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At the starter solenoid there is a small wire this is the trigger wire (gives power to solenoid solenoid contacts close and power is given to starter).
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During the compression cycle, the refrigerant passes through four major components within the chiller: the evaporator, the compressor, the condenser, and a flow-metering device such as an expansion valve. Mechanical compression chillers are classified by compressor type: reciprocating, rotary screw, centrifugal and frictionless centrifugal. Reciprocating: Similar to a car engine with multiple pistons, a crankshaft is turned by an electric motor, the pistons compress the gas, heating it in the process. Rotary Screw: The screw or helical compressor has two mating helically grooved rotors in a stationary housing.
Centrifugal: The centrifugal compressor operates much like a centrifugal water pump, with an impeller compressing the refrigerant. Frictionless Centrifugal: This highly energy-efficient design employs magnetic bearing technology.
Absorption chillers use a heat source such as natural gas or district steam to create a refrigeration cycle that does not use mechanical compression. Chillers produce chilled water in the evaporator where cold refrigerant flows over the evaporator tube bundle.
The chilled water passes through coils in the air-handler to remove heat from the air used to condition spaces throughout the building. Vaporized refrigerant leaves the evaporator and travels to the compressor where it is mechanically compressed, and changed into a high-pressure, high-temperature vapor.
Inside the condenser, hot refrigerant flows around the tubes containing the condenser-loop water.
The EPA has enacted regulations regarding the use and handling of refrigerants to comply with the Clean Air Act of 1990. Operate multiple chillers for peak efficiency: Plants with two or more chillers can save energy by matching the building loads to the most efficient combination of one or more chillers. Raise chilled-water temperature: An increase in the temperature of the chilled water supplied to the building's air handlers will improve its efficiency.
Reduce condenser water temperature: Reducing the temperature of the water returning from the cooling tower to the chiller condenser by 2-3°F will reduce chiller energy use 2-3%. Purge air from refrigerant: Air trapped in the refrigerant loop increases pressure at the compressor discharge. Optimize free cooling: If your system has a chiller bypass and heat exchanger, known as a water-side economizer, it should be used to serve process loads during the winter season.

Verify Performance of hot-gas bypass and unloader: These are most commonly found on reciprocating compressors to control capacity. Maintain refrigerant level: To maintain a chiller's efficiency, check the refrigerant sight-glass and the superheat and subcooling temperature readings, and compare them to the manufacturer's requirements.
Compared to a major chiller failure, a sound preventive and predictive maintenance program is a minor cost.
To effective maintain chillers, you must 1) bring the chiller to peak efficiency, and 2) maintain that peak efficiency.
Checking water treatment: Checking the water treatment of the condenser-water open loop weekly will reduce the frequency of condenser tube cleaning and the possibility of a tube failure.
Checking the water treatment of the chilled-water closed loop monthly will reduce the frequency of evaporator tube cleaning and the possibility of a tube failure.
Inspecting and cleaning tubes: The tubes in the evaporator and condenser bundles should be inspected once a year, typically when the chiller is taken offline for winterizing. Indicated when pressure drop across the barrel (tube bundle) exceeds manufacturer's recommendations, but at least annually. It includes pumping out the septic tank measuring it and evaluating the condition of the tank. Remove the wire and with the key in the start position check for battery voltage on this small wire. There is no power to the starter and check under the dash with a light tester and have power everywhere.
A preventive and predictive maintenance program is the best protection for this valuable asset. The evaporator is the low-temperature (cooling) side of the system and the condenser is the high-temperature (heat-rejection) side of the system.
As the helical rotors rotate, the gas is compressed by direct volume reduction between the two rotors. The compressor requires no lubricant and has a variable-speed DC motor with direct-drive for the centrifugal compressor.
The refrigerant evaporates (changes into vapor) as the heat is transferred from the water to the refrigerant. The warm water (warmed by the heat transferred from the building ventilation air) returns to the evaporator and the cycle starts over.
Each type of refrigerant used in a chiller compressor has specific safety requirements for leak detection and emergency ventilation. All personnel working with refrigerants covered by this act must be appropriately licensed. The temperature setpoint for the water leaving the cooling tower should be as low as the chiller manufacturer will allow for water entering the condenser.
Taken together, these readings serve as a valuable baseline reference for operating the system and troubleshooting problems. Implementing a best-practice maintenance plan will save money over the life of the chiller and ensure longer chiller life.
There are some basic steps that facilities professionals can take to make sure their chillers are being maintained properly. The evaporator and condenser tube bundles collect mineral and sludge deposits from the water.
Alternately, for systems that operate all year to meet process loads, tube scaling and fouling can be monitored by logging pressure drop across the condenser and evaporator bundles. 2 wires to starter from battery and wire from soleniod on starter and goes into the firewall.
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They also provide cooling for process loads such as file-server rooms and large medical imaging equipment. The pistons have intake and exhaust valves that can be opened on demand to allow the piston to idle, which reduces the chiller capacity as the demand for chilled water is reduced. Capacity is controlled by a sliding inlet valve or variable-speed drive (VSD) on the motor. They can be equipped with both inlet vanes and variable-speed drives to regulate control chilled water capacity control. The chilled water is then pumped, via the chilled-water distribution system to the building's air-handling units. The condenser water is pumped from the condenser bundle to the cooling tower where heat is transferred from the water to the atmosphere. Once through the valve, the refrigerant expands to a lower pressure and a much lower temperature. If the equipment malfunctions, the safety control shuts the chiller down to prevent serious damage to the machine. A reset schedule can typically adjust the chilled-water temperature as the outside-air temperature changes. Condenser water circulates through the cooling tower to reject heat, and then goes to a heat exchanger (bypassing the chiller) where the water is cooled sufficiently to meet the cooling loads.
Many newer chillers automatically save logs of these measurements in their on-board control system, which may be able to communicate directly with the DDC.
Many chiller manufacturers offer training for building operating engineers in operating and maintaining their chillers.
An increase in pressure from the inlet to the outlet of 3-4 PSI indicates a probable increase in scale or fouling requiring tube cleaning. If an air-purge device is not installed, bubbles in the refrigerant sight-glass may also indicate refrigerant leak.
As with other types of air conditioning systems, most chillers extract heat from water by mechanically compressing a refrigerant.
This unloading allows a single compressor to provide a range of capacities to better match the system load. It flows around the evaporator tubes, absorbing the heat of the chilled water that's been returned from the air handlers, completing the refrigeration cycle.
On a centrifugal chiller, increasing the temperature of chilled water supply by 2-3°F will reduce chiller energy use 3-5%.
Daily or weekly tracking of run time will show if a leak has developed that permits air to enter the system.
Scale buildup also insulates the tubes in the heat exchanger reducing the efficiency of the chiller.
So some how that switch is in between the power and the starter, that is why it is a safety switch.
This is more efficient than using a hot-gas bypass to provide the same capacity variation with all pistons working.
To better monitor chiller performance, the chiller control system should communicate with the facility's direct digital control (DDC). Some units use both methods, unloading pistons to a minimum number, then using hot-gas bypass to further reduce capacity stably.

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