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Central Chiller: The Ultimate FAQ Guide

I know you’re probably looking for a high-performance central chiller.

That’s why this guide will answer all questions you have been asking about this chiller system.

Whether you want to learn about the specifications, parts, working principles, or classifications, all the information is right here.

Keep reading to learn more.

What is Central Chiller?

A central chiller is a machine efficient at extracting heat from a liquid (usually water).

Thereby, cooling it to a favorable temperature.

It performs cooling either through vapor compression cycles, absorption refrigeration processes, or absorption refrigeration cycles.

However, the chiller is uniquely designed.

This is because it efficiently cools down several processes all over a factory simultaneously.

It means you can cool numerous applications concurrently with a single machine at a uniform temperature.

What are the Available Types of Central Chillers?

Generally, central chillers are available in the two root primary classes of chillers, i.e., Air-cooled chillers and water-cooled chillers.

Consequently, we classify the central chillers into two major types:

• Air-cooled central chillers
• Water-cooled central chillers.

1. Water-cooled Central Chillers

These chillers have got water-cooled condensers connected to a cooling tower

The water-cooled chillers are most prevalent in medium to large industrial setups and commercial industries with a reliable water supply.

These chiller types perform averagely constant due to relative independence on the continuously fluctuating ambient temperature.

The water-cooled central chillers are available in several working capacities ranging from twenty tons to thousands of tons.

Besides, the more giant capacity machines are standard in large enterprises such as airports, shopping malls, factories, etc.

The standard water-cooled central chillers use recirculating water condenser from the cooling tower to condense the circulating refrigerant.

Standard water-cooled central chillers are indoor setups void of damaging elements.

Thus, the chillers have a longer lifespan than corresponding Air-cooled central chillers.

Water cooled central chiller

2. Air-cooled Central Chiller

Air-cooled central chillers have got condensers reliant on ambient air for effective cooling.

Therefore, these air-cooled chillers are convenient for use in small to medium enterprises with space constraints.

More importantly, Air-cooled central chillers present a typical practical solution to enterprises with unreliable water supplies.

Usually, these chillers have got propeller fans or employ mechanical tubings to draw ambient air over the finned coil, which condenses the refrigerant.

Significantly, the Air-cooled central chillers avail an option of lower installation costs.

Besides, they are easier to maintain due to their relatively simple structure compared to the water-cooled type.

Due to their reliance on a fresh supply of ambient air, the Air-cooled central chillers will most appropriately require an outdoor setup.

That will, however, expose them to numerous elements that may compromise their lifespan.

Ultimately, the general flexibility concerning space utilization, costs, and performance of the air-cooled central chillers makes them suitable for many installations.

Air cooled central chiller

Why Should You Install Central Chiller?

You should undoubtedly install a central chiller in case your situation matches any of the following scenarios:

Simultaneous operation: operating on several processes can be challenging.

However, with the central chiller, you shall promptly and efficiently manage them concurrently—just one chiller for all.

Better and improved indoor air quality control: the term indoor air quality refers to the air quality inside buildings.

That is, how it affects the occupants’ health.

Particulates and harmful gases to human health may influence air quality.

Luckily, the chiller system does not hamper the air quality.

Instead, it enhances improved IAQ control due to non-emissions.

Reduced life cycle expenditure: the central chillers’ life cycle expenditure refers to the total of the recurring expenses and the non-recurrent fee.

Usually, the costs span from acquisition to disposal.

By extensions, the central chillers consume little life costs.

Energy efficiency: with the central chillers, you will enjoy lots of energy savings compared to the typical chillers.

The cost savings on energy is amongst the sole reasons for the preference of the central chillers.

Offers room for expansion: with the modular series, your central chiller is expandable to achieve greater cooling heights and capacity.

Therefore, you can add more chillers but under a similar control panel.

Are There Limitations of Central Chillers?

The central chillers do have some additional drawbacks.

A significant one is a need for extensive floor space requirements.

The chillers’ bulky nature and size will require a more expansive floor room and plenum space for installations.

The ultimate result; the need to increase the building’s height.

They tend to have complicated installation procedures.

This is because the central chiller may come with countless auxiliary parts and connections, together with piping.

In such situations, installation may be tiresome and tricky.

What Should You Consider When Installing Central Chilling System?

Installation of a central chiller is a necessary procedure that needs a specialized technical approach.

Whereas the process could be direct, you still have to follow some protocols before setting in.

Below are some of the factors that you have to consider before installing the central chiller.

Floor space: central chillers are generally quite large.

Though their size might vary depending on the machine type, the chillers are usually extensive in scope, thus demanding large space.

Consequently, you have to allocate an adequate room to cater to that enormous space need and maintenance allowance.

Plenum space: Before anything else, reconsider the plenum space allocation. The height of your building should be higher.

If possible, consider increasing the size of the building.

Installation ground: always install the chiller on a level, tangible and concrete floor capable of withstanding the chiller’s weight.

Therefore, chillers vibrate when operating, thus, constructing a broad concrete foundation for the machine.

Plus, you can fix flexible joints to help with the vibration

Piping and wiring preparedness; note that the machines come with technical specifications documents.

Always refer to the manual for the connection sizes, piping, and electrical demands.

Central chiller piping system

Which are the Components of the Central Chiller?

The central chiller’s main components include a compressor, condenser, evaporator, expansion valve, power unit, and control unit.

Compressor: The compressor creates a differential pressure that is adequate to drive the refrigerant throughout the machine system.

You can choose a suitable compressor depending on your application from the following types: screw, scroll, centrifugal and reciprocating compressors.

You shall find the compressor in between the evaporator and the condenser.

Condenser: it expels excess heat from the refrigerant, that heat might have accumulated in the evaporator.

The condenser is always located just before the expansion valve and behind the compressor.

Most often, you will choose from the two condenser types, i.e., air-cooled and water-cooled condensers.

Expansion valve; the valve heats the refrigerant, thereby expanding, reducing its pressure, and finally increasing its volume.

Such refrigerant thus easily pick-up the excess heat accumulated in the evaporator.

In the unit, the component exists between the condenser and the evaporator.

Evaporator: it accumulates excess heat from the system and then stirs it into the refrigerant.

Subsequently transmitting the thermal energy to the cooling tower for rejection.

Its location is between the compressor and the expansion valve.

Power unit: it controls the flow of electrical energy to the chiller.

The power unit could contact the machine, be mounted to the wall, or be installed separately from the chiller.

The power unit comprises starters, circuit breakers, etc.

Control unit: the controls come attached to the chiller.

With the control unit’s help, you get to monitor the machine’s performance, thus allowing you to tweak its performance.

You can safely monitor alarms, shut down the engine, and remotely control the device through the control unit.

Water box; the water box either directs the flow of water or segregates the exit or entrance.

The water boxes have either 1 or 2 flanged door or entrance holes depending on the evaporator and condenser passages.

Better still, you can choose a wholly capped water box that redirects the flow back into a nearby pass.

Note that the water box only applies to the water-cooled central chillers.

Central chiller thermal expansion valve

How do You Improve the Efficiency of Central Chiller?

You can improve the central chiller’s efficiency by undertaking deliberate yet critical measures.

Nonetheless, we can widely classify these measures under the following vote heads.

i. Continuing Maintenance

Just like other typical machines, the central chillers require constant maintenance to operate efficiently.

Considering that, you need to follow standard practices to ensure that the chiller maintains its optimum functionality.

• Always inspect and clean the condenser coils.

The maintenance practice should involve checking the rings for any clogging and blocked passageways.

• Strive to maintain a refrigerant charge. The benefit is that it aids in cutting down the energy costs by almost 5% to over 10%.
• Maintain purified condenser water. The water should be free from debris such as sand, fouls, scales, and contaminants.

ii. Prognostic Maintenance

Chiller systems often experience total breakdown and system failures.

However, with the integration of Artificial Intelligence, you can significantly avoid any potential and unpredictable maintenance.

Incorporating the AI algorithm enables the prior collection of system data and subsequent analysis to aid in scheduling maintenance practices.

That would readily avert potentially catastrophic system failures.

Moreover, the Internet of Things also helps provide a data collection center for accumulating data suitable for enhancing the AI applications in predictive maintenance.

IoT comes ahead of every other prognostic care because it helps collect actual data from a chiller system, thus enabling continual data analysis.

iii. Optimization

Before setting out your optimization goal, you have to evaluate the central chiller’s performance by analyzing every component’s total power.

However, such an action wouldn’t be possible without reliable data.

The excellent news – IoT provides the data required to perform a holistic optimization of the chiller.

The adjustments you may reconsider include: adjusting setpoints, load balancing, cooling tower management, chiller sequencing, etc.

What are Central Chiller’s Specifications?

You can always find the complete guide to the chiller’s technical information and specifications imprinted in the product’s manual.

Nonetheless, below is an overview of what information you should expect regarding the machine’s specifications.

Cooling specifications: refers to cooling capacity, fluid discharge temperature.

Pump specifications: process flow, process pressure, compressor motor horsepower, pump rating, reservoir capacity.

Power source; rated in voltage/ Frequency/ Phase i.e 115/60/1, 380/ 50/3

Industry/application; include industrial, HVAC, medical, hydraulic, laboratory, laser, plastics, etc.

Operating environment; incorporate installation- indoor, outdoor, weatherproof, explosion-proof, operating temperature.

Condenser cooling system; Air-cooled, water-cooled, remote air split system, other

P.S the above specifications are never constant amongst central chillers but vary depending on the central chiller’s size/ tonnage.

For instance, a 100 tone central chiller would have completely different magnitudes of specifications from a corresponding 1000 tone machine.

Central chiller system diagram

How Does Central Chillers Work

The working of the central chiller begins from the compressor.

It creates a pressure difference to move the refrigerant all through the system.

An electric motor drives the compressor.

The refrigerant enters the compressor at low temperature and pressure while in a gaseous state.

However, it exits the compressor at high temperature and high pressure to the condenser.

The refrigerant then enters into the condenser from a distinct chamber and exits through another.

Also, the condenser extracts the heat from the refrigerant, which accumulated in the evaporator.

The condensers are of two types; Air-cooled condensers and water-cooled condensers.

For a water-cooled central chiller, the hot water leaves the condenser and enters the cooling tower.

Due to the cooling tower’s occurring evaporation, the water goes and flows into the condenser at a lower temperature.

The cycle then continues repeatedly.

Note that the refrigerant and the water never mix; they are always kept separate by a piped wall shell.

In the condenser, the refrigerant flows inside the pipes while the refrigerant flows outside the tubes.

Elsewhere, for air-cooled central chillers, the cooling tower does not exist.

Instead, blown air flows through the exposed condenser pipes to extract heat from the refrigerant flowing through the condenser pipes.

After that, the refrigerant exits the condenser and enters the expansion valve.

The expansion valve expands the refrigerant increasing its volume while reducing its pressure.

With that, then the refrigerant picks unwanted heat inside the evaporator.

The evaporator collects unwanted heat from the incoming water that enters while hot and subsequently transfers the heat to the refrigerant.

After that, it exits the evaporator having a lower temperature.

That temperature is adequate to cool the buildings.

The refrigerant enters the evaporator at a mixed state of liquid and gas and exits at a gaseous state to join the compressor.

The cycle then repeats itself.

Central chiller working diagram

What are the Available Types of Compressors In Central Chillers?

There are majorly four kinds of compressors, namely:

• Screw compressors
• Scroll compressors
• Centrifugal compressors
• Reciprocating compressors.

Screw compressor central chiller

What are the Differences Between a Centralised Chiller and a Decentralised Chiller System?

A centralized chiller system serves several distinct machines concurrently.

Elsewhere, a decentralized chiller system is limited to a single particular device.

Meaning, you would use a centralized chiller with numerous equipment while a decentralized chiller for a single machine.

Therefore, if you run a plant with several machines that require similar cooling specifications, then a centralized chiller system is perfect.

However, in factories that utilize devices with varying temperatures and specificities, the process water would require installing a decentralized chiller type.

Nevertheless, you can still utilize the services at your facility.

That is possible if you have two sets of machines that require two distinct kinds of cooling.

Most importantly, you have to note that there is no better-centralized chiller between the two; the difference only lies in the efficiency ratings amongst similar machines.

Nevertheless, centralized chiller systems are most prolific due to their energy efficiency and conservation rates.

How Much Do Central Chillers Cost?

Central chillers never cost much, but most importantly, their costs vary by the following critical factors:

• Chiller’s size, i.e. a 25-ton chiller, costs less compared to a 100-ton chiller.
• The chiller’s horsepower (HP); highly rated ones cost more.
• Company’s profile; some companies generally have lower rates compared to others. The injunction is to buy a quality chiller at reasonable prices.

How Do You Install Central Chillers?

Location; Initially, you have to determine the machine’s precise location, whether outdoor or indoor.

Air-cooled central chillers are usually outdoor equipment, while the water-cooled type is indoor machines.

Ensure that the supporting base is completely flat and free from any obstacles whatsoever,

Foundation- support; Construct foundation support for the machine; you can select between dual parallel U-steel or I-steel.

Plus, you may install anti-vibration Mounts (AVM), either spring or rubber types on the foundation. That equipment dramatically reduces noise and vibration.

Spacing: next, accord the machine sufficient spacing/ room for ventilation and maintenance. Note that you should access any particular side of the machine for the post-installation kind of care.

A distance of 1.5meters to 2 meters is ideal.

Water piping; Design any water piping while ensuring that you maintain the least quantity of elbows and a minimum number of abrupt changes in the direction.

That mode of installation saves you significantly the installation costs while enhancing the machine’s performance.

Water treatment; Before starting the machine, clean the water circuit properly.

Flow switch; always install a flow switch in the water circuit to guarantee that only sufficient water flows via the evaporator.

Heat recovery, if you may, incorporates a heat recovery system.

Electrical installations; qualified, certified personnel should be the ones to do all electrical kinds of setup.

Moreover, the technician has to follow the prerequisite guidelines and protocols.

Central chiller installation

What Are The Testing Protocols For Central Chillers Before Shipping?

Before shipping, you must do the following two primary tests;

I. Energy performance assessment

II. Seasonal variation/ part-load performance.

Energy performance assessment; aims to assess the amount of energy a chiller requires to implement a specific cooling quantity given in  KW/TR units.

Seasonal variation/ part load performance; assess the central chiller’s performance while operating under part loads.

Precisely, you need to initiate the integrated part-load value to determine the chiller’s performance when working under part-load conditions.

How Do You Maintain Central Chillers?

Routine maintenance is essential for the central chiller to maintain optimum performance.

However, qualified personnel has to perform full maintenance.

Firstly, you have to create a standard routine maintenance plan for your central chiller.

The program should outline all the necessary activities against the corresponding frequency of performing them.

The plan incorporates general activities, including reading the operational data, cleaning, visual inspection of any damages, analyzing water, verifying the flow switch process, etc.

It also includes the electrical activities, visual inspection for overheating, checking control sequence, and confirming whether all electrical terminals are tight.

Furthermore, it also involves cleaning the electrical control board, measuring compressor motor insulation, etc.

Activities related to the refrigeration circuit; verify whether there is a refrigerant leakage, confirm the refrigerant flow rate by use of sight glass, analyze vibration of the compressor, etc.

Condenser section; check whether fans are tight enough, check the condenser bank fins, etc.

Please note that you will find more of the maintenance practices even specific to your machine from the technical manual.

Which Safety Features Do Central Chillers Have?

The following are a few of the various safety features of the central chillers.

• Capacity controls
• The high and low-pressure trip, low oil pressure trip
• High and low pressure cut out
• Low oil pressure cut out
• Oil separator
• Refrigerant flow controls
• Fuses
• Flow switches, amongst others.

Central chiller emergency stop button

What is the Average Cooling Capacity of Central Chillers?

The average cooling capacity of central chillers is 2500KW in metric units, or 8533364BTU/h in imperial units, or 711 refrigeration tons.

Do Central Chillers Have a Warranty?

Yes, though the warranty duration varies amongst the manufacturers or suppliers.

Some units have 12 months warranty as of initial start-up or 18 months as of delivery.

Most importantly, you always need to verify and conform to the chiller’s stipulated terms of the warranty, as indicated in the warranty leaflet.

How Do Central Chillers Compare to HVAC System?

An HVAC system refers to heat, ventilation, and conditioning chillers.

It is a regulatory heat machine that combines the mechanisms of heating, air circulation, and conditioning.

Unlike the central chillers, the HVAC’s working principle entails the technique of fluid dynamics and thermal energy exchange to obtain cooling.

Moreover, the HVAC system works by availing the three core roles of ventilation, heat generation, and air conditioning.

Consequently, a central chiller is entirely different from an HVAC system.

HVAC system

How Do Central Air Conditioners Compare to Central Chillers?

Well, central air conditioners are machines that regulate several rooms’ temperatures by controlling the air humidity.

The device is suitable whenever you require a similar temperature range for different places.

Air conditioners efficiently convert the room temperature from hot to cold (moderate) temperature.

Better still, some advanced central air conditioners may heat cold room air temperature to a suitable warm temperature range.

Interestingly, some of them have got wireless control systems allowing users to control them remotely.

Moreover, central air conditioners are suitable for use in rooms, offices, and homes to regulate temperature levels.

Therefore, central chillers and central air conditioners are far apart in terms of function, application, and performance.

Where Can You Install Central Chillers?

The two prime locations for installing the central chillers are outdoor and indoor sites, depending on the chiller type.

It is recommended by manufacturers that you install air-cooled central chillers outdoors to enhance proper ventilation.

However, you can install water-cooled central chillers either indoors or outdoors, depending on your application.

What Is The Working Temperature of The Central Chillers?

Well, chillers have different ranges of working temperature depending on your application.

What’s paramount is that the chillers inlet process water is at higher temperatures while the outlet temperature is significantly low.

Most chillers deliver the process water at a temperature range of 50(10◦C) to 5F (-15∘C) and less depending on the machine.

What are The Quality Certifications For The Central Chillers?

The following are some of the necessary quality certifications that your central chillers should achieve:

• Engineered systems: NFPA 79 compliance; electrical safety measure for an industrial machine.
• Power and control panel; NEMA 1, 3, 4, 4X, 7, 12 and IEC electrical enclosures, UL and cUL 508A listed panel, NEMA 12 rated electrical caps
• Heating and cooling equipment; CAN/CSA C22.2
• Environmental Management System; DIN EN ISO 14001:2015
• AHRI certifications ( AHRI WCCL and AHRI ACCL)

With the information in this guide, you can choose perfect central chiller systems.

However, in case you have any questions or inquiries, TopChiller is here to help you – contact us now.

Central Chiller-The Ultimate Buying Guide by TopChiller

What is a Central Chiller?

A Central Chiller is a machine that cools down multiple processes being simultaneously carried out in a machine.

The main part of a Central Chiller is a stand-alone device that must be connected to a pump and a separate reservoir via piping.

The Central Chiller would normally have different controls with an electrical link for each part of the system.

The controls should be wired together for preventing the Central Chiller from cooling until the rotating pump is off.

Central chiller

What are the General Features of an Air-Cooled Central Chiller?

• Rotary screw compressors on 75-125 ton
• single-zone units and 150-210 ton
• dual-zone units using HFC-407C refrigerant
• Hermetic scroll compressors on 5-60 ton
• single-zone units and dual-zone units by 120 ton
• using HFC-410A refrigerant
• Liquid line solenoid valve
• Thermostatic extension valve
• plate, as well as the shell along with tube evaporators, are brazed
• Refrigerant vision screen with a moisture detector
• System Capacity Management
• By-pass for hot gas (scroll compressors are present in single zone units)
• Unpacking (scroll compressors are present in single zone units)
• Compressor staging and bypassing hot gas (Scroll compressors in dual zone units)
• Unloading and staging of compressors (Scroll compressors in dual zone units)
• Unloading of a digital compressor (digital scroll compressors in single zone systems)
• Compressor staging (dual-zone vs. single zone) and digital compressor
• Air-cooled condenser with vertical air discharge
• Filled with non-ozone depleting refrigerant
• Unloading versions with tandem or several compressors

Air cooled central chiller

What are the Electrical Features of a Central Chiller?

• An electrical cabinet that can be seen outside
• 5 kA RMS SSCR branch circuit fusing
• Disconnect the main power supply
• Sub-panel with UL labeled line voltage and step tracking

Which Pressure Indications are Available in a Central Chiller?

• Low-pressure refrigerant (in each zone)
• High-pressure refrigerant (in each zone)
• Refrigerant demand

What are the Components of a Coolant Circuit in a Central Chiller?

• Process pumps with a larger capacity.
• Pumps and/or manifolds on standby.
• Heater for the reservoir (mild or stainless steel tanks only).
• There are no pumps or reservoirs.
• A strainer in a basket (On dual-zone modules, this is ordinary).
• System for installing overhead piping.
• Low reservoir level turn (This is standard on dual-zone units).
• The tank is made of epoxy-coated mild steel.

Central chiller water tank

How does the Refrigeration Cycle of a Central Chiller Work?

Central Chiller pump cold water between the temperatures of 40 and 45 degrees Fahrenheit through the air handlers.

The heat shifts to the water while the air is drained and passes through the finned coil.

The water exiting the coil in most cooling systems has been heated 10 degrees Fahrenheit at the full air-conditioning load.

The heat being received from the building’s circulating water is turned into vapors through the air handler or evaporator by the liquid refrigerant.

The vapors are pulled into the compressor and heated to a higher temperature and pressure. The compressor causes an increase in the pressure and temperature to the condenser’s specifications.

The gas moves to the condenser, and there an air-cooled condenser fan cools the gas. Or the cooling tower performs this task and then converts once more into a fluid. The cycle then undergoes repetition.

What are the Refrigerants Used in a Central Chiller?

Many environmental factors impact refrigerant supply in the future for Central Chiller applications.

• The boiling point is slightly lower than the desired coolant temperature.
• Increased vaporization heat.
• If liquefied, it has a moderate density; when gaseous, it has a high density.
• The critical temperature is very high.

Commonly used in the refrigerants

• HCFC

There are hydro chlorofluorocarbon compounds that make up a category of refrigerants. They have a high GWP and are very dangerous. R123, R2, R151, and so on are examples of these.

• HCS

Hydrocarbons are a form of refrigerant that have applications in both domestic and industrial chilling equipment. R600A (isobutene) and R290 (propane) are two commonly used refrigerant hydrocarbons (propane).

• Water

Using water as a refrigerant is a low in cost, non-toxic, readily available, and environmentally safe alternative.

Central chiller refrigerant

What is the Cooling Capacity of a Central Chiller?

The cooling power of a Central Chiller ranges from 30 to 580 tones.

The cooling capacities of the Central Chiller are available in single or dual-circuit configurations with 1 or 2 screw or scroll compressor refrigeration systems to suit your processing needs and ambient temperature.

The application area and market demand decide which type of compressor should be used.

What is the Function of a Cooling Tower in a Central Chiller?

Water is injected into the cooling tower from the Central Chiller and sprayed into the air or released onto media mats, where heat is transmitted into the airstream through evaporation.

The water is first cooled and then moved back to the system to repeat the heat absorption process.

Central chiller cooling tower

How does the Compressor Function in a Central Chiller?

A compressor is a gas mover and system that uses mechanical labor to raise the pressure of a gas. In the chemical process industry, compressors of Central Chiller are used in many applications (CPI).

Their output is often affected by adjustments in process parameters. T

The discharge pressure and power demand curves are given by the manufacturer against an inlet volumetric flow may not be valid for differences in process conditions.

The following tasks include the use of a gas compressor:

• Petrol injection
• Refrigeration
• A power delivery system
• A gas lift system
• Boosting of the wellhead separator

What is the Function of Air-Cooled Condenser in Central Chiller?

In a Central, Chiller fan blades are used for drawing atmospheric air above a finned coil in a Central Chiller to condense the refrigerant. It may have anywhere from as low as one and as high as five compressors.

Since they do not need a condenser water cooling system, air-cooled condensers of chilled water systems have low maintenance and installation costs.

When a cooling tower is not feasible, such as when the water source is limited or of poor quality, air-cooled condensers are used.

In a Central Chiller, the condensing temperature of the refrigerant is determined by dry-bulb air or atmospheric temperatures, and this should be less than 95°F.

Kit units weight about 500,000 tons are available.

How does the Water-Cooled Condenser of your Central Chiller Work?

To condense the refrigerant, recirculating water is used by the Central Chiller from a cooling tower.

Water-cooled Central Chiller is more powerful and has lower running costs.

The refrigerant temperature condensing in a Water-cooled Central Chiller is determined by the quantity and temperature of the water getting into the condenser.

The temperature of refrigerant if the water-cooled system is less than that of an air-cooled system. Also, the water-cooled condenser requires affordable service.

Many gauges that quantify and report pressures, temperatures, and electrical measurements can be found on this sort of device, and all of them should be registered during the inspection.

What is the Function of the Expansion Valve in a Central Chiller?

The flow of high-pressure liquid to the low-pressure evaporator is regulated by the expansion valve. The thermostatic and electronic forms of direct expansion circuits are the most common.

Pulse width modulated and constant modulation are the two forms of electronic modulation. Capillary tubes and restrictors are two other styles that use a fixed orifice and are used in small structures.

The float valve can regulate the flow of liquid into a flooded evaporator. This may be a high- or low-pressure kind. Low-pressure receiver circuits use low-pressure styles.

How does the Evaporator Works in Central Chiller?

An evaporator is a system used in the process of converting a chemical substance’s liquid state into its gaseous form/vapor.

In that step, the liquid evaporates or vaporizes to turn into the gas phase.

A particular kind of evaporator may be used to heat and potentially boil a product that contains a liquid for the liquid to evaporate.

Water or other liquids should be removed from liquid-based mixtures using the proper procedure.

Evaporation is often used to concentrate liquid ingredients, such as broth, or to provide concentrated milk by removing water from the milk.

The aim of evaporation in the concentration phase is to vaporize the majority of the water from a solution containing the desired substance.

What is the Function of Air Handlers in a Central Chiller?

An air handler of Central Chiller usually has a single blower or fan, separate coils, and pipes for heating and cooling.

The supply and return ducts are normally connected to the air handler. The supply ducts carry return air (and, in most cases, any outside air) over the cooling or heating coils and then enters into separate areas.

On the top of the ceiling and the adjacent floor, there is an air duct for the returning air.

The room thermostats regulate the air temperature. The in-duct temperature controls also facilities this regulation in some dual-path systems, which have heating and cooling coils running parallel.

What are Some Refrigerant Zone Options of Central Chiller?

• Digital Scroll Compressor that helps in energy saving capacity control
• Multiple condenser coils are featured with a protective coating and increase the life of the Central Chiller in rough environmental conditions.
• The oversized condenser that meets the need of full system capacity at surrounding temperature levels above 95°F
• Tandem scroll compressors that are present on single-zone units and help in offering superior capacity staging

What is the Micro Control of a Central Chiller?

Specially built for a single circuit Central Chiller, a microcontroller is the most suitable controller.

LCD readout of the setpoint, the true fluid tempera, microprocessor-based control, and compressor lead-lag are the prominent features.

However, a Central Chiller has even greater additional features like a long span of readout of time in terms of the compressor.

The portable and small microprocessor performs at its best while using little sources.

The safety functions shall also not be missed as it is important to control the compressor capacity. The safety features are built-in and therefore, the best performance is guaranteed.

Central chiller controller

What are the Features of PCO Central Chiller Control?

The PCO Central Chiller control is necessary for a dual circuit system. It has a well-controlled LCD touch screen with advanced software and a microprocessor.

The LCD and the graphics display help obtain greater system performance and enhanced efficiency.

The numerous digital signals as input and output, enhanced safety features, compressor lead-lag, and a clock further add to the efficiency of the system making it more reliable.

With access to the latest technology and improved systems, a PCO Central Chiller has the most accurate control. This further enables better communication and enhanced performance.

How does the Heat Mode of Central Chiller Work?

When on heat mode, the water is heated by the boiler, which is then moved to the air handler. Then here the air is moved through the finned heating coil with the help of a blower fan.

The coils transmit the heat to the cold water which is then moved back into the furnace. After that, the cycle begins again.

When is the Single Refrigerant Zone Model of a Central Chiller Beneficial for your Applications?

You can go for the single refrigerant zone model when the cooling load of the desired process is steady. It is also helpful when you have a low service requirement.

How is the Dual Refrigerant Zone Model of a Central Chiller Advantageous for your Applications?

When there are multiple fluid use points under observation, dual refrigeration zone models are most suitable.

Also, when the cooling loads are not fixed, this feature of the Central Chiller is helpful.

It offers greater capacity to meet the application needs. Another advantage is the built-in redundancy.

Even if one of the refrigeration zones is out of order, the other one can still perform the best function due to sufficient capacity.

Thus the Central Chiller provides safe use and can be reliable even in times when it’s not performing its best.

When is a Centralized Central Chiller Useful for your Applications?

A Central Chiller is present in the center of the factory and has pipes connecting it to the other devices.

A Centralized Chiller system can save money for factories, but not all factories can have one to keep their machinery and production processes cool.

When is a Decentralized Central Chiller Used for your Applications?

A Decentralized Central Chiller system offers each machine its particular cooling machine.

Production lines that have numerous machines that require a similar cooling power frequently pick concentrated frameworks.

While industrial facilities having machines requiring specific cooling procedures and temperatures commonly go for decentralized Central Chiller.

Can you Use Both Centralized and Decentralized Central Chiller Together for your Applications?

Both the mechanisms are equally important in a factory. Whether it is a centralized or a decentralized Central Chiller, it is needed in a factory.

Its application is not decided depending on the cooling mechanism. Both these mechanisms are used in a factory.

However, the efficiency ratings of both the chilling systems vary according to the circumstances but still, no one mechanism is preferred over the other.

Therefore, it is safe to say that yes, both the centralized and decentralized Central Chiller can be together used for a single application.

How is a Central Chiller Accurate, Reliable, and Green Friendly?

• Cooling capacities range from 30 to 120 tons.
• Monitor process fluids down to 20°F
• Configurations of a single or dual circuit
• Condensing that is air-cooled as well as water-cooled
• Compressors that scroll
• For power management, automatic compressor staging is used.
• For partial load situations, hot gas bypass with an electric connection is used.
• Controlled by a microprocessor
• Environmentally friendly refrigerants
• Systems with a Central Chiller and a pump tank are available.

What are the Applications of Central Chiller?

The most common Central Chiller applications are:

• Plastic Processing

The process involves the conversion of raw plastic material into semi-finished items. This is helpful in the making of tanks, bottles, pipes, automobile parts, etc.

• Tool Manufacturing

Tool manufacturing involves the manufacturing tools that aid in different mechanical tasks. These tools are drills, mills, grinders, etc.

• Die-cutting

The process in which a die is used for shearing low-strength material webs like fiver, rubber, cable, etc.

Central chiller used in the tool manufacturing industry

What are the Benefits of Using an Air-Cooled Central Chiller for your Applications?

• Affordable

It has a low installation cost because it requires less equipment for the installation process.

• Simple

It has a simple design construction and does not require any additional condenser pump for proper working.

You can obtain maximum efficiency from it without even using additional parts.

• Low Maintenance

The best thing about Air-Cooled Central Chiller is that it has low maintenance requirements if compared to the other type that is Water-Cooled Central Chiller.

This means you don’t have to spend a lot on the maintenance sessions of your Air-Cooled Central Chiller.

Also, you don’t have to stress out about the repeated monthly maintenance sessions, they can be carried out after 6 months or even on annual basis.

What are the Benefits of Using a Water-Cooled Central Chiller for your Applications?

• Efficiency

Water-Cooled Central Chiller offers greater efficiency than Air-Cooled Central Chiller.

• Quiet

The best thing about a Water-Cooled Central Chiller is that it has a quiet operation which is safe for your health.

• Increased Suitability

It provides suitability for both commercial-scale and small-scale cooling. This makes it good to be used for multiple applications.

How can you Customize a Central Chiller for your Applications?

• Audible alert
• C3 Cold Climate Coolers: Cost-compelling answer for measuring cooling in chilly climate regions.
• A shut-circuit cooling framework requires no make-up water or compound treatment.
• CPR valve
• Evaporator complex
• Evaporator complex with separation valves
• Evaporator sifter
• Low-temperature encompassing unit
• Water-cooled condenser complex
• Water-cooled condenser complex with separation valves
• Water-cooled condenser sifters
• Visual alert

Customized central chiller

Should you Consider Rigid or Flexible Tubes for Control Cables for your Central Chiller?

The instrument cabling is connected to the Central Chiller outside, which is standard industry practice.

It could be beneficial to enable the Central Chiller maker to mount the wiring in rigid or flexible conduit to provide an extra degree of security against inadvertent harm when operating on the system for the durability of life and protection of the cabling in the industrial campus plants.

How does your Central Chiller Provide Maximum Safety and Low Maintenance?

• Electrical enclosure with NEMA 12 rating
• Protection systems for low and high refrigerant pressures
• Disconnect the main power supply.
• Freezestat, any fault in the compressor, including no flow state are examples of general and specific device alarms.
• The refrigerant is isolated for routine operation by the refrigeration shut-off mechanism.
• A fast emergency shutdown is possible with an emergency stop.
• An audible warning will sound if there are any issues with the reset.

What are the Maintenance Tips for Using a Central Chiller?

• Carry Out a Regular Inspection and Cleaning of the Condenser Coils

The transfer of heat is essential when it comes to chilling process efficiency. For this reason, you must carry out regular inspections of your condenser coils and clean them following a proper schedule. This will prevent the dirt and dust build-up in your condenser coils.

• Conduct Proper Refrigerant Charge Maintenance

The cooling efficiency of your Central Chiller depends on the refrigerant levels of the system. The cooling caused can also be reduced by 5 to 10% if you will maintain the proper refrigerant of the system.

• Condenser Water Maintenance

It is important to conduct regular maintenance of the condenser water to make sure that the flowing water of your Central Chiller is clean and dirt-free. This helps in the prevention of water contamination and also keeps you away from problems like scaling and fouling which affect operational efficiency.

How is Predictive Maintenance of your Central Chiller Helpful for your Applications?

Artificial Intelligence (AI) aims to make strides in daily implementations. AI algorithms that can predict possible defects in machinery such as Central Chiller would be beneficial.

Predictive maintenance uses the compilation and review of operating data from the systems to assess when maintenance can be performed before a catastrophic failure.

Since these devices are the important part of most modern HVAC systems, that work for the prevention of catastrophic failures that result in substantial “downtime” would save both money and prestige.

The importance of a Central Chiller justifies the heightened attention. AI will cut back on downtime while increasing efficiency.

Central chiller compressor oil checking

What Is Medium Voltage Variable Frequency Drives Protection of your Central Chiller?

Medium-voltage VFDs account for a significant portion of the cost of Central Chiller (its selling price is 50 percent or more of the total cost.).

Overlooking the VFD’s implementation specifications will result in the VFD’s premature failure. The below are some general guidelines for considering when placing Medium Voltage VFDs:

• Position the Medium Voltage VFDs in a different room with a mild positive pressure compared to the whole building’s pressure (5 to 10 percent outside air is typically sufficient)
• Have a separate air-handling system for space, with MERV 11 or higher filters.

How to Use a Central Chiller Safely?

Central Chiller can be used safely by following these instructions:

• Wear proper safety equipment before using the Central Chiller.
• Make sure that all the electrical wires are properly insulated and do not touch them with bare wet hands.
• Do not directly touch the refrigerant or other chemicals related to your Central Chiller usage.
• If a part of your Central Chiller is damaged, discontinue usage and repair before the second use.

What Are Some Common Problems you can Face when Using your Central Chiller?

Does not Power Up: Not enough power supply is being used by the Central Chiller.

Insufficient Fluid Flow: The fluid flow amount and rate is not normal

Not Enough Cooling: The cooling efficiency and supply are reduced.

How to Solve the Common Problems of your Central Chiller?

Does not Power Up 

• Check if the line voltage or connection supply is being properly received
• Locate incorrect phase connection and connect to the correct one
• See if the circuit breaker is blown or fused and replace it with a new one
• If the power switch is in an “off” position change it to the “on” position

Insufficient Fluid Flow

• This can be due to improper line voltage or fluctuating voltage. Stabilize the incoming voltage to resolve this issue
• Ensure that fluid present in the reservoir is enough
• If the process lines are pinched or damaged replace them with the new ones
• Open the process valve if it is completely or partially closed
• Make sure that the coolant fluid you are using is suitable for the temperature requirements
• Open the fluid filter if it is blocked
• Replace the process piping with larger piping if it is too small

Not Enough Cooling

• Remove the accumulated dirt and open the air filter if it is clogged or blocked
• Use an appropriate coolant fluid that matches the temperature demands of your required process.
• Change the coolant fluid of its heat transfer properties have deteriorated
• Look out for a refrigerant leak and repair it immediately
• Get rid of the evaporator ice if you come across an iced up evaporator
• Lower down the ambient temperature if the ambient temperature is too high

Central chiller troubleshooting