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HVAC Chiller-General Introduction by TopChiller

Understanding of HVAC Chiller

An HVAC chiller constitutes the series of components in an HVAC system that allows for the diminution of heat.

In short, an HVAC chiller is how an HVAC system “chills” the environment, whether it be a commercial setting or industrial complex.

High-performance commercial HVAC systems almost always use a chiller in their design.

In most cases, HVAC chillers are not used in residential or very small commercial settings. Contact us, or talk with an HVAC company near you for more details on commercial vs. residential cooling.

Types of HVAC Chillers

Air Chiller: most, if not all, HVAC systems set up on the outside of a building are air chillers.

These HVAC systems work by absorbing heat through duct systems into liquid refrigerant contained in evaporator coils.

The added heat from ambient air absorbed through the duct system causes the liquid refrigerants to become gaseous.

The gas then travels to the compressor, where the heat is exhausted to the outside of the HVAC chiller unit, into the open air. As the heat is released, the refrigerant again becomes liquid and returns to the evaporator coils.

Air chillers are more useful in situations where an HVAC chiller can be placed on a building’s exterior.

They wouldn’t be very useful indoors, in most cases, as the heat exhaust would simply heat the room again, even as the HVAC chiller cooled it off.

Water Chiller: water HVAC chillers have a distinct advantage over air chillers in situations where it’s necessary to have the chiller indoors.

These types of chillers are more often used in medical and industrial situations, where machinery must be kept at a suitably cool temperature, even while in use.

Another advantage is that water chillers can operate in areas that have high ambient heat, as their cooling system is based on their water supply, as opposed to air temperature in the surrounding environment.

These types of chillers are often much smaller than air chillers, as well, though they do require access to a mechanical room, for water supply.

When exchanging heat, instead of exhausting into the environment, water HVAC chillers typically exhaust heat via a water tower in a mechanical room.

Alternatively, they can use an adiabatic system, which reduces heat by evaporating water in the presence of air pulled in from the exterior environment.

Centrifugal Chiller: centrifugal chillers are much smaller than air, and even water, chillers. They are a very compact form of cooling but operate in much the same manner as air and water chillers.

Though the components of a centrifugal chiller are similar to those of other chillers, they instead use the vapor compression cycle to chill water and exhaust heat.

They have fewer moving parts than air or water chillers and have become more popular in recent years, as a result. They are also relatively easy to maintain and offer a high degree of cooling power.

HVAC Chiller Application

HVAC chillers are often used in large commercial settings, such as sports venues, retail stores, restaurants/ food services, shopping centers, hotels, condominiums, and commercial office buildings.

They’re also prevalent in industrial settings, such as manufacturing, mining, farming, and production.

HVAC chillers can typically process up to 20 tons per hour, which is ideal for large-scale cooling needs. For example, 20 tons per hour would be extremely excessive for a typical home or property’s cooling needs.

it’s also worth noting that commercial or industrial buildings without ducts can be fit with a ductless HVAC chiller.

This is important because it saves the cost of retrofitting the entire commercial/ industrial space (often many thousands of square feet) with a ducting system.

In this case, the heat exchanger and compressor can be placed apart from the main building. Ductless HVAC chillers are especially ideal if the building has limited space, as components can be placed anywhere.

TopChiller HVAC Chillers

TopChiller International has been a leading chiller manufacturing company since 1999. Since all commercial and industrial chiller needs are unique, we work with you to determine the proper fit of the product.

Our HVAC high-quality HVAC chillers range from 12KW to 980KW. And though typical HVAC chillers are rated between 5-450 tons, we can manufacture systems capable of up to 800 tons of cooling.

Please contact us with any questions, or if you’d like more information on our HVAC chillers. We’re here as your resource, for making sure you’re getting and setting up the proper equipment for your needs.

HVAC Chiller-FAQ Guide by TopChiller.

What is an HVAC Chiller?

HVAC Chiller is the cooling system that is used to transfer the heat from one area to the other area for cooling purposes.

Refrigerant is pumped by an electric motor which absorbs heat and provides a cooling effect.

HVAC Chiller serves to cool down the fluid, industrial machinery, and environmental area by absorbing heat from the things that need temperature control for good performance.

What are the Components of an HVAC Chiller?

HVAC Chiller consists of the major components that increase the system efficiency and provide cooling to the process and environment.

These components include:

• Compressor

HVAC Chiller comprises of piston-operated vaporization pump that functions using an electric motor pump.

• Condenser

The condenser is a major component of the HVAC Chiller which transfers heat by passing through the circulating fluid to cool the outer system.

• Evaporator

An evaporator is used to transfer heat from outside water by the heat exchange process.

• Expansion Valve

A thermal expansion valve is used in the HVAC Chiller that is in charge of the pressure and flow of the refrigerant coolant.

What are the Outstanding Features of an HVAC Chiller?

HVAC Chiller has outstanding features that make it a remarkable product for industrial and commercial use.

These features include:

Microprocessor Controls: Micro-computer controls are available in HVAC Chiller which performs precise programming for performance.

Emergency Alarms: Emergent situations are controlled by emergency alarms and signals such as over-heating, concentration moisture, and temperature fluctuation.

Modular Systems: Modular systems are a unique feature of HVAC Chiller in performing various tasks.

How does an HVAC Chiller Work?

An HVAC Chiller works by changing the transition form of the refrigerant to transfer heat from one area to the other.

The liquid form of refrigerant is changed into gaseous form and heat is released.

HVAC Chiller performs three basic functions which include heat generation, ventilation, and air conditioning to provide the cooling to the equipment and processes.

What is the Cooling Cycle of an HVAC Chiller?

The cooling cycle of an HVAC Chiller is very simple to understand. In the first step, the compressor pumps refrigerant to the condenser after that the refrigerant moves to the cold water.

The liquid flows through the expansion valve and turns into gas. The gas turns into vapor in the next step, and the refrigerant transfers heat from outside to cool down the area surrounding it.

Hot gas transfers from the evaporator to the compressor and refrigerant moves to the condenser and removes the heat it absorbed lately and the cycle restarts again.

Which Type of Refrigerant is used in HVAC Chiller?

A refrigerant is a liquid or gas that absorbs heat from the equipment and environment and provides low temperatures.

Different refrigerants are used in different kinds of chillers.

In HVAC Chiller, the following types of refrigerants are typically used:

• Water
• Hydro Chlorofluorocarbons
• Chlorofluorocarbons

What are the Cooling Methods in an HVAC Chiller?

There are three basic cooling methods in an HVAC Chiller that are normally found in every other chilling system.

These methods are:

• Air-Cooled: Air-Cooled HVAC Chiller uses a fan and filters to force air over the condenser coils.
• Water-Cooled: This type of cooling method is operated by circulating water in the condenser coils.
• Remote Air or Slit System: Remove air or slit cooling system positions the condenser remotely and cold air is circulated to absorb the heat.

What are the Applications of an HVAC Chiller?

There are wide applications of an HVAC Chiller. It is used in various industries for various purposes such as:

• Cooling of liquids
• Cooling of plastics
• Printing equipment
• Laser cutting machines
• Medical industries
• Molding processes

How does a Refrigerant Compressor Operate in an HVAC Chiller?

The refrigerant compressor operates in an HVAC Chiller by compressing the refrigerant to vapors by providing excessive heat.

Once the refrigerant changes its transition state, it leaves the compressor.

What is the Temperature Range of an HVAC Chiller?

The temperature range of an HVAC Chiller ranges between 1 ̊C and 7 ̊C.

The temperature range of the cooling system must be controlled and monitored using the temperature controlling devices called thermostats.

What is the Capacity of an HVAC Chiller?

The capacity of an HVAC Chiller refers to the amount of heat removed from the system over time.

The capacity of an HVAC Chiller is normally 20 tons per hour.

The cooling system’s capacity can be increased by the extension of compressors such as screw compressors that provide extra tones of cooling capacity and add to the efficiency of the system.

Where is HVAC Chiller used?

An HVAC Chiller is used in achieving the environmental requirements of different types of buildings including industrial, commercial, institutional, and residential buildings.

It is used to control the temperature of equipment and process stages in industries of beverages, food, drugs, and molding units.

Its use is extended to die casting, metal cutting, and welding .industries and cement processing units.

What Control Devices are used in an HVAC Chiller?

Several control devices are used in HVAC Chiller to control the temperature, flow rate, level, concentration, and current supply.

These control devices are named as follows:

• Valves
• Speed drives
• Thermostats
• Control sensors
• Current control sensors and transducers

How you can Operate HVAC Chiller at High Temperature?

There are some ways to operate an HVAC Chiller at high temperatures.

These ways include:

• Improve air circulation and distribution.
• Increase the chilled water temperature set point.
• Control the temperature accurately to avoid over-heating.

What are the Benefits of Cooling Tower in HVAC Chiller?

A cooling tower is used in an HVAC Chiller to filter the air that circulates in the distributional channels and pipelines.

It also controls the optimum temperature of the chilling system.

A cooling tower also benefits to balance the flow of hot water basins and cooling the circulating fluids that absorb heat from different stages of the entire process.

How can you Measure Anti-freezing Concentration in an HVAC Chiller?

Anti-freezing concentration can be measured in an HVAC Chiller by using a device called a refract meter.

It gives the anti-freezing concentration that can be controlled by increasing the flow rates.

What is the Split system in HVAC Chiller?

The term ‘split’ refers to the type of HVAC Chiller in which the components are split and placed at different locations.

Mini and central split systems are the types of this cooling system.

In this system, a heat exchanger is used to distribute the heat that is absorbed from the processing environment and equipment.

What is a Ductless HVAC Chiller?

This is the smallest type of HVAC Chiller that is designed specifically for small industries with minimal spaces.

The heat exchanger and compressor can be placed away from the building.

A ductless HVAC Chiller is designed for domestic use as it fits the consumer-mass consumption model and its components can be placed anywhere.

It is the best chilling system for retrofitting existing buildings as it doesn’t require ducts for installation.

What is the Role of Technological Advances in an HVAC Chiller?

Technical advances are now in trend to enhance the functioning of components of the HVAC Chiller to maintain the efficiency level, performance, and lifespan of the cooling system.

Technological advances are now used for energy conservation options and cost reductions.

What is Packaged HVAC Chiller?

Packaged HVAC Chiller is a cooling system designed specifically for small industries and domestic use.

This type of HVAC Chiller is designed specifically with low capacity components and provides 5 to 20 tons cooling capacity.

What Kinds of Air Systems are Available for an HVAC Chiller?

Some types of air systems are used in an HVAC Chiller to perform all the tasks related to air circulation.

For example:

• Chilled beams
• Dampers
• Louver
• Fan & blower
• Variable speed drives
• Energy recovery ventilators
• Variable air volume distributers
• Heating and cooling coils

What Energy Conservation Systems are used in an HVAC Chiller?

Energy conservation is an important part of the latest technologies to save electricity and cost expenses.

Here are two types of energy conservation systems in HVAC Chiller:

• The modular distributed energy storage system
• The in-built distributed energy storage system

What is HVAC Chiller Validation?

HVAC Chiller validation has three facets including installation qualification, operational qualification, and performance qualification.

The documentation of these essential subjects provides the accuracy of results that is called validation of HVAC Chiller.

What is Equipment Selection for Energy Efficient Operation in HVAC Chiller?

To maintain the energy-efficient operations in an HVAC Chiller, use the latest technical devices that consume less electricity and provide water consumption also.

For instance:

• Use energy-efficient monitors for continuous use.
• Use DC inverter electrical devices to maintain energy efficiency.
• Use a controlled cooling tower with fans that operate on a low-temperature approach.

How to Resolve Electrical Issues in an HVAC Chiller?

Electrical systems are a bit more complex in the HVAC Chiller as compared to the other components of the system.

If there is any genuine electricity issue or a power supply failure, the system detects it and shuts down the system itself.

Electrical issues can be resolved by completely monitoring the power supply and using the right phase and frequency.

Wires and cables must be checked if they are damaged or working completely fine.

How Corrosion is Prevented in HVAC Chiller?

Corrosion is a sensitive issue in cooling systems. HVAC Chiller also contains metal tubes where oxygen presence can rust the tubes and damage the fittings, valves, and reservoir tanks.

To prevent corrosion try to keep the tubes dry and don’t let the refrigerant freeze in the tubes.

Use hot water to clean the tubes and also inspect tubes for any fungal or bacterial growth.

What Flow Rate Measuring Instruments are used in HVAC Chiller?

Flow rates can be monitored and regulated by using measuring devices and instruments.

HVAC Chiller also controls the flow rates by using measuring devices such as:

• Air-flow handling units
• Air-flow controlling condensers
• Flue gas flow measuring devices
• Heat based vapor absorption machines

How to Control Flow Rates in an HVAC Chiller?

In an HVAC Chiller, the flow rate can be controlled and regulated by modeling the system.

It is suggested to remodel the piping system and make a computerized hydraulic model for piping and distributional channels.

The modeling of the system gives a good understanding of the interaction of pipes, pipelines, and control valves and control the moisture level and flow rate of coolant and refrigerant.

Which Environment is Best for an HVAC Chiller?

Mostly chilling systems are placed in an open and spacious environment as the tanks and pipelines need space and area.

For an HVAC Chiller, an outdoor environment is recommended and considered reasonable.

Split and ductless types of HVAC Chiller are mostly placed in outdoor areas.

What Precautions Should be Adopted while Testing an HVAC Chiller?

Testing is an important step after the installment of an HVAC Chiller.

Some major precautions must be adopted while testing an HVAC Chiller such as:

• Ensure that all the components and controller devices are installed correctly.
• Check the cables with portable instruments under safety measures.
• Make sure that clamp on jaws are closed and there is no gap between them.
• Check the anti-freezing agent level before starting the chiller
• Keep a safe distance from electrical instruments and devices.

What are the Preventive Measures for an HVAC Chiller?

Few things must be prevented from getting the excellent performance of an HVAC Chiller.

These preventive measures include:

• Prevent freezing of refrigerant in the pipelines.
• Don’t use contaminated refrigerants.
• Prevent the tubes from damaging as they can result in leaks.
• Inspect the tubes on regular basis to monitor any blockage.

What is the Age of an HVAC Chiller?

The life expectancy of an HVAC Chiller depends upon a variety of factors such as performing the compressor and condenser.

Normally, the age of an HVAC Chiller is 15 to 20 years.

What is the Price Range of an HVAC Chiller?

The price range of an HVAC Chiller normally lies between $6500 and $10,000.

It can be customized depending upon the requirements of the user and the capacities of components.

How to Maintain Efficiency of your HVAC Chiller?

It is very important to maintain the performance and efficiency of an HVAC Chiller by following the maintenance tips and tricks.

Follow these tips to increase the efficiency of the system:

• Use DC inverters for electrical devices.
• Clean the tubes of the system every week to inspect any blockage.
• Inspect and regulate the compressor seals to avoid refrigerant leaks.
• Check the level of the refrigerant and maintain the level to avoid freezing.
• Avoid poor distribution of the fan inlet and check the flow rates.
• Use energy-efficient motors for continuous operation.