1. Smardt Chiller Training
PRODUCT BASICS
PRESENTATION
Presented By: Christine Lazo
Vertical Systems
7113 Telegraph Rd.
Montebello, CA 90640
310 451 0630
christine@vertisys.net

2. Smardt History in Brief
• Turbocor compressor was invented in Australia in 1993
• Turbocor was relocated to Montreal in 1999
• Smardt was founded in 2004 to manufacture chillers
• Danfoss formed 50/50 partnership with Turbocor in 2004
• Smardt and PowerPax form common ownership .
• Smardt, PowerPax and Axima signed a global agreement.
• Water Cooled product range grows up to 1200 tons in 2010
• Air cooled Product range grows up to 300 tons in 2010

3. Smardt Nomenclature

4. Smardt Nomenclature

5. Smardt Chiller Variety
 Air Cooled
 60 tons – 400 tons
Largest
 Water Cooled Range and
Flexibility in
 60 tons – 1200 tons TurboCor
Applications
 Heat Recovery
 Condenser Less / Evap Condensed

6. Air Cooled Chillers
 90 to 400 tons
 Capable of operating at as low as 45F ambient

7. Water Cooled Chillers
 60 to 1200 tons

8. Heat Recovery

9. Evaporative Condensed
Discharge EVAPCO
P
Line D ATCE
P
A E
S Liquid
Chilled T
V Line
water
Pumps F
D
S
Evaporator

10. Smardt Nomenclature

11. Turbocor Compressor

12. Turbocor Compressor: Components
2 Stage Centrifugal Compressor
Variable Speed Drive Soft Start
Pressure & Temp
Transducers
DC Motor
On Board Digital Controls Inlet Guide Vanes

13. Turbocor Compressor: Components
2 Stage Centrifugal Compressor
Inlet Guide Vanes

14. Turbocor Components
 Centrifugal Compressor
 Two stage
 Operates on R-134A
 Has infinitely variable capacity
control
 Uses guide vanes and diffusers to
optimize performance
 Does not require oil for
compression sealing

15. Turbocor Compressor: Components
DC Motor
&
Magnetic Bearings

16. Turbocor Components
 Synchronous Permanent Magnet Brushless
DC Motor
 Gives the compressor:
 Low 2A inrush current
 High reliability – minimal stress on stator windings
 High efficiency throughout operation range
 Compact size and light weight
 Lower cost

17. Turbocor Components
 Magnetic Bearings
 Rotor shafts and impellers
levitate during rotation and
float on a magnetic cushion.
 97% efficient
 When not powered, the
rotor is supported by carbon
composite, touchdown
bearings designed for years
of use.

18. Turbocor Components
 Magnetic Bearings (cont’d)
 Two radial and one axial magnetic bearing are employed.
 Bearing sensors feed back real-time orbit information to
digitally controlled bearings.
 Centered rotation is instantaneously self-corrected and
maintained

19. Turbocor Components
 Magnetic Bearings (cont’d)
 Shaft position is monitored and centered 100,000 per second!
 Centered rotation is instantaneously self-corrected and
maintained

20. Turbocor Component Benefits
Magnetic Bearings Mean NO Oil!

21. Turbocor Component Benefits
Magnetic Bearings Mean NO Oil!
Percent Oil
•Efficiency loss accounts for
substantial operation costs
• ASHRAE sampling shows
average percentages of oil
present in chillers

22. Turbocor Component Benefits
NO Oil =Maintained Heat Transfer Efficiencies

23. Turbocor Component Benefits
NO Oil Means Less Maintenance!

24. Turbocor Component Benefits
Magnetic Bearings
 One Moving Part
 Eliminates high mechanical friction losses
 Eliminates oil-related heat transfer losses
 Eliminates cost of oil management systems (controls
and hardware)
 Eliminates maintenance of oil management
 Increases equipment life – no wear surfaces

25. Turbocor Components
Variable Speed Drive Soft Start
On Board Digital Controls

26. Turbocor Components
 Built-in Variable Frequency Drives
 Unmatched part load efficiency
 Compressor speed adjusts to changes in load and/or
condensing temperature.
 As compressor speed reduces due to lower loads and /or
condensing temperatures, energy consumption dramatically
reduces.
 Part load energy efficiency is outstanding, with energy savings
greater than 30% compared to traditional screw compressors.

27. Turbocor Components
 Built-in Digital Controls
 World's first "smart" compressors.
 Digitally controlled bearings
 Digitally controlled power electronics
 Digitally controlled compressor control
 Digitally controlled chiller control
 Digitally controlled expansion valve controls

28. Turbocor Components
 Built-in Digital Controls
 Microprocessors proactively manage compressor operation.
 Self-diagnosis and correction are built in.
 Eliminates traditional HVACR product control and power
electronics functions saving costs for OEM's.
 Plug n'Play control modules are easy to replace on site.
 Interactive control capability with easy access for BAS and
web-enabled monitoring.

29. Turbocor Components
 The Electronics
 Designed to maximize compressor performance
 Maximum energy efficiency
 Low vibration
 Higher reliability
 Efficient component cooling

30. Energy Efficiency
 The achievement of Turbocor’s high efficiency
comes from:
 The compression technology
 The magnetic bearing technology
 The motor technology
 The power electronics technology
 The controls
 The combination of all these
features into one product
FULLY INTEGRATED SYSTEM

31. Energy Efficiency

32. Why is Part Load So Important?

33. Energy Efficiency

34. Turbocor Benefits
 Quiet Operation
 Quietest compressors in the
industry!
 They operate at 70dBA
(conversation level) sound with
virtually no vibration.
 Given normal equipment room
background sound levels, one
literally can not hear the
compressor operate.

35. Turbocor Benefits
 Lightweight
 Under 300 lbs
 Fraction of weight of conventional compressors

36. Turbocor Benefits
 Small Footprint
 ~ 50% smaller footprint than conventional compressors

37. Turbocor Overview
 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
.33 kw/ton IPLV.
 2A Low In-Rush Current
reduces installed cost and peak
load.
 Lowest Noise - Only 72 dBa
 Intelligent Control – high full
load and part load performance

38. Turbocor Compressor Models
 TT300 : 60 to 90 tons
 250 – 320 kW nominal capacity
 Air cooled and Water cooled
 TT400 : 100 to 145 tons
 400 – 500 kW nominal capacity
 Water cooled ONLY
 TT500 : 150 to 185 tons
 600 – 700 kW nominal capacity
 Water cooled ONLY

39. Turbocor Compressor Models

40. Chillers Using Turbocor

41. Why Smardt?
 If Turbocor is the key component and
there are other manufacturers who use
it on their chillers, then…..
Why use
?

42. Smardt Nomenclature

43. Smardt and Turbocor
 How Smardt uses Turbocor to Size Chillers
 Each compressor is infinitely selectable for rated capacity in its
range
 Each compressor is applied in parallel up to qty (6)
 WC: Chiller barrels are matched to compressor’s size range
 AC: Chiller barrel and fans are matched to compressor range

44. Turbocor Compressors
 Turbocor TT300 – infinitely selectable
Head limit as function Power
of max power Limit
Full Vane
Part Vane Area
Area
Capacity
Limit

45. Multiple Turbocor Compressors
45
 Scaleable 1 to 6 compressors per chiller
 60-140 ton Selections/Compressor
 Brings Peak Size to 1200 tons
 Largest range and flexibility of Turbocors in market
kW/ TonR Vs System Capacity
0.75
0.70
1 comp
0.65
2 comp
kW / TonR
3 comp
4 comp
5 comps
0.60
6 comps
0.55
0.50
0.0 100.0 200.0 300.0 400.0 500.0 600.0
Evaporator CAPACITY - TonR

46. Smardt Nomenclature

47. Barrel Types
 Narrow
 Standard
Configuration
 Stacked Orientation
 Slim Design
 Up to 4 compressors

48. Barrel Types
 Compact
 Designed for tight fits
 Can be modular
 Dimensioned to fit through
elevators and doors
 Limited to 1 compressor
 60 tons – 150 tons

49. Compact Parallel Modular Approach

50. Barrel Types
 Side by Side
 Barrels are oriented beside
each other
 Panels are mounted above
condenser barrel
 For short and wide layouts
 Up to 3 compressors

51. Barrel Types
 Low Profile
 Condenser is located on top
 For height sensitive projects
 For largest tonnages
 550 tons – 900 tons
 Only 4 and 5 compressors

52. Barrel Types
 Fat Max
 Fatter/ Bigger Barrels
 Staggered compressor
orientation
 More expensive to make
 Up to 6 compressors

53. Air Cooled – Fan Types
 V=Variable Speed
 F=Fast Speed
 S=Slow Speed
 H=High Static
Variable

54. Why Smardt?
PRODUCT FLEXIBILITY
 Widest product variety with Turbocor technology
 Air cooled, Water cooled, Split Systems
 60 to 1200 tons range – Up to 6 compressors
 Competitors limited to 2 compressors
 Variety of chiller barrel configurations
 Enables higher flexibility in design

55. Why Smardt?
TRUE REDUNDANCY
• Up to 6 compressors on single barrel
• Mechanical Isolation on each compressor
• Electrical disconnects for each compressor
• ZERO down time on compressor changeouts
• Single chiller operation becomes viable when
applied to 2 or more compressors

56. Why Smardt?
PROTECTION
• Temperature sensors
• Fuses
• Disconnects
• Flow switch – Paddle Type
• Flow Switch – Thermal Type
• Flow Switch – Differential Pressure
Transducer/Switch
• Control Limits – discharge High Pressure Low
pressure switch

57. Why Smardt?
SUPERIOR LIQUID LEVEL CONTROL
 Immersion sensors provide real time input
verification of condenser levels
 Allows precise expansion valve control
 Results in SUPER LOW LIFT essential for optimal
all variable plant performance.
 Competitors use superheat control
 Requires conservative chiller temperature and flow limits
 “Guessing”

58. Why Smardt?
SUPERIOR CONTROLS KNOWLEDGE

59. Smardt Advanced Controls
 Sophisticated Control
 Easy to use
 Color Touch Screen

60. Why Smardt?
SUPERIOR CONTROLS KNOWLEDGE
 TurboCor compressor maps built into controls
 Avoids chokes and surges

61. Why Smardt?
SUPERIOR CONTROLS KNOWLEDGE
 Adaptive, non static microprocessor controls
 Real time compressor mapping monitoring 150+ points
 Far advanced than competition’s offering

62. Why Smardt?
SUPERIOR CONTROLS KNOWLEDGE
 Compressor Status Feedback
 Real-time Chiller Controller Output of Compressor Data
 Compression Ratio
 Compressor Actual Speed
 Surge Speed
 Choke Speed
 Essential for optimal chiller staging in all variable
central plants

63. Why Smardt?
 Compressor Status Feedback

64. Why Smardt?
SUPERIOR CONTROLS KNOWLEDGE
 Patented compressor staging algorithms work at the
optimized power curves
 Smardt is more efficient across ENTIRE load profile.
 Real-Time Feedback and Compressor Selection Logic
 Maximizes the compressors online to minimize RPM
 Requires lowest chiller power input

65. Control System kW Optimization
65

66. Why Smardt?
SYSTEMS KNOWLEDGE = ENERGY SAVINGS
 Control of High Performance All Variable Plants

67. Why Smardt?
SYSTEMS KNOWLEDGE = ENERGY SAVINGS
 Optimized control of system yields 20:1 turndown

68. Why Smardt?
SYSTEMS KNOWLEDGE = CPECS
 Central Plant Energy Control System
 A proven & repeatable packaged system that optimizes
plant performance
 Factory mounted package on Smardt Chiller
 Package includes:
 Controls
 Sensors
 NIST Certified BTU Meter
 Touch Screen Swing Arm Panel
 Central Plant Start up (single source)
 No finger pointing on startup!

69. Why Smardt?
SYSTEMS KNOWLEDGE = ENERGY SAVINGS
 CPECS combined with SMARDT oil free variable
speed chillers aims to provide the following:
 Optimized tower water temperature control.
 Load matched variable speed condenser water pump control
that respects chillers minimum safe flow limits.
 Optimized chiller sequencing.
 Load based chilled water temperature reset
 Variable primary chilled water pump control.

70. Why Smardt?
 CPECS combined with SMARDT provides the
highest performance targets
0.4 – 0.5
kW/ton for
the
ENTIRE
Plant

71. Why Smardt?
EXPERIENCE
 Most experienced with Turbocor than any other
manufacturer
 Smardt CEO is original co-founder of Turbocor and former
CEO of Turbocor
 Turbocor development engineers designed Smardt controls

72. Why Smardt?
EXPERIENCE
 Most experienced with Turbocor than any other
manufacturer
 Best understanding of Turbocor nuances
 Only chiller built from ground up to optimize Turbocor
compressors

73. Why Smardt?
PROVEN INSTALLATIONS
 Largest installed base with Turbocor than any other
manufacturer
 Over 1,300 installations. More than twice the competition.
 ~100 local installations in Southern California
 Patented control system assures accurate trouble-free
operation
 Global sales and service support

74. Why Smardt?
PROVEN INSTALLATIONS

75. Smardt Overview