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REVOLUTIONARY ENERGY SAVINGSAir-cooled oil-free centrifugal chillers from Smardt Chiller GroupTD – 0081B16 Dec 2011

Table of ContentsINTRODUCTION AND OVERVIEW . 4SMARDT Chiller Group - World Leader In Oil-Free Chiller Efficiency. 4Certification . 4Strong LEED Contribution . 4Strong Support For The EPA Responsible Use Vision. 4SMARDT PRODUCT BENEFITS . 5SMARDT Air Cooled Chiller Range . 5Chiller Cost Comparison . 6A Quantum Leap In Energy Efficiency . 7PRODUCT DESCRIPTION . 9General Description . 9Compressor Technology . 10User Friendly Controls . 12Air Cooled Chiller – Principal Components . 14General Piping Schematic . 15CHILLER NOMENCLATURE . 16CHILLER DIMENSIONS & CLEARANCES . 17Minimum Placement Clearances . 18Overall Dimensions, Weights, & Physical Data . 19ELECTRICAL . 20Field Wiring . 20Electrical Ratings . 21ELECTRICAL, INSTALLATION . 25General . 25Electrical Wiring . 25DESCRIPTION OF OPERATION . 26Chiller Cycle. 26Evaporator Description . 26Compressor Description . 26Condenser Description . 28Hot Gas Valve Control . 28CHILLED WATER SYSTEM . 30Evaporator Water Circuits . 30Chilled Water Pumps . 30Water Volume . 31Variable Water Flow . 31Operating Limits. 31Flow Switch. 32High Pressure & Low Pressure Switches . 32Relief Valves . 32Relief Valve Characteristics. 32Relief Valve Application . 33Vent Line Sizing . 33CONTROLS . 35Controls Wiring . 35Control Panel Wiring . 36SPECIFICATIONS – SMARDT AIR COOLED CHILLERS . 38SMARDT CHILLER GROUP.TD – 0081B3

Introduction & OverviewINTRODUCTION AND OVERVIEWSMARDT CHILLER GROUP - WORLD LEADER IN OIL-FREE CHILLER EFFICIENCYThe PowerPax and SMARDT companies joined forces in 2005 to merge their global operationsin engineering, development, testing and certification, supply chain, technical services andcustomer support.PowerPax, based in Melbourne, Australia, was founded in 2000 by a team of HVAC industryexperts, to specialize in high-efficiency shell-and-tube heat exchangers and their optimization inoil-free centrifugal chillers.SMARDT, based in Montreal, Quebec, was founded in 2005 by a team of Turbocor veterans, toproduce chillers which optimized the energy efficiency potential of the Turbocor compressortechnology.The SMARDT Chiller Group now has well over 2000 operating chiller installations across theworld, all delivering high reliability, outstanding part-load efficiencies, and the overall lowest costof ownership in the market today. Achieving these goals consistently remains the Group’s corepurpose, and clearly differentiates it from competitors with conventional machines.CERTIFICATIONAll SMARDT chillers are ETL listed, have lifetime electrical safety coverage, and incorporateevaporators and condensers that fully comply with ASME pressure vessel codes.SMARDT chiller energy efficiency performance is certified according to AHRI standard 500/590(ref: www.ahrinet.org). IPLV performance always far exceeds the minimum levels set out byASHRAE standard 90.1, CSA 743, Eurovent, Australia’s MEPS, and other governing bodies.STRONG LEED CONTRIBUTIONUse of SMARDT chiller technology can significantly contribute to achieving Leadership inEnergy & Environmental Design (LEED ) certification for a building, be it in existing buildings,core and shell constructions, or new construction, because it can help win critical points in theEnergy & Atmosphere category. Market research by the U.S. Green Building Council (USGBC)finds that the streamlined LEED process is second only to rising energy costs as a driver forstronger adoption of green building practices and the transformation of the built environment tosustainability. SMARDT is a member of the USGBC.STRONG SUPPORT FOR THE EPA RESPONSIBLE USE VISIONThe EPA’s Responsible Use vision, encourages manufacturers, system designers, and owners,to invest in products and technologies which document sustainability of the highest efficiencies,in tandem with the lowest emissions. SMARDT is a strong supporter of the vision and of theEPA.SMARDT CHILLER GROUPTD – 0081B4

SMARDT Product BenefitsSMARDT PRODUCT BENEFITSSMARDT AIR COOLED CHILLER RANGE60 TR to 300 TRLowest Lifetime Operating CostsCustom Design and Problem SolvingSMARDT workshard to minimizecomplexity in chiller design and operation,and SMARDT simplicity is reflected in lowproduct operating costs. The thinking makessimple sense: no oil, flooded ption, low maintenance costs andhigh reliability, with only one main movingpart.SMARDT design engineers are alwaysready and willing to resolve particularequipment design challenges. For example,high-efficiency heat recovery and freecooling applications can all be customdesigned and supplied competitively, andcorrosion protection and other options arealso available.RedundancySMARDT field reliability has beenoutstanding, and not surprising when oneconsiders that some 80% of all chillerproblems in the field are due to failures incompressor oil return. And SMARDT chillersuse no oil.The growing fraternity of turbocor-trainedengineers and technicians often suggeststhat total maintenance costs for oil-freechillers run at well under half the costs oftraditional lubricated chillers.ServiceabilityAlways important in minimizing operatingcosts, is ease of serviceability. Serviceaccess is swift and simple with SMARDTchillers, as is access to operating historythrough remote monitoring. Operatinghistory and compressor and chiller setpoints are all accessible remotely by trainedand authorized service personnel.Simple BAS IntegrationIntegration with Modbus, Bacnet andLONworks building management systems isstandard, as is connectivity with mostindustry-standard protocols.The use of multiple compressors allows forbuilt-in redundancy safeguards. SMARDT’sredundancy potential can offer systemdesigners unique opportunities to eliminatemultiple chillers, multiple controls, andmultiple pumps, thus bringing furthersavings for owners.Multiple compressors also allow systemdesigners to save on low-load or ponychillers, because with a VFD integrated intoeach compressor control, a chiller whichuses multiple compressors can be efficientlydriven right down below 10% or even 5%load.Optimization in DesignCondenser coils use a W configuration tooptimize heat rejection and footprint. Coilsare baked and double-coated and withsealed edges as standard, so as to extendthe coil’s physical protection fromenvironmental corrosion.Remote Air-Cooled CondensingRemote location of the condenser can be apreferred option in some applications.SMARDT can supply either a full packageas desired, or, on a condenser-less basis.SMARDT CHILLER GROUPTD – 0081B5

SMARDT Product BenefitsCHILLER COST COMPARISONThe above diagram shows a 2 year total chiller cost comparison, for a hotel in San Diego, CA.The left-hand option is a competitor low-cost lubricated screw chiller. The right-hand option is anoil-free 300TR SMARDT air-cooled chiller.SMARDT CHILLER GROUPTD – 0081B6

SMARDT Product BenefitsA QUANTUM LEAP IN ENERGY EFFICIENCYAll SMARDT chillers, whether air-cooled orwater-cooled, are designed to optimize theperformance of the highly efficient DanfossTurbocor oil-free centrifugal compressor.Oil-free magnetic bearing technology andvariable-speed drives deliver better IPLVefficiencies than conventional oil-lubricatedcentrifugal, reciprocating, scroll, and screwcompressors. They are also high-speed – upto 48,000 rpm, very compact, very quiet,rugged, and reliable. The Power Factor is ahigh .92.Proprietary magnetic bearings replaceconventional oil lubricated bearings, whicheliminate high friction losses, mechanicalwear,andhigh-maintenanceoilmanagement systems, to deliver chillerenergy savings of 35 percent and more overconventional chillers, while ensuring longterm reliability. Over 75,000 magneticbearing machines are operating in the field,mainly in high-end vacuum pumps and CNCspindles - any innovation risk having beenlong overcome.Turbocor’s one main moving part (rotorshaft and impellers) is levitated duringrotation by a digitally-controlled magneticbearing system. Position sensors at eachmagneticbearing,providereal-timefeedback to the bearing control system at120 times each revolution, thus ensuringconstantly centered rotation.Key benefits of SMARDT chillers can besummarized as:Heat transfer optimization throughoil-free designExtraordinary soft-start efficiencyRugged & built-in defense againstpower failureHFC-134a ozone friendly refrigerantSignificant noise reductionSpectacular energy cost savingsImproved part load efficienciesHeat Transfer Optimization Through OilFree DesignThe well-known ASHRAE study (researchProject 361) concluded that typicallubricated chiller circuits show reductions indesign heat transfer efficiency of 15-25%,as lubricant accumulates on heat transfersurfaces, denatures and blocks normalthermodynamictransferprocesses.Logically, no oil in your chiller means no oilcontamination over time, so designefficiency is maintained effortlessly.Extraordinary Soft-Start EfficiencyThe compressor’s power electronics, furtherenhanced by SMARDT’s chiller controllers,require only 2 amps for start-up, comparedwith 500-600 amps for conventionalmachines. This means further savings forowners, who can reduce maximum powerloads and reduce backup generator size,cost and capacity.Rugged & Built-in Defense Against PowerFailureEach compressor has a bank of capacitorsfor energy storage and to filter DC voltagefluctuations. In case of a power failure, thecapacitors provide continuity power to thebearings to keep the shaft levitated,allowing the motor to turn into a generatorand to power itself down to a stop. Extendedlifetestingconfirmsthesystem’sremarkable durability.HFC-134a Ozone Friendly RefrigerantR134a has no ozone depletion potential andno phase-out schedule under the MontrealProtocol; it has an A1 rating under ASHRAEstandard 34 (no flame propagation, lowertoxicity). Positive pressure chiller designs(compared with negative pressure designsSMARDT CHILLER GROUPTD – 0081B7

SMARDT Product Benefitsusing R123, for example) enhancesustainable performance, as neither air ormoisture can leak into the chiller. No purgeunit is required – a further saving. LiquidR134a refrigerant is used in SMARDTchillers to cool critical electronic andelectromechanical components, to assuremaximum efficiency and safe operation.Significant Noise ReductionVery low sound and vibration levels areachieved, because there is no physicalcontact between moving metal parts,eliminating the need for expensiveattenuation. Testing of SMARDT air cooledchillers, with reference to AHRI standard575, yields readings as low as 77dBA at 1meter.Spectacular Energy Cost SavingsCompared with a new screw chiller,SMARDT IPLV energy efficiency is routinelymore than 32% better. Compared with olderlubricated reciprocating, screw, scroll, orcentrifugal chillers, year round energysavings with SMARDT chillers can be aspectacular 50% and more. Under AHRIconditions, SMARDT IPLV performance canbe as low as .33 kW/TR while part-loadefficiency can be under .30 kW/TR.Improved Part Load EfficienciesThe graph below (data source: AHRI 2005)shows very simply that a wide range of largeUS cities all demand the vast bulk of theirchiller operations at part load – enablingmuch lower operating costs with a SMARDToil free chiller, compared with a lubricatedalternative.SMARDT CHILLER GROUPTD – 0081B8