Modularproduct Familydesign

ModularProduct FamilyDesign

A UTC Perspective

Trevor Bailey April 7, 2009 United Technologies Business units Pratt & Whitney

aerospaceaerospace systemssystems powerpower solutionssolutions Sikorsky Carrier UTC Power

Hamilton UTC Fire Sundstrand & Security buildingbuilding Otis systemssystems

2 United Technologies 2008 Revenues: $58.7 billion Business unit revenues …

UTC Fire & Carrier Security 25% Segment … 11% 62% Commercial Sikorsky 9% 38% Aerospace Hamilton Sundstrand 11%

Pratt & Whitney Europe United States 22% Otis 22% 27% 48%

Geographic revenues …

Asia Pacific 14% Other 11% 3 United Technologies A tradition of innovation

Willis Carrier Elisha Graves Otis Igor Sikorsky Frederick Rentschler

Thomas Hamilton David Sundstrand Charles Chubb Walter Kidde

4 Modular Product Family Design

Develop process/tools to architect and design modular-based HVAC&R product families

Carrier Product Families Modular Systems Architecting

System SystemRequirements Requirements

Functional Residential Decomposition Module Functional Module HVAC Decomposition ClusteringClustering Technical TechnicalSolutions Solutions

System architecture + Module/interface specification

Supply/Return Ambient Building Env . Building & Ducts e n r i r

Environment b i a i A m t A u r l y

Power Supply s p

Electrical Voltage r e S u a i r

Current p e Bldg Env I/O

Voltage i o t s

current Air s t c

Sensing and i o n Thermostat b u d u s t Controller Sensors m r o System Controls b u o P

m Heating, Refrigerant cycle, Air C n Interface C o A i r Mgmt I/O CombustionElectric Strips (opt) Exhaust Products Fan Heating Gas Burner Gas Heat identificationInterface Exchanger Architecture + n

Structure / Frame t u r

Panels / Insulation e i r Identification Insulation R a Module/Interface Refrigerant Air Compressor Refrigerant Re -heat coil Cycle Condenser

i r Superheat Evaporator t a

e n Tubing / Piping Exp Device

b i R410A

m Air

A Air Air Specification Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Commercial Fan (VAV) HVAC Design for Modularity

Product Line with No Gaps Product Outdoor Air Model Verified Unbuilt Units Variant Condenser Fan Height EER Cost Weight dbANoise Product Outdoor Air 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 Variant Condenser Fan Height EER Cost Weight dbA Noise

Supply/Return 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 1.5T Tier 1 24 24 1.6 15.2 $650 100 45

Building & Ambient n r BuildingEnv . Ducts

Environment b i e a r A i 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 A m t

Power Supply s u r p l y 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 3.0T Tier 1 24 29 2.9 10.3 $650 140 64

Electrical Voltage r e s S u p a i r

Current Bldg EnvI/O p e 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Voltagecurrent s t i o c t s System Architecture 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 Sensing and t i o n Thermostat Air b u o d u 6.0T Tier 1 29 29 6.3 14.4 $650 200 48

Controls b u s Controller Sensors o m P r 5.0T Tier 1 27 27 5.1 16.3 $650 180 55

o m i r Heating, Refrigerantcycle, Air C n 7.0T Tier 1 29 32 7.5 16.3 $650 220 54

C A Mgm tI/O Exhaust 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 Gas CombustionProducts Electric Strips (opt) Fan + Module 80T Tier 1 29 34 7.9 14.4 $650 240 55 Heating Burner Gas Heat 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 Exchanger 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 80T Tier 1 29 34 7.9 14.4 $650 240 55

r n 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 Structure / Frame Panels /Insulation e t u i r Specification 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 Insulation R a 11.0T Tier 1 35 34 11.5 16.3 $650 300 55 10.0T Tier 1 35 42 10.5 14.4 $650 280 54

Refrigerant Air Compressor Refrigerant Re- heat coil 11.0T Tier 1 35 34 11.5 16.3 $650 300 55

Cycle Condenserr Superheat

t a i Evaporator i e n Tubing / Piping Exp Device ECS

A m b Verification R410A Air Ai r Air

Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Fan (VAV) Parametric Product Cases Family Models Optimization / Visualization

x Transport 1

Subsystem Models Refrigeration Modularity Alternatives Commercial 5 sizes Product Outdoor Air 1 2 3 4 Variant Condenser Fan Height EER Cost Weight dbANoise t 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 s 1 2 3 Prototype o Product Line w No 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 C Refrigeration 1 2 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 Gaps 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Adjustment Factors 1 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 80T Tier 1 29 34 7.9 14.4 $650 240 55 Performance Coverage Eff Eff Eff Coverage 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 11.0T Tier 1 35 34 11.5 16.3 $650 300 55 x1 x2 x 3 Product Gap s s s Analysis x1 x2 x 3

Tech Review QRB Test Plan QRB Design Freeze QRB 5 Modular Systems Architecting

System Requirements

Functional Decomposition Module Clustering Technical Solutions

Modular Architecture and Interfaces

Supply/Return Ambient Building Env. Building & Ducts n r e r i

Environment i i b a A

m t A

r y u l p

Power Supply s s p

Electrical Voltage e u i r r

Current p e S a

Voltage Bldg Env I/O o s t i t

current c n Air s u u

Sensing and i o Thermostat b d t o

s Controller Sensors m r u P o

Controls b C n

m Heating, Refrigerant cycle, Air o i r

C A Mgmt I/O Interface Combustion Electric Strips (opt) Exhaust Gas Products Fan Heating Burner Gas Heat identification Exchanger

n r

Frame u Structure / Panels / Insulation t e r i Insulation R a

Refrigerant Air Compressor Refrigerant Re -heat coil Cycle Condenser

r Superheat i Evaporator a t n

e Tubing / Piping Exp Device i b R410A Air m Air Air A Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Fan (VAV)

6 Modular Systems Architecting Systems Architecture View

Environment Outdoor Environment Container Box Environment

Electrical Ckt 460V Transformer Breaker Supply air Sensing & User IO Control temp Controls Ambient Interf air ace Humidity temp Contactors Return air temp

Air & Thermal Mgt Fan Motor Motor Fan

Cond Pr TXV Receiver Filter/ Dryer Liq-Suc HX Refrigerant Evaporator Cycle Condenser Heater Compressor thermostat Defrost Coil Discharge Discharge Suction Modulating TXV heater pressure pr & Temp pressure Valve bulb Valve Temp Structure Frame

Skins/ Access panels

Motion Refrigerant Structure Air Information Electrical Sensor 7 Modular Systems Architecting Architecture Commonality (Modules, Interfaces)

Environment Outdoor Environment Container Box Environment

5 Electrical Ckt 9 460V Transformer Breaker Supply air Sensing & 8 6 User IO temp Controls Ambient Control Interf air ace Humidity temp Contactors 4 Return air temp 7

Air & Thermal Mgt Fan Motor Motor Fan

Cond Pr TXV Receiver Filter/ Dryer 2 Liq-Suc HX Refrigerant Evaporator Cycle Condenser 3 11 1 Heater Compressor thermostat Defrost Coil Discharge Discharge Suction Modulating TXV heater pr & Temp Valve pressure 10 pressure bulb Valve Temp Structure Frame

Skins/ Access panels

Motion Refrigerant Structure Air Information Electrical Common Sensor 1 interfaces 8 Modular Systems Architecting Architecture Commonality Assessment

Category Modules Product 1 Product 2 Product 3 Design Rationale Refrigeration Refrigenrant

Compressor

Condensor

Filter/Dryer

Evaporator

Evaporator coil heater

Heater thermostat

Mod valve No Data Availa ble No Data Availa ble No Data Availa ble

No Commonality

Some Commonality

All commonality

No data available

9 Design for Modularity - Process Design for Modularity Module Verification Product Line with No Gaps Product Outdoor Air Model Verified Unbuilt Units Variant Condenser Fan Height EER Cost Weight dbA Noise

1.5T Tier 1 24 24 1.6 15.2 $650 100 45 Product Outdoor Air Variant Condenser Fan Height EER Cost Weight dbA Noise 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 Supply/Return Building & Ambient Building Env . 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 n Ducts e r i r

Environment i i A b a 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 m t 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 A

r l y

u p 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 Power Supply s p Electrical Voltage e s u r 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 r i

Current p e S a Bldg Env I/O 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 Voltage 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 i o t s

current t c

n Air s u o u d System Architecture 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Sensing and t i Thermostat b o s Controller Sensors m r 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 u o P

Controls b C n 6.0T Tier 1 29 29 6.3 14.4 $650 200 48

o m r Heating, Refrigerant cycle, Air

i 80T Tier 1 29 34 7.9 14.4 $650 240 55

C A Mgmt I/O Exhaust Combustion Electric Strips (opt) 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 Gas Burner Products Fan + Module Heating Gas Heat 80T Tier 1 29 34 7.9 14.4 $650 240 55 Exchanger 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 9.0T Tier 1 29 38 9.2 16.3 $650 260 48

11.0T Tier 1 35 34 11.5 16.3 $650 300 55 n r

Structure / Frame t u Panels / Insulation e r 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 i Specification Insulation R a 11.0T Tier 1 35 34 11.5 16.3 $650 300 55

Refrigerant Air Compressor Refrigerant Re-heat coil Cycle Condenser

r Superheat

i Evaporator a n t Tubing / Piping Exp Device i e

b R410A Air ECS m Air Air Verification A Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Fan (VAV) Parametric Product Cases Family Models Optimization / Visualization

Subsystem Models Modularity Alternatives

5 sizes

1 2 3 4 Product Condenser Outdoor Air Height EER Cost Weight dbA Noise Variant Fan t 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 s 1 2 3 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 Prototype o 3.0T Tier 1 24 29 2.9 10.3 $650 140 64

C 1 2 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Adjustment Factors 1 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 80T Tier 1 29 34 7.9 14.4 $650 240 55 Performance Coverage 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 Eff Eff Eff Coverage 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 11.0T Tier 1 35 34 11.5 16.3 $650 300 55 x x x Product Gap 1 2 3 s s s Analysis

x1 x2 x3

Tech Review QRB Test Plan QRB Design Freeze QRB

10 Design for Modularity Key elements: Design Space Exploration & Decision Making Design Space Exploration Infeasibility Constraints Cost Model Scalability Demand Model

Pareto Inputs Product frontier Mixed ModelProduct exploration Decision Making Continuous ModelProduct Product Multiple integer Model Model Objectives Interactive Categorical Visualizing family and decision product level attributes making Actual or Variations surrogate model Data Robust design Analysis Commonality Design Optimization Product Selection Combinatorial +Attribute sizing Human in Commonality Features of product family problem in black loop selection Standard work Technical challenges shown in red for commonality Quantify benefits selection of commonality Practical challenges shown in green

11 Design for Modularity Challenge Problem: Coil commonality analysis

SST Expected: Tcond Efficeincy, (1) How many coils are needed Compressors Cost, Type of coil (2) What are their dimensions Coil Length Velocity V70 10 Ton Coil = Same Type + Same Length

SST Objectives Tcond EER, (1)Minimize number of coils Compressors Cost, (2)Minimize Cost Type of coil Coil Length Velocity V70 55 Ton (3)Maximize EER Variables in blue are categorical Constraints •11 Chiller models (1)Compressor capacity between 95% to •33 Continuous variables 105% •22 Categorical Variables (2)Possible compressor combinations •23 Objectives (3)Fan speed: 1140+/-50 RPM •100+ Constraints (4)EER > 9.8

12 Design for Modularity Approaches & Status Carrier Current Practice State of Capability Future Direction Two Stages: All-in-one Optimization 1. Individual Optimization Chiller 10 Ton 2. Commonality Selection Chiller 20 Ton Chiller 30 Ton Chiller 30 Ton Chiller 20 Ton Optimization Optimization Chiller 10 Ton Optimization Decomposition-based Optimization Optimization Top Optimization

Sub Opt Sub Opt Sub Opt

Coil length Chiller Chiller Chiller 10 Ton 20 Ton 30 Ton Advantage: Advantage: -Expert based -Pareto optimal solutions Advantage: -Iterative sequential -Handle multiple Disadvantage: decision making commonality assessment -Not all options -Global optimal solutions explored Disadvantage: -Knowledge tied to -Requires substantial post-processing Disadvantage: expert -computational resource intensive 13 Design for Modularity Method Comparison – Current Experience

Method 1 Method 2 Method 3

Optimal Solution Worst Best Worst

Ease of use Best Moderate Worst

Computational Moderate Best Worst resources Human-in-the-loop Best Best Moderate interactivity Transparency of results Best Best Worst

Training required Best Moderate Worst

Selected Approach

14 Design for Modularity Commonality Decision Making Process: Standard Work

Build individual baseline models with PM tool Design Space Exploration

iSight: System R E

Integrate model with Integration and E optimization tool Optimization Tool

Individual product Cost optimization (NSGA-II) Tube Products Length 10 15 18 20 25 30 35 40 45 50 55 27 31 40 45 55 60

r 65 70 e

t 75

e 80

Decision Making Optimization results post m 55

a 60 r processing 65 a 70

P 75 Interactive visualization 80

Select commonality with interactive visualization

Ton Baseline A B 10 60x60 60x48 60x48 R 15 60x60 60x48 60x48 E 18 80x48 60x48 60x48 Generate alternative E 20 80x48 60x48 80x48 25 80x48 80x60 80x48 concepts

h 30 80x60 80x60 80x48 t

35 (60/60)x60 60/60x48 60/60x48 g g

40 (60/60)x60 60/60x48 60/60x48 n n 45 (80/80)x60 60/60x48 60/60x48 i e v

L 50 (80/80)x60 80/80x60 80/80x60 a Cost l S

i 55 (80/80)x60 80/80x60 80/80x60

o t Compare performance s C Chiller concepts o and cost savings C

35~55 Ton 1 2 3 Chiller conceptsConcept 15 Design for Modularity Commonality Decision Making: Coil Commonality

35 Ton h 40 t

45 g

Results from n R Ton Ton e E

individual L E l

50 i

optimization o Ton 55 C Ton

35 40 45 50 55 Cost Ton Ton Ton Ton Ton Human-in-loop decision

making No 45 Ton design available

h Coil B t g n e R

Common coil L E

l E i

Selection o Coil A C

35 40 45 50 55 Cost Ton Ton Ton Ton Ton 16 Design for Modularity Impact: Rationalized coil commonality Commonality Decisions • >10X reduction in coil variety; ~2X reduction in compressor variety • Benefits of commonality: • Increases volume discount opportunities • Addresses quality issue (materials shortage: #1 factory escape) • Part count reduction leads to less design & sustaining engineering • Manufacturing consolidation (assembly line reduction: 3 lines to 2 lines) Modularity analysis to rationalize coil commonality Chiller (Tons) Split (Tons) MCHX Coil Ltube 10 15 18 20 25 30 35 40 45 50 55 25 27 30 40 50 60 02Passes_070_026 45 2 50 2 1000 55 2 ) $

60 2 1 K ( 800 8.9%

2 2 2 2 65 s g Coil 70 2 2 2 1 2 n

i 600

75 2 2 2 1 2 1 v

a 5.2% 2 2 2 2 2

Design 80 S

400 85 2 2 2 2 2 2 l a

90 2 2 2 2 2 2 2 u

n 200

95 2 2 2 2 2 2 1 2 2 n

100 2 2 2 2 2 1 2 2 A 0 105 2 1 2 2 2 02Passes_076_030 40 2 EER/Cost Pareto 2 Coils 3 Coils 45 2 optimal 50 2 Concepts 55 2 1 Valid solution: Not 60 2 2 1 2 65 2 2 2 1 2 EER/Cost Pareto 70 2 2 2 2 2 1 Material Cost Savings vs Baseline 75 2 2 2 2 2 2 2 optimal 80 2 2 2 2 2 2 2 2 2 Not valid solution 85 2 2 2 2 2 2 2 2 2 2 17 Module Verification - Process Design for Modularity Module Verification Product Line with No Gaps Product Outdoor Air Model Verified Unbuilt Units Variant Condenser Fan Height EER Cost Weight dbA Noise

Environment i i A b a 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 m t 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 A

r l y

u p 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 Power Supply s p Electrical Voltage e s u r 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 r i

Current p e S a Bldg Env I/O 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 Voltage 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 i o t s

current t c

n Air s u o u d System Architecture 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Sensing and t i Thermostat b o s Controller Sensors m r 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 u o P

Controls b C n 6.0T Tier 1 29 29 6.3 14.4 $650 200 48

o m r Heating, Refrigerant cycle, Air

i 80T Tier 1 29 34 7.9 14.4 $650 240 55

11.0T Tier 1 35 34 11.5 16.3 $650 300 55 n r

Structure / Frame t u Panels / Insulation e r 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 i Specification Insulation R a 11.0T Tier 1 35 34 11.5 16.3 $650 300 55

Refrigerant Air Compressor Refrigerant Re-heat coil Cycle Condenser

r Superheat

i Evaporator a n t Tubing / Piping Exp Device i e

b R410A Air ECS m Air Air Verification A Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Fan (VAV) Parametric Product Cases Family Models Optimization / Visualization

Subsystem Models Modularity Alternatives

5 sizes

Tech Review QRB Test Plan QRB Design Freeze QRB

18 Module Verification Common & Robust Limit Switch Location Gas heat exchanger configurations Objective Down shot . Develop common limit switch location (CLSL) optimization to identify locations that are Side shot .Common between different configurations Limit .Robust against spatial variation Switch . Benefits: standardized assembly line and maintenance (LS)

Challenges/ Risks . Design space representation .Large design space: multiple configurations + Leaving Air (LAT) conditions .Accuracy of CFD models Status . Design Space Exploration .Common Limit Switch Location (CLSL) .Highly non-linear design spaces: multiple optima optimization procedure developed .Account for special sensitivity to identify robust .Demonstrated using CFD data locations .Validated using experimental Data . Decision Making .Compromise between common and robust location .Human-in-loop 19 Module Verification Common Limit Switch Location: Optimization Procedure Down shot CFD/ experimental data Side shot Design Space Limit Sample design space Switch Representation (LS) Determine • Correlation coefficient (ρ) • slope (S) • Temp (T200) when LAT = 200F

Leaving Air (LAT) Construct and validate approximations for ρ, S, T200

Suitable Limit switch Location Design Space Correlation coefficient: Feasible design space searching Exploration optimization p T ,T 0.95 m 200 LS LAT e T T Robust limit switch location h Slope (Relative Change) c t i optimization T w  LS TLS S

0.5  1.5 t i TLAT TT

m LAT i Decision L 200ºF Temp when LAT = 200F Visualize robust location in Making Leaving Air Temp design space T 200 140F

20 Module Verification Design Space Representation: Constructing Approximation Models Validation Challenges: Individual Configuration: Down Shot-Slope • Large design space: (100k grid points) (Mean Sq Error = 0.0185) • Multiple configurations • Non-uniform CDF grid • Highly non-linear responses

Approach: • Remove grid points near combustion tube • non-preferred area CFD Data Approximation • Construct approximation over remaining grid • Radial Basis Function Common Location: Down Shot and Side Shot • Suitable for highly non-linear spaces Correlation Coeff ≥0.99, 0.90 ≤Slope ≤1.5

Key Learning: • CFD Data: • Difficult to identify common locations • Complexity proportional to # of products

• Approximation models • Very easy to identify common locations • Suitable for identifying robust location CFD Data Approximation

21 Module Verification Design Space Exploration: Common Robust Limit Switch Locations

min δDownShotS + δSideShot Challenges: Optimization X, Y, Z • Highly non-linear responses: formulation Subject to • Slope and T200 sensitive to location ρdown, ρside ≥0.99 • Need framework to identify robust locations 0.90 ≤Sside , Sdown ≤1.5 • Should be able to explore multiple optima Y-Z Plane • Computationally efficient

Approach: Common • Define robustness measure function (RMF) Robust • Use Finite difference: Central difference Locations S(x, y, z) S(x x, y, z) S(x, y, z) S(x x, y, z) x  2x

x y z DownShot DS  DS DS Non- Robust location • ∆x, ∆y, and ∆z = 1”- based on sensor size Y-Z slice

Robust location Robust Key Learning: location is on plateau • CLSL optimization able to locate robust locations • Approximation+ Optimization required for identifying robust limit switch locations 22 Modular Product Family Design

Develop process/tools to architect and design modular-based HVAC&R product families

Carrier Product Families Modular Systems Architecting

System SystemRequirements Requirements

Functional Residential Decomposition Module Functional Module HVAC Decomposition ClusteringClustering Technical TechnicalSolutions Solutions

System architecture + Module/interface specification

Supply/Return Ambient Building Env . Building & Ducts e n r i r

Environment b i a i A m t A u r l y

Power Supply s p

Electrical Voltage r e S u a i r

Current p e Bldg Env I/O

Voltage i o t s

current Air s t c

Sensing and i o n Thermostat b u d u s t Controller Sensors m r o System Controls b u o P

m Heating, Refrigerant cycle, Air C n Interface C o A i r Mgmt I/O CombustionElectric Strips (opt) Exhaust Products Fan Heating Gas Burner Gas Heat identificationInterface Exchanger Architecture + n

Structure / Frame t u r

Panels / Insulation e i r Identification Insulation R a Module/Interface Refrigerant Air Compressor Refrigerant Re -heat coil Cycle Condenser

i r Superheat Evaporator t a

e n Tubing / Piping Exp Device

b i R410A

m Air

A Air Air Specification Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Commercial Fan (VAV) HVAC Design for Modularity

Supply/Return 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 1.5T Tier 1 24 24 1.6 15.2 $650 100 45

Building & Ambient n r BuildingEnv . Ducts

Environment b i e a r A i 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 A m t

Power Supply s u r p l y 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 3.0T Tier 1 24 29 2.9 10.3 $650 140 64

Electrical Voltage r e s S u p a i r

Controls b u s Controller Sensors o m P r 5.0T Tier 1 27 27 5.1 16.3 $650 180 55

o m i r Heating, Refrigerantcycle, Air C n 7.0T Tier 1 29 32 7.5 16.3 $650 220 54

Refrigerant Air Compressor Refrigerant Re- heat coil 11.0T Tier 1 35 34 11.5 16.3 $650 300 55

Cycle Condenserr Superheat

t a i Evaporator i e n Tubing / Piping Exp Device ECS

A m b Verification R410A Air Ai r Air

Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Fan (VAV) Parametric Product Cases Family Models Optimization / Visualization

x Transport 1

Tech Review QRB Test Plan QRB Design Freeze QRB 23 Thank-you …

Trevor Bailey

Project Leader Carrier Program Office (860) 610-1554 [email protected] United Technologies

Product Line with No Gaps Product Outdoor Air Model Verified Unbuilt Units Variant Condenser Fan Height EER Cost Weight dbA Noise 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 Product Outdoor Air Variant Condenser Fan Height EER Cost Weight dbANoise 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 Supply/Return 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 Building & Ambient Building Env . n Ducts e r i r 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 Environment i i A b a 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 m t A

r l y 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 u p

Power Supply s p 3.0T Tier 1 24 29 2.9 10.3 $650 140 64 Electrical Voltage e s u r r i

Current p e S a Bldg Env I/O 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Voltage 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 i o t s

current t c

n Air s u o u d System Architecture 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 Sensing and t i Thermostat b o s Controller Sensors m r 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 u o P

Controls b C n

o m r Heating, Refrigerant cycle, Air 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 i

C A Mgmt I/O 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 Exhaust Combustion Electric Strips (opt) 80T Tier 1 29 34 7.9 14.4 $650 240 55 Gas Burner Products Fan + Module Heating Gas Heat 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 Exchanger 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 80T Tier 1 29 34 7.9 14.4 $650 240 55

n 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 r

Structure / Frame t u 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 Panels / Insulation e r i Specification Insulation R a 11.0T Tier 1 35 34 11.5 16.3 $650 300 55 10.0T Tier 1 35 42 10.5 14.4 $650 280 54

Refrigerant Air Compressor Refrigerant Re-heat coil 11.0T Tier 1 35 34 11.5 16.3 $650 300 55 Cycle Condenser

r Superheat

i Evaporator a n t Tubing / Piping Exp Device i e

b R410A Air ECS m Air Air Verification A Air & Thermal Condenser Indoor Air Management Fan Fan Filter (IAQ) Exhaust Fan (VAV) Parametric Product Cases Family Models Optimization / Visualization

Subsystem Models Modularity Alternatives

5 sizes

1 2 3 4 Product Condenser Outdoor Air Height EER Cost Weight dbA Noise Variant Fan t 1.5T Tier 1 24 24 1.6 15.2 $650 100 45 s 1 2 3 2.0T Tier 1 24 27 1.8 15.6 $650 120 44 Prototype o Product Line w No 3.0T Tier 1 24 29 2.9 10.3 $650 140 64

C 1 2 4.0T Tier 1 24 24 4.5 14.4 $650 160 54 Gaps 5.0T Tier 1 27 27 5.1 16.3 $650 180 55 Adjustment Factors 1 6.0T Tier 1 29 29 6.3 14.4 $650 200 48 7.0T Tier 1 29 32 7.5 16.3 $650 220 54 80T Tier 1 29 34 7.9 14.4 $650 240 55 Performance Coverage 9.0T Tier 1 29 38 9.2 16.3 $650 260 48 Eff Eff Eff Coverage 10.0T Tier 1 35 42 10.5 14.4 $650 280 54 11.0T Tier 1 35 34 11.5 16.3 $650 300 55 x1 x2 x3 Product Gap s s s Analysis x1 x2 x3

Tech Review QRB Test Plan QRB Design Freeze QRB