Cooler controls. In this article we will consider the controls of a chiller. By looking at where the controllers are, what they do, and how they detect chiller operation and control chiller operation.
Scroll Down For Chiller Controls YouTube Tutorial
The control box is usually mounted to the chiller in a lockable metal box. Below is an example of the inside of a centrifugal chiller control panel. Wires come out of this controller and connect to various sensors throughout the chiller. You can also allow remote access through the BM, building management system.
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| Chiller-controls-box jcool |
Why do we need the control box?
The control box houses the controller that performs critical actions anywhere on the machine, as well as the transmitting instructions. These not only help to control the machine, but also protect it in the event of a breakdown. The controller typically records operational data over a period of time within the machine, or it can be recorded externally, allowing maintenance engineers to diagnose the machine and ensure it is operating as it should.
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| Chiller Data Log |
You can see an example of the chiller log data above for a running static chiller. Not much to see here, but you can see that you can go back a bit and diagnose the machine from the display unit as it will also show spikes and drops in operating temperatures/pressure/current/% open as fault alarms.
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| The cooler controls the front end. |
The display end will allow you to view live data coming out of the chiller in a much more user friendly way. You can see the different temperatures, pressures and states, as well as the charging amps, lift, etc. The image above also shows the chiller in alarm.
What does the cooler measure?
The first thing the chiller should know is that there is water circulating in the evaporator and condenser water loops. The chiller will not or should not start if there is not enough flow. This is to protect the cooler from freezing and bursting of the internal heat exchanger tubes
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| Cooler Flow Sensor |
The chiller usually has flow sensors connected to the chilled water and condenser water loops, each chiller has its own sensors. If adequate water flow is detected, the machine will be allowed to start.
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| Chiller-temperature-sensors jcool |
Next, the chiller also needs to know the temperature of the entering and leaving water in the chilled water loop, as well as in the condenser water loop. Therefore, there will be flow and return temperature sensors in each one.
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| Chiller-refrigerant-temperature-and-pressure-sensor jcool |
Then the chiller will control the pressure of the evaporator and also the condenser. The chiller will also want to measure the temperature of the refrigerant around the system, so it will measure the suction line temperature as well as the discharge line temperature and the liquid line temperature. From these temperature and pressure measurements of the refrigerant, the operation can be plotted on pressure enthalpy diagrams. You can find more information and refrigerant tables here.
In this example, we have a centrifugal chiller that uses vein guides
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| Chiller-motor-sensors jcool |
The induction motor, which drives the chiller, is mounted at the rear of the compressor and is an essential component of the chiller. Obviously, we're going to have to keep track of that. The control panel will also measure the induction motor winding temperature, the number of amps drawn by the motor per phase, and the voltage. If the voltage or temperature rise too high, the motor could burn out. By monitoring them, the engine can protect itself. You can limit the amount of amps and can even shut down the motor if a serious fault occurs or preferably just before it does.
The oil sump pump will also need to be monitored. The oil sump pump pushes lubricating oil around the machine and pushes it into the gears and into the engine. This lubricating oil prevents the gears and motor from overheating and essentially keeps it from burning itself out.
There are a number of codes programmed into the controller to check for potential problems. The operator can then be warned that the pressure and temperatures have exceeded or fallen below the threshold. You can even just stop the machine from running. For example, the chiller can be triggered at high pressure and stop working for a period of time to prevent damage.
The controller may also record the hours of operation and the number of starts. You can log the run time since the last service. Most coolers can only turn on a certain number of times per hour, especially the big ones, and that's to protect yourself again. The inrush current in these motors is extremely large, so if the chiller were to turn on and off and off, it could overload the circuits and motor, as well as the building's electrical distribution system.
If you watch the video, we also included some example screenshots of the real world chiller controller with actual operating data.
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