Residents Association
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Real Savings in Real Jobs
Florida Community College, North Campus Jacksonville, Florida We installed a 300-ton Daikin magnetic bearing centrifugal chillers as part of an upgrade to our campus chiller plant and BAS system. The North Campus reduced its electrical usage by 519,514 kWh in the first six months. This chiller contributes 30 to 40% of our energy savings for the entire system upgrade. Mark Gandy, North Campus HVAC Facilities Manager
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Among the quietest Chiller in its Size Range
Sound pressure levels as low as 76 dBA per ARI Standard 575 Ideal for schools, condos, libraries and healthcare facilities The Daikin Magnitude chiller is the quietest chiller in its size range with sound pressure ratings as low as 76 dBA per ARI Standard That makes it ideal for sound sensitive environments such as schools, performance halls, museums, condominiums and libraries.
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Daikin Magnitude® Chiller
Seismic compliant option California Office of Statewide Health Planning and Development (OSHPD) pre-approved International Building Code (IBC) certified International Building Code (IBC)– 2009 Adopted by most states References ICC AC-156 for shaker table testing California Building Code – 2010 References ASCE/SEI-7-05 for minimum load for building and structures References back to ICC AC-156 for shaker table testing OSHPD – Office of Statewide Health Planning and Development Enforcement Agency Requires certification documentation before delivery Neither Standard references “Zones” anymore Differences between IBC and OSHPD IBC Largest model shaker table tested Certificate available OSHPD Largest and smallest model shaker table tested; Daikin tested to Mapped Spectral Acceleration (SDS value) of 1.6 which covers majority of California including Los Angeles and San Francisco Number given by OSHPD to manufactures as a blanket pre-approval Product is listed on their website Typically OSP is good for 5 years - Our OSP is good through 2016 All Daikin centrifugal chillers included for both certifications – WMC, WME, WSC, WDC, WCC, TSC, HSC Also included: OSP/IBC sticker is provided (Sticker is required by IBC) IBC certificate tailored for individual job site is available All Voltages Neither IBC or California OSHPD Standards reference “Zones” anymore but rather Mapped Spectral Acceleration (SDS) values. This reference map is based on Ground Acceleration Values. Daikin Chiller label
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Daikin Magnitude® Chiller
Advantages of seismic pre-approval Lower costs to achieve seismic certification Faster approvals Faster building occupancy Increased protection for your building investment
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More Magnitude® Chiller Benefits
Feature Benefit Multiple vessel and tubing options Design flexibility to meet specific performance requirements Open Choices™ feature for communication with your choice of BAS using BACnet, LonTalk or Modbus protocols Easy integration without expensive gateway panels Intelligent controls system with touch screen interface Intuitive, easy to use for enhanced operator productivity AHRI certification and factory functional testing Verified performance Certified and witness test options Customer confidence that the chiller performs as specified Comprehensive factory support after installation, including operator training Customer satisfaction through the life of the chiller
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Magnitude Rapid Restore®
Quickly restores cooling capacity in mission critical facilities! RideThrough® - Beyond quick start – Compressor rotor never stops and re-synchronizes during short duration power failures Maximum Compressor Start Time* Fast Loading Time to 80% Load* Minimum RideThrough® Time WMC 43 sec 120 sec NA WME 60 sec 75 sec 5 sec** The Magnitude line boasts a small footprint making it especially suitable in areas where usable space maximization is critical or there are small mechanical rooms. The Magnitude fits well in tight spaces with the WMC line, depending on specific model, fitting through standard 3’ or 4’ wide doors. * Time after power is restored after a power failure ** Power Loss Duration Times may vary slightly based on system conditions at the time of power failure and at the time of power restoration. WME requires separate controls UPS for Rapid Restore and Fast Loading 18
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Magnitude® Chillers—a Great Choice for
Areas with high electric rates Immediate savings and quick payback Sound-sensitive environments It’s the quietest chiller in its size range Buildings with high lease rates Small footprint means smaller equipment rooms and more space available for leasing Limited space for moving or install units WMC models fit through standard 4’ wide doors Magnitude is appropriate in all commercial HVACR applications – new construction and renovation. Magnitude has been used across North America in all building types – from schools and universities to office buildings to hospitals to data centers. Magnitude is an appropriate choice in sound-sensitive locations - the WMC in particular. Measured in accordance with AHRI Standard 575, sound levels for the WMC are as low as 76 dBA. This impressive sound performance means that a normal volume conversation can be held standing next to the chiller. In many cases, the chilled water pumps are louder than the actual chiller. The WME is inherently louder due to its larger size. However, it is comparable in sound to a Daikin WSC w/ VFD and remains quieter than other competitive centrifugal chillers on the market. A feature of all Daikin chillers, unlike our competitors, Magnitude becomes quieter as it unloads. Magnitudes can be particularly useful in areas with high utility rates where owners can experience an immediate energy savings and enjoy a quick payback on their investment. Magnitude is appropriate in buildings where floor space comes at a premium – financially and in square footage. The Magnitude line boasts a small footprint making it especially suitable in areas where usable space maximization is critical or there are small mechanical rooms. The Magnitude fits well in tight spaces with the WMC line, depending on specific model, fitting through standard 4’ wide doors. Despite boasting small footprints, there will be times when a customer has limited options for bringing Magnitude chillers into their space. Daikin offers a variety of knockdown options which range from simple bolted construction that allows for field assembly/disassembly to full component knockdown conducted at the factory.
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Ideal for Retrofit Compact size of the Magnitude chiller makes it ideal for retrofit and replacement Stacked Shells = Smaller Footprint! H = 84.0” (2137 mm) The Magnitude line boasts a small footprint making it especially suitable in areas where usable space maximization is critical or there are small mechanical rooms. The Magnitude fits well in tight spaces with the WMC line, fitting through standard 4’ wide doors. L = 170.6” (4333 mm) W= 45.5” (1158 mm) Magnitude WMC-290D, C-vintage unit shown
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Reliable Magnitude® chillers have proven their reliability in 2,900+ installations around the world From 2004 through 2011, more than one thousand Magnitude chillers have been installed around the world, providing consistent comfort and energy savings. The fact that Magnitude chillers have been successfully installed around the world, providing consistent comfort and energy savings to all types of installations, is a testament to the reliability and consumer trust in the product. Daikin believes magnetic bearing technology is the future in high-efficiency chiller products. While already the leader in the user of magnetic bearing chiller technology, in it’s goal to become the #1 leader in the chiller industry, Daikin Daikin plans to continue offering high performance and environmentally-friendly products at competitive prices. We believe this can be done by continuing to develop and expand the Magnitude line. Over the next few years, expect to see the number of Magnitude chillers grow exponentially, along with a greater capacity range.
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A Favorite Choice of Green Buildings
Child Development Centre, University of Calgary – LEED® Platinum Johnson County Office Building, Kansas – LEED Gold Magnitude Frictionless Centrifugal Chillers are a favorite choice of green buildings because of their high efficiency. Here are just a few of the green buildings where Magnitude chillers are installed. Harford Board of Education Office Building, Maryland – LEED Gold Northbrook Junior High School, Illinois – Energy Star® rated
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Top 6 Reasons To Specify and Buy a Daikin Magnitude® Chiller
Significant energy savings World-class, sustainable, and reliable performance Environmental commitment LEED® points and potential rebate qualifications Great value with fast payback opportunity Seismic certified The benefits of Magnitude make it a clear choice for specifications and purchases. - Magnitude units offer significant energy savings over standard centrifugal chillers. - Magnitude leads the way in performance. WME performance is world-class in performance, sustainability, and reliability across many commercial building applications. - Magnitude units exhibit Daikin’s commitment and the customer’s commitment to the environment – the use of environmentally-friendly R-134a, oil-free design, high efficiency, and the efficient use of materials. - Magnitude units result in LEED points and in some cases, help owners qualify for responsible energy use incentives and rebate dollars. - Overall the Magnitude is a great value with fast payback opportunity. 23
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What a Magnitude® Chiller Means for the Facility Owner
+ + = High Efficiency Reduced Maintenance (no oil, no purge) Sustainability Lowest Total Cost of Ownership The high efficiency combined with reduced maintenance obligations of a Magnitude chiller result in sustainable design and performance and a lower total cost of ownership. 24
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Make it a Complete Daikin System
Magnitude® Chiller 100 to 700 tons Vision™ Indoor Air Handler ,000 cfm Skyline™ Outdoor Air Handler ,000 cfm Destiny™ Air Handler ,000 cfm After you have selected a Magnitude Chiller, choose Daikin air handlers or terminal units for optimum system performance and reliability. Unit Ventilator ,000 cfm Fan Coil units ,000 cfm RoofPak™ Outdoor Air Handler ,000 cfm
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