NRG & NRJ Microchannel Condensers
Customer Briefing
Microchannel Coil Overview
WHAT IS A MICROCHANNEL COIL?
 Flat Streamlined Tubes
 One larger tube split into multiple smaller
parallel ports
 Overall heat transfer efficiency due to
 Improved airside performance
 Higher primary surface area
 Reduced refrigerant side pressure drop
Microchannel Coil Overview
VALUE PROPOSITION, FEATURE AND BENEFITS

Key Microchannel Primary Benefits
 Reduced Refrigerant Charge
 Corrosion Resistance
 Lighter Weight vs. RTPF
Microchannel Coil Overview
MICROCHANNEL APPLICATIONS
Heatcraft ½-6hp
Condensing Units
(>150,000)
Automotive
Photo: Modine Website
Residential Air
Conditioning
Rooftop Air Conditioning
Chillers
Microchannel Coil Overview
OBSTACLES TO ADOPTION
 Volumes
 Traditionally automotive volumes
 All Aluminum Design
 Negative Connotations due to early
experiences with aluminum round-tube
plate fine


Subject to leaks
Not easily repairable
 Early Design Challenges
 Initial refrigeration implementations might
not have permitted sufficient expansion
and contraction

Needs floating (or otherwise flexible) coil
mounting design
Source: Modine Website
NRG & NRJ Microchannel Condensers
Variable Speed EC
Variable Speed EC (VSEC)
WHERE ARE THESE MOTORS COMMONLY USED




Fitness Equipment (treadmills, etc)
HVACR equipment
Large industrial machines
Household electronics
Variable Speed EC (VSEC)
WHAT IS A EC MOTOR?
 Electronically Commutated (EC, ECM) Motor = Brushless DC
(BLDC) Motor
 Just different names
 EC Motors are current trend in motor technology due to high
efficiency
 up to 75% efficient

51-59% increase vs shaded-pole motors

30-35% increase vs permanent split-capacitor (PSC) Motors
Variable Speed EC (VSEC)
WHAT IS A VSEC MOTOR
 Varies Speed continuously to meet system requirements
14
Typical
Operating
12
*NH*
10
Power Consumption (kW)
*NL*
8
*NE*
6
NRG*
4
*NQ*
2
0
30%
40%
50%
60%
70%
Load Requirement
(NRG Baseline)
80%
90%
100%
Variable Speed EC (VSEC)
WHAT IS A VSEC MOTOR
 Power Consumption increases disproportionally with fan speed
Source: http://www.dchuddle.com/
Variable Speed EC (VSEC)
ENERGY SAVINGS
Direct Condenser Power
Consumption
Rack Power Consumption
In field test, Store B, equipped with VSEC motors, was verified to have obtained a 69%
reduction in condenser energy costs and 13% reduction in rack energy
costs**compared with Store A and its fixed-speed motor unit.
Variable Speed EC (VSEC)
ENERGY SAVINGS
Electricity Expense Comparison of
VSEC vs. Standard Fixed Speed Motor
13
Variable Speed EC (VSEC)
ENERGY SAVINGS
Motor Testing
shows significant
performance improvement
 Significant energy savings
• 75% to 80% reduction in power
usage
 Maintains constant head pressure
• More stable temperature control
NRG & NRJ Microchannel Condensers
Product Training
Microchannel Air-Cooled Condenser
FIRST FIELD TRIAL INSTALLATION – JANUARY 05, 2012
15
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS
238lbs

Reduced Refrigerant Charge
 More than 70% reduction in refrigerant charge1, 2
 Up to $2000 in refrigerant charge cost savings per unit2,3
= Microchannel Condenser
= Round-Tube, Plate-Fin Condenser
104lbs
69lbs
40lbs
30lbs
35lbs
20lbs
10lbs
2 Fan
1Based
4 Fan
6 Fan
on R-404A refrigerant charge for flooded condenser based on NRGD02A014 vs BNES02A015 at -20F ambient
not include receiver, piping or manifold charge
3Based on 198 lbs of refrigerant charge reduction in comparable 8 fan units at $10 per pound price for R-404A
2Does
8 Fan
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS
 Very efficient Variable Speed EC fan motors
 Vary speed to match system demands
 Up to 10% additional savings on compressor/rack energy consumption
Power Consumption (kW)
*NH
*NL
*NE
NRJ
NRG
*NQ
Load Requirement
(NRG Baseline)
Microchannel Air-Cooled Condenser
REPRESENTATIVE ENERGY COMPARISON – 540 RPM
BNQ*
NRG*
NRJ*
NRJ* (VFD)
Unit: BNQ-D12=A069
Units: NRGD06A041
NRGD04A027
Units: NRJD06A041
NRJD04A027
Units: NRJD06A041
NRJD04A027
kWh Consumed: 22,180
Energy Cost: $2,218
kWh Consumed: 12,435
Energy Cost: $1,244
kWh Consumed: 80,971
Energy Cost: $8,097
kWh Consumed: 23,571
Energy Cost: $2,357
Unit: BNQ-D04A023
Units: NRGD04A027
Units: NRGD04A027
Units: NRGD04A027
kWh Consumed: 12,201
Energy Cost: $1,220
kWh Consumed: 3,436
Energy Cost: $344
kWh Consumed: 33,535
Energy Cost: $3,354
kWh Consumed: 7,300
Energy Cost: $730
Total
kWh Consumed: 34,381
Energy Cost: $3,438
kWh Consumed: $15,871
Energy Cost: $1,587
kWh Consumed: 114,506
Energy Cost: $11,451
kWh Consumed: 30,871
Energy Cost: $3,087
Microchannel
Energy Savings
-
$1,851
N/A
$351
Medium
Temperature
Low
Temperature
Assumptions:
1.) Climate information per ASHRAE Std 550 – US avg
2.) Energy rate: $0.10 cents per kWh
Microchannel Air-Cooled Condenser
REPRESENTATIVE ENERGY COMPARISON – 1140 RPM
 Significant energy savings opportunities by upgrading to higher
efficiency, energy efficient motors
• Variable Speed EC (VSEC)
1140RPM vs Replacement Condensers
Existing
Condenser
BNH-D08-A058
Assumptions:
Location: Atlanta, GA
Energy Cost: $0.11/kWh
Replacement
Condenser
Annual Energy
Savings (kWh)
Annual Energy
Savings (USD)
BNE-D08-A062
57,270 kWh
$6,300
NRG-D08-A054
72,896 kWH
$8,019
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS

Significant Sound Reduction
 Up to 3.4 dBA vs standard *NE* series condenser at 10ft.
 More than 50% reduction in sound intensity
Sound by Percentage of Max Speed
30%
50%
70%
100%
(255 rpm) (425 rpm) (595rpm) (850rpm)
BNE @
100%
NRG
Advantage
NRGD02A014
44.3 dBA
50.6 dBA
57.6 dBA
66.5 dBA
69.9 dBA
3.4 dBA
NRGD04A027
47.3 dBA
53.7 dBA
60.6 dBA
69.5 dBA
72.9 dBA
3.4 dBA
NRGD06A041
49.1 dBA
55.4 dBA
62.4 dBA
71.3 dBA
74.7 dBA
3.4 dBA
NRGD08A054
50.3 dBA
56.7 dBA
63.6 dBA
72.5 dBA
75.9 dBA
3.4dBA
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS

Low Profile
 Over 25% lower cabinet height1
• May reduce need for visibility fencing and/or walls
26”
Microchannel Air-Cooled
Condenser
1vs.
20”
comparable Round Tube Plate Fin Air Cooled Condenser
35”
20”
Standard Air-Cooled
Condenser
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS

Reduced Weight
 More than 20% reduction in unit weight
• May reduce need for structural supports
• Reduction in shipping costs
NRG* Model
1vs.
Weight
*NE* Model
Weight
Reduction %
NRGD02A014
510
BNES02A015
640
20%
NRGD04A027
1015
BNED04A031
1390
27%
NRGD06A041
1520
BNED06A046
2060
26%
NRGD08A054
2005
BNED08A062
2730
27%
comparable Round Tube Plate Fin Air Cooled Condenser
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS

Corrosion Resistance
 Monometal coil
• Virtually eliminate galvanic corrosion
Coastal Performance Comparison
Heat Transfer Capacity (BTUH)
Heat Transfer Capacity (BTUH)
Uncoated Coil
30,000
25,000
20,000
Significant decrease in
capacity due to corrosion
after one year
15,000
10,000
5,000
0
Microchannel Coil
30,000
25,000
No significant change in
performance after one year
20,000
15,000
10,000
5,000
0
0
0.01
0.02
0.03
Air Horsepower (hp)
0.04
0.05
0
0.01
0.02
0.03
Air Horsepower (hp)
0.04
0.05
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS
Corrosion after 1 Year in Coastal Application
Microchannel Coil
Round-Tube, Plate-Fin
BASELINE
AFTER 1 YEAR OF
EXPOSURE
Microchannel Air-Cooled Condenser
VALUE PROPOSITION, FEATURE AND BENEFITS
Corrosion Resistance
 Monometal coil
• Virtually eliminate galvanic corrosion
Accelerated Corrosion Testing
6,000
5234
5,000
Time to Failure

4,000
3,000
2759
2,000
1,000
0
Round Tube – Plate
Fin with E-Coat
Microchannel
Time to Failure= time (hours) until capacity is degraded by 15%
Microchannel Coil remained “functional” for 89% longer
than Round Tube – Plate Fin coated with E-Coat
Accelerated Corrosion Test
Repeated, Cyclic Exposure to:
1. Salt Fog
2. High Humidity – Hot Ambient
3. High Humidity – Cold Ambient
4. Low Humidity – Low Ambient
Questions?