1. Arctic Cool Oil-Free Chillers

2. The Arctic Chiller Group

3. Remarkable Turbocor Compressor
100% Oil Free eliminates oil system maintenance costs.
R134a Refrigerant meets Montreal protocol and is not subject to phase-out.
Magnetic Bearings eliminate frictional losses.
One moving part assures long service life.
Unmatched Efficiency as low as .30 kw/ton IPLV.
Low 2-amp In-Rush Current reduces installed cost and peak load.
Lowest Noise - Only 70 dBa.

4. The Turbocor Compressor
Soft-Start
(<2amps Inrush)
2 stage centrifugal compressor
Inverter speed control
Pressure and temperature sensors
Synchronous brushless DC motor
Inlet Guide Vanes
Motor and
bearing control

5. VFD and Inlet Guide Vane Operation
The Compressors speed adjusts automatically to match the load and 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 is reduced, energy consumption is reduced by the cube of the energy

6. Shaft is monitored and positioned 100,000 / sec.
The Magnetic Direct-Drive System
Magnetic bearings and sensors keep the shaft properly centered and positioned at all times. The rotor shaft is held in 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 whose signal is fed back to a digital controller. Movements of less than ”are sensed and adjustments are made accordingly.
Shaft is monitored and positioned 100,000 / sec.

7. The Magnetic Bearing System
Permanently magnetized shaft does not require electrical power.
97% energy efficient
Uses 0.5% of the energy required for conventional 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 elimination of wear surfaces

8. Leveraging Affinity Laws
Energy Used is Proportional to the Cube of the Speed of the Motor
Two pumps at 50% speed use 25% of the power of one pump at 100% speed
Optimizing the System involves leveraging Affinity Laws and Real-Time Tracking and Tuning of Components to shift Load to where total PLANT ENERGY across all related components is reduced.
This is not simple PID loop feedback, but Dynamic Optimized kW Input

9. Variable Speed Factors
Power is proportional to the speed cubed
To achieve power reduction, the speed of fans, pumps and compressors should be reduced at lower loads.
Emerging VFD plant controllers optimize the technology.
Flooded designs with water in tubes can limit flow range due to velocity and laminar flow issues. DX can be better solution in some applications, but with efficiency loss.
Cooling tower selections optimized for lower temp and flow. Can increase installed cost yet reduce operation costs.

10. Load Profile Reveals Dollars

11. Why Is Turbocor So Compelling?

12. Compressor Sizes and Uses
Model Capacity IPLV Turndown
TT tons tons
TT tons tons
TT tons tons
TT tons tons
Chilled Water Range – 28F to 60F – 134a limited
Condenser Water Range – 50F to 90F
Ambient Range – 10F to F
Rule of thumb – 12 degrees minimum between LWT and ECT

13. Compact Size - Easy to Service
125 HP motor is in the foreground.
150 HP Turbocor permanent magnet motor behind.
Variable-speed, magnetic bearing and cooling controls.

14. High Capacity – Smaller Size

15. Oil-Free Eliminates Piping Complexity
No need for elaborate piping designs compared with oil management systems.
No traps and risers
Lower installed costs
Eliminates leak sources
Enables centrifugal chiller with remote condenser to be placed at greater distance.

16. Lowest Cost of Service Replace capacitors every ten years
Annually check electronics for tight connections
No oil service or oil disposal - EVER.
Replace capacitors every ten years

17. Lowest Noise and Vibration Levels
“Best in Class” low sound levels. No moving mechanical part touches any part of the housing or frame to transmit acoustic energy.
Tested at 70 dBa at 1 meter with no sound attenuation. Other compressors, by comparison, are approximately 80 dBa and higher.
Vibration is essentially non-existent.
The chiller with 5 compressors operating at full speed only produces 75 DB of sound at 10 feet., about the sound level of your television.

18. What Happens with a Power Outage?
In the case of a power outage, the compressor is fully protected.
Within 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 adequate power to fully support the bearing system during the switch. Capacitors are replaced every ten years.
After the compressor comes to a complete stop, the rotor de-levitates normally onto touchdown bearings. Carbon or roller touchdown bearings are also used as a back up bearing system to act as a cradle for the rotor during the off-mode.
The system then determines if normal power is restored, if YES, the shaft levitates. If there is a call for cooling, the rotor will then begin to rotate. The entire cycle from loss of power to normal operation takes about 3-5 minutes.

19. Automatic Bearing Compensation
This compressor continued to operate even though this hole saw slug was embedded in the 1st stage impeller.
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.
The compressor continued to operate at 35,000 rpm with this imbalance.

20. Turbocor Monitoring Software

21. Turbocor Monitoring Software

22. The Dramatic Effects of Oil
ASHRAE 601-TRP - Oil contamination can be caused by several factors, including gasket failure, but the most common cause of oil migration in comfort chillers is the continued use of a chiller at low loads during the beginning or end of the cooling season. How much does excess oil in the evaporator degrade performance? Table 1 gives typical ranges.
Oil in Evaporator Performance Loss
1-2% % loss
3-4% % loss
5-6% % loss
7-8% % loss
Percent Oil
ASHRAE study reached the same conclusion: “Flow boiling results have been obtained for newer enhanced boiling tubes with R-134a. This enhanced tube shows a decrease in heat transfer with the addition of even a small amount of oil throughout various heat loadings. Even at 1 percent (by weight) oil, the heat transfer coefficient is reduced by 25 percent from its no oil baseline. At higher oil content, a 30 percent reduction has been typically measured.”
Oil causes 50% of downtime and cost

23. The Dramatic Effects of Oil
Percent Oil
ASHRAE study shows average percentages of oil present in chillers
Efficiency loss in heat exchangers account for substantial operation costs
Percent Oil

24. The Dramatic Effects of Oil
In the ten chillers tested in the ASHRAE study, the average overcharge of oil in the system was 12.88%, this equated to an average energy loss of about 21%
Efficiency loss - %
Percent of oil

25. High Cost of Chiller Maintenance
Procedure
Daily
Weekly
Quarterly
Yearly
Record operating conditions (log) X
Check oil levels
Check refrigerant levels
Check oil return system
Check operation of motor starter
Check sump heater and thermostat operation
Inspect and adjust safety controls
Leak check and repair leaks
Lubricate motor
Check and tighten all electrical connections
Megohm motor windings
Perform oil analysis on compressor lube oil
Replace oil filter and oil return filter/dryers
Replace or clean starter air filters

26. High Cost of Oil - Bearings
Stop Operation & provide backup chiller (rental)
Open the compressor and hermetic motor for inspection
In addition to normal annual maintenance, inspection occurs every 40,000 hrs of operation or every 5 years, whichever occurs first. 5 times during a 30 year service life.
Shutdown, disassemble motor, replace bearings, replace seals.
Cost approximately $25,000 each time 5 times over 30 year service life $125,000 over life of equipment.
Burnout & oil induced acid eliminated.

27. ArcticCool Chiller with TT300
ArcticCool Chillers vs Screws
ARI 550/ Conditions
Leading Screw
WATER COOLED
ArcticCool Chiller with TT300
Load
ECW
F/C
LCHW
SST
SCT
COP
kW/Ton
100%
85/29.5
44/6.7
42/5.6
98/36.7
5.33
0.64
5.56
0.63
75%
75/23.9
42.3/5.8
89.6/32
5. 73
0.6
7.31
0.48
50%
65/18.3
42.5/5.9
5.49
72.2/2.2
11.38
0.30
25%
42.8/6.
4.11
0.845
42.8/6
70/21.1
10.86
0.32
IPLV COP kW/Ton
Conclusion – The Arctic Cool Chiller using the Turbocor TT300 compressor is 45% more efficient than the leading screw compressor

28. ArcticCool Chillers vs Screws
ARI 550/ Conditions
Leading Screw
AIR COOLED
ArcticCool with TT300
Load
Air
F/C
LCHW
SST
SCT
COP
kW/Ton
100%
95/35
44/6.7
35.5/2
122/50
3.19
1.10
3.08
1.13
75%
80/26.7
36.5/2.5
104/40
4.20
0. 83
4.44
0.79
50%
65/18.3
37.5/3
86/30
5.26
0.69
82.5/28
7.23
0. 48
25%
55/12.8
38/3.5
3.98
0.88
66.2/19
9.77
0.35
IPLV COP kW/Ton
Conclusion – The Air Cooled Chiller using the Turbocor TT300 compressor is 29% more efficient than the leading screw compressor

29. Standard Stacked Design
Oil-Free design eliminates frictional losses and high cost.
Lowest IPLV in the industry.
Variable-speed Drive.
Flooded evaporator for thermal buffer and approach.
Cleanable condensers.
NEMA 1 Panels Standard.
Danfoss Controls Standard
Marine Water Box Option.

30. Compact 90 Ton Low Profile
Sub-cooled Inter-stage and condensed liquid can increase both Capacity and Efficiency
Compact Low Profile Design Allows for difficult rigging under existing piping.

31. Standard Low Profile Design
Standard designs include stacked, offset and low profile.
Air Cooled systems to 400 tons.
Split systems are available.
Multiple Circuits available.
Condenser-less and Condensing Units available.

32. Water Cooled Chillers Up to four compressors per circuit
Provides the ability to use the entire heat transfer surface even when using few compressors, thereby ensuring close approach temperatures.
Water cooled products from 60 to 1,500 tons.

33. Low Profile Water Cooled Chillers
Low Profile Design
60 to 1,500 tons
Removable Controls Option
Evap-Condensed Options

34. Air Cooled Chillers
Single Turbocor compressor per circuit to 420 tons.
Assures that refrigerant is properly managed during staging and load variations.
Eliminates the known issues of refrigerant migration with single circuited centrifugal compressors.

35. Modular Chillers
Modules with Scroll, Screw or Turbocor Compressors. Any size.
Air cooled, water cooled, free-cooling and VFD pumping systems are available.

36. Air Cooled Evap Condensed Chillers
New Advances in Evap Condensing
• Microchannel Coils
• No Carry-Over
• Far Less Make-Up • Far Less Charge • Microprocessor • VFD Fan Option
• Short Payback

37. Advantages of High-Side Float
High-Side Float provides enhanced performance, reliable operation and system protection.
Assures sub-cooling section in the condenser with slightly better efficiency.
Any leak over time could result in suction pressure fault, but expensive compressors always receive critical motor cooling.

38. Training and Certification
Conducted by most knowledgeable in Turbocor technologies and application nuances.
Classes in Toronto, Florida and California
Includes Compressor, Controls and Chillers

39. Application Notes
Heat Recovery – 120 °F maximum. Special high-lift compressor required. Only works with TT300, no TT400s.
120 ton TT350 high-lift compressor is now available.
Controller has settable minimum flows to avoid laminar conditions.
Operating Envelope. 28°F min at 25% max PG. Glycol applications above 25% may require DX, not flooded design.
Staging relief valves required for process applications to increase temperature stability. Also needed for most glycol and low unloading.
Differential temp for TT °F °F for TT400. This is the difference between the entering condenser and leaving chilled water

40. Practical Application Constraints
Capital Cost – Premium cost, less competitive with multiple compressors, new high capacity models to reduce cost-per-ton. Better pay-back with higher utility rates. DOE 23% prediction.
Energy Only Emphasis – Lifecycle cost should contain annual maintenance, U-value, rebuilds, green and LEED compelling story.
Quality of Utility – Fluctuations of 10% of voltage and 3% of phase can reset compressors. No harm done. Will not apply where power is poor. 460/3/60 only – NO 208 Volt compressors.
Local Remote Service – DTC mandate. No service, no sale. USA fine.
Temperatures – Less than 25°F and 25% PG. Less than 110° ambient. Process temp stability need staging valves.
Rebates – many success stories include utility rebates to reduce pay-back gap. Retrofit versus new chiller analysis.

41. Series Counter-flow Advantages
Where Parallel flow requires each chiller to produce the entire system Lift, Series-Counter-Flow reduces the total work for each chiller resulting in reduced total system energy.
In series-series arrangements, both evaporator and condenser circuits are in series and counter current flow, so the downstream chiller producing the coldest chilled water temperature rejects heat to the coldest condenser water temperature.

42. Lowest Total Cost of Ownership
Lowest Energy Consumption – low as .30 IPLV
Lowest Noise Levels – 70 dB compressor
NO Oil Maintenance Costs
NO Degradation of Tubing U-Value, Min 8%
NO Compressor Rebuild Cycles - High MTBF
Advanced Danfoss Controls, EnergyMonitor.NET
Qualifies for Deepest Rebates, LEED Points.
Fuel Cell Project – DC to DC lowest cost
Reverse flow generator powers compressors.

43. Questions or Comments…

44. Contacting Arctic Cool
The Arctic Chiller Group
2100 Steeles Avenue
Brampton, ON L6T 1A7
Phone: (905)
Patrick Legare, Vice President, Arctic Cool
Mark Rogan, Group VP Sales and Marketing
Barry Werts, VP ArctiChill