Case Studies - · PDF fileThe MCS-MAGNUM is a durable microprocessor based controller ......

Case Studies

5580 Enterprise Pkwy., Fort Myers, FL 33905Office: 239-694-0089 Fax: 239-694-0031

www.mcscontrols.com

Providing HVAC/R Control Solutions Worldwide

Our BusinessDesign & Manufacturer Microprocessor HVAC/R controls

Combined controls experience of over 100 years

Over 50K controllers shipped

Representative Hanbell Screw Compressors

Partners with Sensing Technologies

52%45%

3%

Customers Types

ContractorsOEMNuclear

69%

31%

Customer Location

United StatesInternational


MCS North American OEMs and Contractors


Total Solution for all your Control Needs

5580 Enterprise Pkwy., Fort Myers, FL 33905Office: (239) 694-0089 Fax: (239) 694-0031

$15,000 IN ESTIMATED ANNUAL SAVINGS!ELIMINATION OF OVER 99%

OF NUISANCE TRIPS !REDUCED SERVICE CALLS BY OVER 98%

Improvements and upgrading is an important part of our business.

Many HVAC Chiller systems have inadequate equipment and poorly designed Control Systems.

Working closely with our OEM customers and installers we are able to evaluate older installations and suggest upgrades or new Control Systems to help reduce operating costs and most importantly, downtime and service requirements to keep these units running.

The MCS-MAGNUM is a durable microprocessor based controller designed for the hostile environments in the HVAC/R industry. It is designed to be the primary manager of the package it is controlling.

The Magnum provides flexibility with setpoints and control options that can be selected prior to commissioning a system or when the unit is live and functioning. Displays, alarms and other interfaces are accomplished in a clear and simple language that informs the user as to the status of the controller.

The Magnum is available as a replacement Control System using your enclosure or with a complete new enclosure. Enclosures are available for indoor or outdoor use, utilizing our New Touchscreen mounted in a NEMA4 box.



Manuals Application Notes Website

SUPPORT

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Case Studies of Equipment New Installs and Upgrades

Controls New Installs & Upgrades

Compressors New Installs

& Upgrades



Case Study Duke Realty Corporation

Clayton, MissouriSite Location:101 S. Hanley, Clayton, Missouri 63105

Concerns:Originally all three of the chillers operated at constant speed thus relying on inlet guide vanes to modu-late the capacity of the chillers.

Equipment:Three 360 ton Trane Centravac chillers

Steps Taken:Variable frequency drives (VFDs) were installed on two of the three chillers.

Results:Realized 36% more saving than the calculated savings.The following graph illustrates the differences in chiller efficiency between constant speed and VFD equipped chiller, assuming a constant 85F condenser water temperature:

VFD vs Constant Speed Chiller Efficiency

Upgrade performed by:

10501 South Hardwick LaneColumbia, Missouri 65201www.intfs.com

MCS-CONNECT monitoring Chillers

The addition of the VFDs on the chillers also allowed the facility to take advantage of a condenser water reset control strategy that was not originally being used. The benefit of allowing the condenser water to reset based on outside wet bulb temperature is it reduced the overall lift of the chiller therefore increasing chiller efficiency.Executive SummaryDuke Realty Corporation received incentives from Ameren Missouri for the installation of VFDs on two pre-existing chillers along with implementation of a condenser water reset control strategy. The combined realization rate for these projects is 136%.

Measurement and Verification EffortADM (third party company that audits the larger incentives that the utility company gives out) visited the facility and confirmed the installation of the VFDs and implementation of the condenser water reset

control. During the M&V visit, site specific construction details were collected to inform eQuest simulation. These details included typical building construction, window construction, floor layout, HVAC zoning, HVAC equipment nameplates, and building space utilization. ADM also interviewed facility staff to determine HVAC sequence of operation, temperature set points, and typical hours of operation.The ex post electrical savings were calculated using a calibrated eQUEST (ver. 3-64) computer simulation model, which was compiled based upon the fore mention collected details. The simulation was first built using as-built parameters which included two of the three chillers being equipped with VFDs and condenser water reset controls. The model was then calibrated using billing data and 2014 weather data for the area. The results of the calibration effort are shown below:In order to ensure that the chiller operation within the eQuest model reflected that of the facility, chiller log data was exported from the facility’s energy management system. The provided data included; chiller tonnage, kW demand, and condenser/chilled water temperatures. Using the provided data in conjunction with corresponding local weather data obtained from NOAA, a regression was developed allowing for the determination of chiller runtime hours. Using TMY3 weather data it was determined that the two retrofitted chiller should operate approximately 5,815 and 1,725 hours per year, while ADM’s eQuest model resulted in annual runtime hours of 5,695 and 1,721 hours. This suggests that the model accurate reflects the operation of the chillers.



North of Chattanooga,TN

Tennessee Valley Authority

5877 Enterprise Parkway, Fort Myers, FL 33905Office: 239-694-0089 Fax: 239-694-0031

www.mcscontrols.com

Case Study: TVA SEQUOYAH MCS-8 UPGRADE

Site Location:• TVA Sequoyah Chillers• Six (6) installed in Safety Area’s

Concerns:

• Number of Failures• Inability to Rotate Chillers• Startup problems when starting backup

Chiller Equipment:

• Four (4) Dunham-Bush Condensing Units• Two (2) Dunham-Bush DX Chillers• All units had standard TX Expansion Valves• All Units had standard Mechanical Controls

Steps Taken:

• Upgrade Controls to MCS-8 Microprocessor• MCS-8 had over ten (10) years in Field• MCS-8 had proven Track Record in Chiller

Controls.• MCS-8 Utilized worldwide• Testing

• MCS-8 was Seismographic tested• MCS-8 Software was validated• MCS-8 was EMI/EMC tested• Passed all test with no changes

TVA Chiller with MCS Controls

Results:

For the three (3) years prior to the MCS-8 microprocessor upgrade there were a total of 35 failures. Forthe three (3) years after the installation of the MCS-8’s there were only 20 failures. A reduction of 42 %. There were twelve (12) control related failures during the three (3) years prior to the MCS-8installations. There were zero (0) control related failures in the three (3) years after the upgrade.

During the startup, after the upgrade, the micro showed that the Hot Gas Bypass solenoid required ad-justment. It was open too much and causing the machine to load & unload. By using the MCS-8 whileadjusting it was possible to pinpoint the adjustment and hold the Target Temperature to ± 0.5 degrees F.

REDUCED FAILURES BY 42% !

ELIMINATED ALL CONTROL FAILURES !




www.mcscontrols.com

Case Study: TVA SEQUOYAH MCS-8 UPGRADE

Site Location:• TVA Sequoyah Chillers• Six (6) installed in Safety Area’s

Concerns:

• Number of Failures• Inability to Rotate Chillers• Startup problems when starting backup

Chiller Equipment:

• Four (4) Dunham-Bush Condensing Units• Two (2) Dunham-Bush DX Chillers• All units had standard TX Expansion Valves• All Units had standard Mechanical Controls

Steps Taken:

• Upgrade Controls to MCS-8 Microprocessor• MCS-8 had over ten (10) years in Field• MCS-8 had proven Track Record in Chiller

Controls.• MCS-8 Utilized worldwide• Testing

• MCS-8 was Seismographic tested• MCS-8 Software was validated• MCS-8 was EMI/EMC tested• Passed all test with no changes

TVA Chiller with MCS Controls

Results:

For the three (3) years prior to the MCS-8 microprocessor upgrade there were a total of 35 failures. Forthe three (3) years after the installation of the MCS-8’s there were only 20 failures. A reduction of 42 %. There were twelve (12) control related failures during the three (3) years prior to the MCS-8installations. There were zero (0) control related failures in the three (3) years after the upgrade.

During the startup, after the upgrade, the micro showed that the Hot Gas Bypass solenoid required ad-justment. It was open too much and causing the machine to load & unload. By using the MCS-8 whileadjusting it was possible to pinpoint the adjustment and hold the Target Temperature to ± 0.5 degrees F.

REDUCED FAILURES BY 42% !

ELIMINATED ALL CONTROL FAILURES !

Tennessee Valley Authority



Lake Worth, Florida EMCOR Group, Inc.Contractor

Washington Mutual Bank

CUT ENERGY CONSUMPTION BY NEARLY 25%

ELIMINATED OVER 99% OF NUISANCE TRIPS




www.mcscontrols.com

Case Study: WASHINGTON MUTUAL BANK Site Location:

• Washington Mutual Bank BuildingLake Worth, Florida

Concerns:

• Repeated Compressor and chiller outages• Service man on location during open hours of

operation• Unable to maintain stable temperatures• A 95º F day required all compressors and chill-

ers to run to hold the building• Convert without interrupting business hours

Equipment:

• Four (4) 90 ton Carrier Chillers• Four (4) Reciprocating Compressors per chiller• Two (2) refrigerant circuits per chiller• Two (2) compressors per refrigerant circuit• One (1) unloader on the lead compressor for

each of the circuits• Air cooled condensers• Three (3) fans per refrigerant circuit• One (1) Carrier Flowtronics EXV per circuit

Panel mounted MCS Controls on Carrier Chiller

Steps Taken:

• Install MCS microprocessor control system• Install new electronic expansion valve (EXV’s)

Results:

The primary objective was to improve up-time on the chillers and reduce failures. The original Carrier controls were removed and replaced with the MCS controls and new EXV’s. The first two chillers wereupgraded on a Saturday at 10:00 AM and completed by Sunday evening using five people for 17 hours.The other two chillers were converted the same way a month later.

After the conversion, the new MCS controller managed the operation of the chillers so much more effi-

ciently that on a 95º F day, only 3 compressors per chiller were needed to maintain the building. Theoriginal plan was to eliminate nuisance trips and improve chiller reliability. This goal was achieved with an added bonus of energy savings that paid for the upgrade in less than 1 year.

CUT ENERGY CONSUMPTION BY NEARLY 25%

ELIMINATED OVER 99% OF NUISANCE TRIPS

Washington Mutual Bank



Edgewood Elementary School

3464 Edgewood AveFort Myers, FL


www.mcscontrols.com Case Study: EDGEWOOD ELEMENTARY ICE CELL SYSTEM

Site Location:

• Edgewood Elementary,Fort Myers, Florida, Lee Co School District

Concerns:

• Pump control system failures at an average repair cost of $12,500 annually

• Frequent nuisance trips and chiller shut downs• Chillers making ice at peak utility times causing

higher electric bills• Building pumps were manual rotation• Ice cell failuresEquipment:

• Two (2) Trane RTAA Chillers• Two (2) circuits per Chiller• One (1) compressors per circuit• One (1) non standard Sporlan Electronic Ex-

pansion valve per circuit• One (1) U-Tube oil separator per circuit• Air cooled condensers• One (1) Oil Pressure Differential Switch per

Compressor• One (1) Trane microprocessor Control

Steps Taken:

• Install MCS controls on each Trane chiller• Install MCS loop water controller as plant

manager• Install standard Sporlan EXV’s

Results:

Trane RTAA chillers with ice cells and the pump

room controlled by MCS controls

The MCS loop controller now operates the chilled water pumps and rotates them daily for a more evenusage and a longer life span thus saving on expensive repairs. Since the MCS controls have beeninstalled, service calls have dropped by over 98%.

Florida Power & Lights 2006 review of the Lee County Schools with ice storage systems showed Edge-wood Elementary as the only one operating correctly. Making ice only on off peak times, resulting in low-er energy costs. The upgrade has also prevented ice cell failures that are caused by producing ice be-fore proper burn off has occurred.

$15,000 IN ESTIMATED ANNUAL SAVINGS !

ELIMINATION OF OVER 99% OF NUISANCE TRIPS !

REDUCED SERVICE CALLS BY OVER 98%




www.mcscontrols.com Case Study: EDGEWOOD ELEMENTARY ICE CELL SYSTEM

Site Location:

• Edgewood Elementary,Fort Myers, Florida, Lee Co School District

Concerns:

• Pump control system failures at an average repair cost of $12,500 annually

• Frequent nuisance trips and chiller shut downs• Chillers making ice at peak utility times causing

higher electric bills• Building pumps were manual rotation• Ice cell failuresEquipment:

• Two (2) Trane RTAA Chillers• Two (2) circuits per Chiller• One (1) compressors per circuit• One (1) non standard Sporlan Electronic Ex-

pansion valve per circuit• One (1) U-Tube oil separator per circuit• Air cooled condensers• One (1) Oil Pressure Differential Switch per

Compressor• One (1) Trane microprocessor Control

Steps Taken:

• Install MCS controls on each Trane chiller• Install MCS loop water controller as plant

manager• Install standard Sporlan EXV’s

Results:

Trane RTAA chillers with ice cells and the pump

room controlled by MCS controls

The MCS loop controller now operates the chilled water pumps and rotates them daily for a more evenusage and a longer life span thus saving on expensive repairs. Since the MCS controls have beeninstalled, service calls have dropped by over 98%.

Florida Power & Lights 2006 review of the Lee County Schools with ice storage systems showed Edge-wood Elementary as the only one operating correctly. Making ice only on off peak times, resulting in low-er energy costs. The upgrade has also prevented ice cell failures that are caused by producing ice be-fore proper burn off has occurred.

$15,000 IN ESTIMATED ANNUAL SAVINGS !

ELIMINATION OF OVER 99% OF NUISANCE TRIPS !

REDUCED SERVICE CALLS BY OVER 98%

Edgewood Elementary School



Quest BuildingDallas, Texas

Upgrade Performed By

Dallas, Texas

One Carrier 30GXR301 Nominal 301 ton Chiller Two (2) Refrigerant Circuits w/ Economizers One (2) Compressors per Circuit, Y-D start One (1) EXV’s per Circuit Air Cooled Condenser

Equipment:

Large number of nuisance trips A lot of man hours spent on sight visits Carrier control not user friendly Will the MCS Controls read motor tempera-

ture

Site Location:

Upgrade performed on three machines of the same model at this location. Two of the machines per-formed ice duty and were equipped with VFD’s on the condenser fans for lower ambient operation. A 243ohm resister is wired in to convert the drives 4-20ma to 0-10volt signal for the MCS-Magnum to con-trol the VFD’s on the condenser fans. The Carrier proprietary EXV’s were replaced with standard Sporlan EXV’s and were controlled by the MCS-Magnum on a 0-10volt signal.

Upgraded using Micro Control Systems. Where there is no preplanned

obsolescence / abandonment of support.

Case Study: Carrier 30GXR301-F-661FX to MCS Controls

5580 Enterprise Parkway, Fort Myers, FL 33905 Office: 239-694-0089 Fax: 239-694-0031

www.mcscontrols.com

Steps Taken:

Remove existing controls Install Sporlan standard EXV’s Install MCS-Magnum Controls Install MCS-Carrier-5k (5.26k resister) Install a 243 ohm resister to VFD fan drives

Results:

Concerns:

Lexington Middle School, Fort Myers Fl. Upgraded 10/12



Two Carrier 30GX125 Nominal 125 ton Chiller Two (2) Refrigerant Circuits w/ Economizers One (1) Compressors per Circuit, Y-D start One (1) EXV’s per Circuit Three (3) Condenser fans per circuit

Equipment:

Failing of linear floats in the economizers Continuous shut down trips Existing Carrier controls were obsolete Excessive man hours spent on sight visits

Site Location:

Two machines were upgraded within six months. Obsolete Carrier controls were replaced with the MCS-Magnum Controller. This provided the customer with a controls platform that is not built with a pre-planned obsolescence. The MCS Controls will allow for future updates and operational changes that can be made through updated software. Previously released MCS hardware remains supported with current and future products. Removal and replacement of Carrier’s old style canister economizers with new plate-frame economizers eliminating reoccurring mechanical issues. The installation of standard Sporlan electronic expansion valves eliminated Carrier’s proprietary electronic expansion valves.


Case Study: MCS Controls upgrade on Carrier 30GX125-Y


www.mcscontrols.com

Steps Taken: Removed existing obsolete controls Installed MCS-Magnum Controls Replaced old canister style economizers with a new plate-frame

style economizers. Replace Carrier proprietary EXV’s with standard Sporlan EXV’s Wired Carrier’s compressor motor temperature sensors to the

MCS-Magnum Controller Customer added additional fan contactors for improvement on

the Discharge PSI control. (Optional)

Results:

Concerns:

Quest Building, Dallas, Tx Upgraded unit #1 in 10/11 Upgraded unit #2 in 03/12

13850 Diplomat Drive Dallas, Texas 75234

972-888-9500

Quest Building



Lexington Middle SchoolFort Myers, Florida


Equipment:


ture

Site Location:






www.mcscontrols.com

Steps Taken:


Results:

Concerns:





Equipment:


ture

Site Location:






www.mcscontrols.com

Steps Taken:


Results:

Concerns:


Lexington Middle School



General Electric CorporationFairfield, CT.

ELIMINATED OIL & NUISANCE TRIPS !ELIMINATED COMPRESSOR FAILURES !



Two (2) Dunham-Bush Chillers PCWX-210(21yrs old)

Two (2) Vertical Screws per chiller Flooded Evaporators Flash Tank with ball valves Each chiller had only one (1) LLS Water cooled condenser with stand alone

head PSI control

Several compressor failures over the years Service calls for continuous nuisance trips No visible oil in old compressor sight glass Low oil amount visible in new compressor Unable to rotate lead compressor

Site Location:

At start up, the MCS controller revealed the basic problem as low discharge superheat. Because the MCS controller monitors all critical areas, it saw that the discharge superheat was less than 5º F on both compressors and the discharge temperature was about 100º F. This low temperature resulted in oil mi-gration from the compressors, causing repeated compressor shutdowns and failures. Adjustments were made to the ball valves on the flash tank bringing the discharge temperature to ap-proximately 130º F and the discharge superheat to approximately 25º F. These changes brought the oil that had migrated to the condensers back to the compressors. The excess oil in the compressors was then removed. The MCS controller also setup the compressors to rotate leads for more even wear and longer life.

ELIMINATED OIL & NUISANCE TRIPS !

ELIMINATED COMPRESSOR FAILURES !

Case Study: General Electric Corporation


www.mcscontrols.com

Dunham-Bush Chiller with MCS Controls in a door mount application at G.E. Corporate Head Quarters.

Steps Taken:

Install MCS microprocessor control system Adjust flash tank ball valves until discharge

superheat was > 20º F Drain off excess oil that was added over

the past 21 years

Results:

Concerns:

General Electric Corporate Headquarters Training Conference Center, Fairfield CT

Equipment:

General Electric Corporation




www.mcscontrols.com Case Study: McQuay ALS185 to MCS Controls & Hanbells

Site Location:• Saint Paul, MN• Upgraded 8/08

Concerns:

• Cost of Mcquay SAL175 compressors• Service history of the SAL 175 compressor• (1) year warranty on McQuay compressor• How would Hanbell fit in the ALS 185 frame• What would be involved in making this upgrade

to MCS Controls and Hanbell Compressors

Equipment:

• One McQuay ALS 185 ton Chiller• Two (2) Refrigerant Circuits• One (1) Compressors per Circuit• One (1) EXV’s per Circuit• Air Cooled Condenser

Hanbell RC2B-300 Compressor replacing SAL-175 screw compressor on a McQuay ALS Chiller

Steps Taken:

• Remove McQuay SAL-175 Compressors• Install steel plates to McQuay frame• Install (2) Hanbell RC2-300B Compressor• Install Sporlan standard EXV’s• Remove McQuay controls and install MCS-

Magnum Controls

Results:

Compressor #2 had failed and compressor #1 was noisy. A decision was made to replace the compres-sors and upgrade the controls to the MCS-MAGNUM. Two days after the order for the compressors was placed, the 2nd McQuay compressor failed. The chiller was located on the roof of a 6 story building. Acrane removed the 2 old compressors and set in place the new Hanbell compressors on a Wednesday. The compressors were set on an adapter plate, piping and wiring changes were completed for one cir-cuit that was operating by Friday afternoon. The 2nd compressor was finished the next week.

NEW COMPRESSORS WITH 3 YEARS WARRANTY AT NO ADDITIONAL COST!

“HANBELL COMPRESSORS WERE MUCH QUIETER.”


930 East 80th StreetBloomington, Minnesota 55420

Ph: 952.854.3800



North Fort Myers High SchoolFort Myers, Florida

One Trane RTAA 400 ton Chiller Two (2) Refrigerant Circuits Two (2) Compressors per Circuit Two (2) EXV’s per Circuit Air Cooled Condenser Two (2) U-Tube Oil Separators per Circuit One (1) Oil Pressure Differential Switch per

Compressor

Equipment:

Cost of Trane rebuilt compressor How would Hanbell fit in RTAA frame How would oil return be guaranteed to the

Hanbell compressor How would the Trane controller respond to

the Hanbell compressor

Site Location:

Compressor #2 on circuit #1 had failed. The Trane compressor was removed and a 3/8” steel plate was installed and bolted through the original Trane compressor mounting holes. The Hanbell compressor was positioned on the plate to allow for the best piping connections. Mounting holes were then made in the plate for the Hanbell compressor. Once the Hanbell was bolted into place, the piping work was com-pleted. This work added less than 8 hours to the total job completion. The wiring was then completed and the Trane controller activated. The wiring connection to the Hanbell was verified and accepted by the Trane controller and the compressor was brought into service.

$7000.00 DOLLARS SAVED BY THE SCHOOL DISTRICT !

NEW COMPRESSOR WITH TWO YEAR WARRANTY !

Case Study: Hanbell / Trane Compressor Replacement on RTAA


www.mcscontrols.com

Hanbell RC15LF Compressor replacing Trane screw compressor on a Trane RTAA Chiller

Steps Taken:

Removal of Trane CHB100 Compressor Install 3/8” steel plate to RTAA frame Install MCS Hanbell RC15LF Compressor

(changed load solenoid to normally closed) Utilize existing Trane controls

Results:

Concerns:

North Fort Myers High School North Fort Myers, Florida Lee County School District



One Trane RTAA 400 ton Chiller Two (2) Refrigerant Circuits Two (2) Compressors per Circuit Two (2) EXV’s per Circuit Air Cooled Condenser Two (2) U-Tube Oil Separators per Circuit One (1) Oil Pressure Differential Switch per

Compressor

Equipment:

Cost of Trane rebuilt compressor How would Hanbell fit in RTAA frame How would oil return be guaranteed to the

Hanbell compressor How would the Trane controller respond to

the Hanbell compressor

Site Location:

Compressor #2 on circuit #1 had failed. The Trane compressor was removed and a 3/8” steel plate was installed and bolted through the original Trane compressor mounting holes. The Hanbell compressor was positioned on the plate to allow for the best piping connections. Mounting holes were then made in the plate for the Hanbell compressor. Once the Hanbell was bolted into place, the piping work was com-pleted. This work added less than 8 hours to the total job completion. The wiring was then completed and the Trane controller activated. The wiring connection to the Hanbell was verified and accepted by the Trane controller and the compressor was brought into service.

$7000.00 DOLLARS SAVED BY THE SCHOOL DISTRICT !

NEW COMPRESSOR WITH TWO YEAR WARRANTY !

Case Study: Hanbell / Trane Compressor Replacement on RTAA


www.mcscontrols.com

Hanbell RC15LF Compressor replacing Trane screw compressor on a Trane RTAA Chiller

Steps Taken:

Removal of Trane CHB100 Compressor Install 3/8” steel plate to RTAA frame Install MCS Hanbell RC15LF Compressor

(changed load solenoid to normally closed) Utilize existing Trane controls

Results:

Concerns:

North Fort Myers High School North Fort Myers, Florida Lee County School District

North Fort Myers High School



South Western Bell Switching Station

Richardson, Texas

Two (2) McQuay ALS-155-A chillers Two (2) Frame 2 Oil-less compressors per

chiller Two (2) circuits per chiller One (1) Sporlan custom Electronic Expansion

valve per circuit (EXV) Air cooled condenser, five (5) fans per circuit Johnson P66 Fan Speed control on the 1st

fan per circuit McQuay Micro Tech microprocessor controller Andover Building Management System (BMS)

Equipment:

Frequent nuisance trips Numerous compressor failures What about the mounting and piping of the

Hanbell compressors in the McQuay frame

Site Location:

This upgrade was completed in January 2006. The McQuay Chillers were to replace older Trane centrif-ugals located in the basement. The McQuay compressors were a new design but due to frequent outag-es and numerous compressor failures, they switched back to the Tranes until a solution was found.

Stability and reliability were found when Hanbell replacement compressors were put in along with the MCS controller. Communicates is via Bacnet with the BMS which rotates the chillers. The Tranes centrif-ugal are now shutdown and the upgraded McQuay chillers have had no failures. Because the upgrade was done for reliability, no data was collected on energy savings. It is expected that a 10 to 15% savings would be achieved based on the MCS controls and the Hanbell screw compressors.

ELIMINATED NUISANCE TRIPS !


Case Study: SOUTHWESTERN BELL


www.mcscontrols.com

McQuay chillers upgraded with Hanbell screws and MCS Controls

Steps Taken:

Install Hanbell continuous loading compressors Install standard Sporlan EXV’s Install MCS microprocessor controller

Results:

Concerns:

Southwestern Bell Switching Station Richardson, Texas



Two (2) McQuay ALS-155-A chillers Two (2) Frame 2 Oil-less compressors per

chiller Two (2) circuits per chiller One (1) Sporlan custom Electronic Expansion

valve per circuit (EXV) Air cooled condenser, five (5) fans per circuit Johnson P66 Fan Speed control on the 1st

fan per circuit McQuay Micro Tech microprocessor controller Andover Building Management System (BMS)

Equipment:

Frequent nuisance trips Numerous compressor failures What about the mounting and piping of the

Hanbell compressors in the McQuay frame

Site Location:

This upgrade was completed in January 2006. The McQuay Chillers were to replace older Trane centrif-ugals located in the basement. The McQuay compressors were a new design but due to frequent outag-es and numerous compressor failures, they switched back to the Tranes until a solution was found.

Stability and reliability were found when Hanbell replacement compressors were put in along with the MCS controller. Communicates is via Bacnet with the BMS which rotates the chillers. The Tranes centrif-ugal are now shutdown and the upgraded McQuay chillers have had no failures. Because the upgrade was done for reliability, no data was collected on energy savings. It is expected that a 10 to 15% savings would be achieved based on the MCS controls and the Hanbell screw compressors.

ELIMINATED NUISANCE TRIPS !


Case Study: SOUTHWESTERN BELL


www.mcscontrols.com

McQuay chillers upgraded with Hanbell screws and MCS Controls

Steps Taken:

Install Hanbell continuous loading compressors Install standard Sporlan EXV’s Install MCS microprocessor controller

Results:

Concerns:

Southwestern Bell Switching Station Richardson, Texas

South Western Bell Switching Station



If you have not seen it, heard about it, or you have and just want to know more about it. Then dedicate an hour to see and discuss ideas that may help grow your business.

MICRO CONTROL SYSTEMS & EMCOR WORKING TOGETHER

Micro Control Systems is a manufacture of micro processor based controls for the HVAC/R industry. Providing controls for OEM’s and contractors all over the world. MCS is also the North American distributor of Hanbell Screw Compressors. ICE Group members throughout the US & MCS have benefited by partnering up on a variety of job applications. We provide a cost effective, quality alternative in controls for chillers and DX systems as well as rooftops and condensing units. Topics of the meeting: -New products & service offerings -Benefits to you and your customers from using MCS -MCS’s non-proprietary OEM controls vs others -Review successful upgrades by others -Hanbell screws as a cost effective option -Adding VFD upgrades to existing machines -And much more

Upgrades controls on Carrier 30HR

23XL Upgraded to MCS controls & Hanbell compressor on a VFD

Boston Gardens Upgrades controls on Carrier 19XL

Upgrade of Trane CVHE, UCP 2 with new cabinet , controls & touch screen

www.mcscontrols.com


5580 Enterprise Pkwy. Fort Myers, FL 33905Office: (239) 694-0089Fax: (239) 694-0031

www.mcscontrols.com

Case Studies - · PDF fileThe MCS-MAGNUM is a durable microprocessor based controller ......

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