TURBOCOR - THE OIL FREE COMPRESSOR

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TURBOCOR - THE OIL FREE COMPRESSOR
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INSIDE THE TURBOCOR COMPRESSOR
Two Stage, Direct Drive, Centrifugal Compressor
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INSIDE THE COMPRESSOR
with Direct Drive Shaft (only One Moving Part),
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INSIDE THE COMPRESSOR
a 95 - 97 Efficient Permanent Magnet Motor,
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INSIDE THE COMPRESSOR
an Integral Variable Frequency Drive,
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INSIDE THE COMPRESSOR
Oil Free Magnetic Bearings,
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INSIDE THE COMPRESSOR
And a Built-In Microprocessor (Magnetic Bearing
and Motor Controller) . . .
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HIGH EFFICIENCY AT FULL LOAD Centrifugal
Design Centrifugal compressors are considered the
most efficient. The centrifugal Turbocor
compressor has full load efficiency equivalent to
or better than todays best conventional
compressor technologies.
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• BEST PART LOAD EFFICIENCY
• The centrifugal design coupled with a Variable
  Frequency Drive delivers the highest available
  part load efficiency.
• Extraordinary chiller IPLVs (weighted efficiency
  average that more accurately reflects annual
  usage).
• Savings of 20 to 50 annually on compressor
  energy costs.

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IS PART LOAD IMPORTANT?
Note Low of Hours at Peak Load
Courtesy Tom Hartman, The Hartman Company
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THE EFFECTS OF OIL IN A SYSTEM
An ASHRAE research project (no. 601)
determined that the majority of
installed chillers have an excess amount of oil
in the cooling system
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AVERAGE OIL OVERCHARGE FROM TEN CHILLERS TESTED

• In the ten (10) 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

Chiller System Efficiency Loss
fully avoided by using the Turbocor compressor
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TURBOCOR
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TURBOCOR ECONOMICS
Purchase Price Annual Operating Cost Energy Efficiency Percent Improvement Payback
Old 400 ton chiller Exists 92,608 0.80 kW/ton

New 400 ton chiller 150,000 47,016 0.62 kW/ton    
Difference 150,000 45,592 0.18 kW/ton 49 3.3 years
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HIGH RELIABILITY Only one major moving part,
no wear surfaces. No gear sets, multiple pistons,
slide valve assemblies,
mechanical bearings or seals. No oil management
problems!
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MAGNETIC BEARINGS

• Frictionless

• Reliable

• Quiet

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Accidents Happen!

• Auto-balance compensation is a unique part of the
  Turbocor bearing system.
• In this case, the compressor continued to operate
  safely even though this hole saw slug was
  embedded in the 1st stage impellor.
• The compressor is not designed to pump hole saw
  slugs.
• However when so challenged, the auto-balance
  feature was robust enough to handle the task. The
  compressor continued to operate at 35,000 rpm
  with this imbalance.

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SUSTAINABILITY

• Less energy means lower CO2 emissions.
• Magnetic bearings mean no wear surfaces, no
  degradation of performance.

Current installed base is saving about 750,000
tons of CO2 and 950,000 mWH of electricity
annually!
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VARIABLE UNLOADING Infinitely variable
unloading from 100 capacity down to as low as 10
- 30 of full load. Matches cooling load for
better control as well as energy savings.
Compressor VFD
Depending on operating conditions
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• SOUND PERFORMANCE
• Low sound and vibration levels.
• Tested at 72 dBA (at 1 meter with no sound
  attenuation). Screw compressors, by comparison,
  are over 80 dBA.

Customers complain they cant tell their
Turbocor compressor is running!
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Sound Data
XXXXX
72.0 dBA
10 tons
10 tons
80 tons
Oil Free centrifugal
Turbocor quieter at 80 tons!
Louder at 10 tons
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Wont even disturb the birds.
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COMPACT, LIGHTWEIGHT DESIGN The standard
compressor is weighs only 265 lbs for capacities
up to 90 tons (and under 300 lbs for up to 200
tons).
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MONITORING / CONTROLS The Turbocor compressor
includes an integral microprocessor to control
cooling capacity and magnetic bearing
function. It also provides monitoring and
documentation to assist commissioning, provide
energy data, and display performance. The
compressor itself uniquely provides outputs to
support end user.
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• Real time screens,
• to monitor performance and trends
• for energy management
• to assist commissioning and servicing (locally or
  remotely)

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REFRIGERANTS Any color so long as it is
R134a Environmentally responsible, with lower
GWP and zero ODP
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TRUE SOFT START The motor is driven by an
integral VFD, thus requiring very low starting
current, drawing less than 2 amps when first
energized. No in-rush! Great for applications
with emergency back-up power systems. Significantl
y reduces thermal stresses on motor for long-life
reliability.
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MAINTENANCE

• Annually check electronics for tight and
  moisture-sealed connections
• No oil service or oil disposal
• Replace capacitors once every ten years

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SUMMARY OF BENEFITS

• Energy efficiency (especially part load)
• System reliability
• Sustainability
• Variable unloading
• Quiet operation

• Compact, lightweight
• Monitoring
• R134a (no phase out)
• Soft start
• Low maintenance, easy service

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TURBOCOR COMPRESSOR CAPACITY

• Mid-Range size for A/C applications
• AAON to apply with evap and water cooled models

• Single compressor full load from approximately
  60 to 180 tons

• Multiple compressors allow total system
  capacities approaching 1000 tons.

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Turbocor Compressor Shaft/Impeller Assemblies
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2004 Environmental Protection Agency
USA Climate Protection Award
2005 Natural Resource Canada Energy Innovation
Award
2003 ASHRAE/AHR - USA Energy Innovation Award
2010 RSES Journal Award
2008 Institute of Refrigeration UK JE Hall
Gold Medal
Danfoss Turbocor ISO 90012008 Certification
2006 Frost Sullivan - USA Technology Leadership
of the Year Award