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Modular Chiller-An Ultimate Buying Guide by TopChiller

When you talk about a cost-effective, mass-productive, and wholly customized chiller, a Modular Chiller should be the first chiller to come to your mind.

A Modular Chiller is low in cost and can be customized according to industrial needs.

Two or more modules are used with a Modular Chiller to extend further the device’s cooling capacity than a regular chiller can.

A greater degree is produced when the modules operate together than one typical chiller.

Moreover, Modular Chiller uses mechanical tanks, pipes, and pumps. These tanks often contain steam that needs to be cooled at some point during the process.

All devices that need to be chilled by a Modular Chiller are known as loads. Modular Chiller is vital for the efficient working of loads.

However, designers of Modular Chiller need to take a lot of care in deciding their size, capacity, number of the compressor to be used, etc.

Therefore, there is a need for a balance between the loads and the Modular Chiller’s functional capacity so that it serves its purpose efficiently and sustainably.

This article will have all the required information about the Modular Chiller including types, features, working, installation, troubleshooting, and many more.

Let’s get started!!!

What is a Modular Chiller?

Modular Chiller is a small package combined with other Modular Chiller modules to make a single larger machine within your Heating, Ventilation, and Air Conditioning (HVAC) system.

A Modular Chiller is used to enhance your industrial systems’ cooling capacity. They also play an important role in the cooling of buildings, commercial areas like hotels, hospitals, shops, cinema halls, etc.

Multiple Modules in a Modular Chiller work together as a single larger machine with high efficiency than a standard Chiller.

The beauty of Modular Chiller is that they are of small size and can be easily incorporated into any system.

Moreover, they are energy-optimized, and their power can be increased to a greater extent as well.

They also serve to dehumidify commercial and residential buildings like flats, hotels, hospitals, etc.

The other good news about Modular Chiller is that they are environment-friendly. This serves all the purposes of a comparatively efficient and sustainable system.

Modular Chiller Designed by TopChiller

What are the Features of Modular Chiller?

• Like a Standard Chiller, a Modular Chiller also has four essential components, i.e., compressor, condenser, expansion device, and evaporator.
• Unlike a Standard Chiller, a Modular Chiller is arranged so that two or more two small capacity chiller modules are balancing together to increase the cooling capacity.
• Each Module of the Modular Chiller can be used as a stand-alone chiller or combined with other modules to make a single, more extensive system with high capacity.
• Modular Chiller is available in different varieties. Some Modular Chiller is present in a typical master/slave relationship in which one master Module controls the other slave modules through a communication cable attached to the slave module.

The master module is equipped with the main microprocessor.

• A Modular Chiller is also available with the unique control algorithm duplicated in each module, which puts an end to the need for any master module.
• It not only provides the cooling mechanism, but it also comes up with heat pump configurations or heat recovery systems that include cooling and heating features at once.
• Unlike the traditional chillers, Modular Chiller possesses the property of being expandable, as they can be simple and easy expansion.
• Modular Chiller is environment friendly as they are entirely in compliance with ASHRAE Standard 15 mechanical ventilation.
• A smaller refrigerant charge in Modular Chiller stamps out the need for additional ventilation, refrigerant monitoring, etc., making it cost-effective.
• Modular Chiller is easy to maintain and troubleshoot as independent modules work in Modular Chiller that can work independently if one module undergoes some technical issues.
• Unlike traditional chiller, Modular Chiller is smaller in size than making them easy to install in a building that has already been built.

What are the Main Components of Modular Chiller?

A Modular Chiller is made up of different components. The main components of a Modular Chiller are:

• Compressor

The compressor is an electronic motor, partially insulated, either mounted internally or externally as a main driving force in a Modular Chiller.

Compressors are available in different designs, i.e., centrifugal: compressor, screw compressor, scroll, and reciprocating type compressors.

A Modular Chiller compressor usually is located between the evaporator and condenser.

In a Modular Chiller, a compressor is a prime mover that helps create a pressure difference to move the refrigerant around the system.

The compressor is the main reason for noise when the Modular Chiller starts to work.

• Condenser

In a Modular Chiller, the condenser’s primary purpose is to take out heat from the refrigerant, taking up an Evaporator.

Usually, the condenser in the Modular Chiller is located between the compressor and expansion valve. Two types of condensers are available in the market:

1. Air Cooled Condensers: Modular Chiller with Air Cooled Condenser works differently.  Air Cooled Chiller does not need cooling towers.

It consists of an air-cooled unit, a cooling medium, and ambient air that do not require any connections.

1. Water Cooled Condenser: In a Modular Chiller, the Water Cool Modular Chiller system has a cooling tower.

In Water Cooled condensers, the condenser water repetitively cycles between the cooling tower and the condenser.

The hot refrigerant enters the condenser from the compressor, transfers its heat into the water transported to the cooling tower, and eventually gets out of the building.

A pipe wall separates the water and refrigerant and does not allow them to mix. Water flows inside the pipes and refrigerants outside the pipe.

• Expansion Valve

In a Modular Chiller, the expansion valve is used to expand the refrigerant by reducing its pressure and increasing its volume, enabling it to grab the heat in the evaporator.

The expansion valve is located between the condenser and evaporator. Expansion valves are available in different types.

The most common is the thermal expansion valve, the pilot-operated thermal expansion valve, the electronic expansion valve, and the fixed orifice expansion valve.

• Evaporator

The evaporator works as a heat exchanger in a Modular Chiller; it captures heat from the building and moves it to the refrigerant to be sent to the cooling tower and eventually out from the building.

During heat transfer, the refrigerant changes from a low-pressure liquid into vapors and evaporates, which reduces the temperature of the process coolant.

Typically, the evaporator is located between the expansion valve and the compressor.

• Power unit

In a Modular Chiller, the power unit controls the flow of electrical power to the chiller. Starter, circuit breakers, speed controllers, and power monitoring equipment are the power unit’s main parts.

In a Modular Chiller, power units usually are attached directly to the Chiller.

• Controls

In a Modular Chiller, controls are used to monitor Modular Chiller performance in various aspects and control these by making appropriate adjustments.

The control unit prevents damages to the Modular Chiller by safely shutting down the system and beeping Alarms to help system engineers identify problems within the systems.

In a Modular Chiller, the controls are typically attached to the chiller.

Modular Chiller Microprocessor Controller

How does Modular Chiller work?

Same as standard Chiller, Modular Chiller also works on the principle of vapor-compression or vapor-absorption. There is a cold-side water cooler system in the Modular Chiller.

A coolant flow is continuously provided to this system, usually at about 10°C.

Stage one: evaporator processing

The evaporator collects all the unwanted heat from the building. It is where chilled water is produced.

It contains the heat, removes it, and sends the water back out around the building to collect more heat.

When this coolant is passed from the loads, it results in an exchange of heat from the machinery.

A modular chiller utilizes an evaporator to connect the vapor compression mechanical refrigeration system with the water system.

The refrigerant’s circulation occurs in the evaporator, compressor, condenser, and expansion device of a chiller as the functions of all are briefly discussed above.

In essence, a change in thermodynamic heat occurs in all the Modular Chiller components like the compressor, condenser, and expansion device.

Here, the evaporator’s function is like a heat exchanger. The heat that the coolant attained during its circulation around the system, whether it is a pump, pipe, or any other load, transfers to the refrigerant.

The refrigerant gets evaporated upon the heat transfer and resultantly convert into vapor. Because of this, the reduction in the temperature of the coolant takes place.

Stage two: heat absorption

After getting converted into vapors, the refrigerant flows to a multi-function compressor.

The very first function which it performs is the removal of refrigerant.

Secondly, it controls the level of pressure in the evaporator. This compressor keeps the temperature at a certain level to absorb heat continually.

This compressor also functions to raise the pressure of outgoing refrigerant vapor. By doing so, the release of heat takes place when it reaches the condenser.

Stage three: Condensation

At the condenser level, the refrigerant returns to a liquid state. During the transition phase of refrigerant, i.e., from vapor to liquid, the latent heat is given up, using a cooling medium, is carried away from the environment.

Modular Chiller Working Diagram

What are the Main Types of Modular Chiller?

Modular Water Cooled Chiller and Modular Air-Cooled Chiller are the two main types of Modular Chiller.

This Modular Chiller is divided into two types based on their cooling principle.

Despite having their different cooling principle, both types have the same central parts: i.e., a compressor, a condenser, an expansion device, and an evaporator.

What is the difference between a Modular Water-Cooled Chiller and a Modular Air-Cooled Chiller?

• Water Cooled Modular Chiller

It uses water to cool the environment. It has a water-cooled condenser that is connected with the cooling tower. It is usually preferred for medium and large installations with sufficient water resources.

Water Cooled Modular Chiller is low cost with high efficiency, but they need a large amount of water to work.

A Water-cooled Chiller is easy to operate, but the certainty of water spilling out is high.

• Air Cooled Modular Chiller

Instead of a cooling tower, Air-Cooled Modular Chiller uses a current of ambient air.

In water access restriction, the Air Cooled Modular Chiller is suitable to use.

Modular Air Cooled Chiller

What are the Applications of Modular Chiller?

Modular Chiller has many applications in the modern era. In metropolitan cities, its use is widespread.

Similarly, its applications are extensive, and range from commercial areas to residential are substances.

In the commercial area, it is used to control the temperature in different commercial zones like factories, mills, ice production units, mechanical, powerhouses, shops, retail plazas, etc.

In the residential area, the buildings are kept cool because of Modular Chiller.

Some of its main applications are appended below,

• Cooling System in Software Houses:

Modular Chiller has one of their primary applications in the chilling of computer systems.

When run continually, computers produce a lot of heat, which is always needed to be controlled or mitigated for its proper functioning for a long time.

The Modular Chiller performs this vital role of controlling the temperature of computers.

• Cooling System of Telecom Towers:

All telecom companies use towers to disseminate signals to their customer. Modular Chiller has its application there as well.

There is a complete setup running below every tower of any telecom company, and the system needs to run for twenty-four hours a day.

Therefore, it becomes necessary for the system to be at a controlled temperature. A Modular Chiller is therefore used to serve this purpose.

• Cooling the Offices

There is a lot of heat around every building and office in summer. The application of Modular Chiller comes once again. This mass-produced item plays its role of cooling the offices as well.

So, all you need to do is to order a Modular Chiller, especially when you are working in a congested office that is not insulated well.

Modular Chiller Applications

What are the Advantages of Modular Chiller?

There are many advantages of Modular Chiller over others. This is the reason that they are high in demand. Few advantages, which are attached to the Modular Chiller, are as follows,

• Small Size

A very big advantage of the Modular Chiller is its small size. Due to this reason, they can be easily incorporated into other systems.

Later, in case of any requirement, they can easily be removed from the location as well. By having this plug-in nature, a Modular Chiller is becoming a priority of every business.

Similarly, their small size is an attraction for residential occupants as well. It covers small space which is a need of congested buildings.

• Energy-optimized

Comparatively, the energy consumption of the Modular Chiller is low. This feature of a Modular Chiller differentiates it from other chillers.

Energy optimization is the need of the hour. Scientists are adapting energy-friendly modes for inventions like solar systems etc.

In this regard, Modular Chiller consumes less energy and plays a very crucial role whether it is planted in some factory or some office.

• Environment Friendly

A Modular Chiller works efficiently to keep the loads working smoothly without disturbing the outer environment. They are supposed to be environmentally friendly.

This advantage that Modular Chiller has over others makes it a perfect choice for an industrialist or occupant.

• Budget-Friendly

Modular Chiller is comparatively cheaper. Their manufacturing cost is not as much as that of others. This is a very important advantage that Modular Chiller has over others

• Quick installation:

Compact systems are suitable for retrofitting an air conditioning system for a building where space is scarce and difficult to reach because they are smaller in scale.

• Cooling Power Management

It has better cooling capacity control. When cooling requirements are smaller, Modular systems allow you to shut down a unit and enlarge the system if further cooling is required.

• No Downtime

Since all the modules are extremely unlikely to fail at the same time, redundancy has been built into a Modular device. And in the event of device failure, i.e., compressor failure, the system provides cooling.

• Expandability

It is simpler to add another unit to the setup than to carry another stand-alone Modular Chiller when faced with a rise in cooling demand due to building expansion.

How to Choose the Right Modular Chiller for Your Application?

Like any appliance, the Modular Chiller is the right choice that can be made by seeing your requirement and budget.

However, there are a few things to keep in mind while choosing a Modular Chiller for your office or for industrial use that are as follows:

Determination of Requirements of the System:

First, calculate the condition of your system for which you are looking for a Modular Chiller.

Do not buy a small size Modular Chiller if your requirement is that of a significant size Modular Chiller.

Determining your system’s heat load will surely guide you about Modular Chiller of what capacity will help your system run smoothly.

Determine any other Parameters as well:

Also, see the type of coolant, its flow rate, and temperature. This will help you decide the suitable Modular Chiller type.

Budget:

The budget also plays a significant role in selecting the type of Modular Chiller. See your feasibility and go with a better option suitable to you.

How to Install Modular Chiller?

To install a modular chiller, there are a few steps to follow.

• Step 1: This step is to determine the position where you want to install the chiller.
• Step 2: Inspect the Modular Chiller carefully. If there is any damage or missing of the component, then quickly report it to the supplier.
• Step 3: Make the piping connections. It includes fitting a strainer, pipes for intake, and other necessary connections.
• Step 4: Now, check the power connection and breakers attached to the Modular Chiller.
• Step 5: You need to open the panel of the reservoir and fill it with water. Check the water level marked on the glass-type transparent tank.
• Step 6: Turn on the pump and verify the rotation of the pump. Also, check the pressure gauges fitted on the pipes.
• Step 7: Then, open the valve of supply and flush the Modular Chiller. After complete flushing, drain the water.
• Step 8: Now, you are ready to turn on the Modular Chiller. Turn on the door switch. Also, set the temperature as per desire.

It is preferred that you do not install a Modular Chiller yourself. Instead, call the team of experts to install the Modular Chiller.

Because any mistake conducted during the installation can lead to malfunction of the apparatus. It can also lead to energy loss if any loose fixation of the fittings is connected.

However, provided with the manual, the installation of the Modular Chiller is easy.

Read the Manual Before Modular Chiller Installation

How to Maintain your Modular Chiller?

Like any device, a Modular Chiller also demands a lot of care for its continual functioning. Keep a check of the following things to have it maintained for long term functioning,

• Record the daily working report of Modular Chiller, like how many hours it remains on or off, etc.
• Clean the Modular Chiller because dust can mitigate its performance
• Use the Modular Chiller in normal ranges.
• Also, keep a check on the oil level in the compressor.
• Point out if any fault or malfunctioning is observed
• These few things can make your Modular Chiller stands efficient for the long term.

Modular Chiller Maintenance

How to Troubleshoot your Modular Chiller Problems?

If a Modular Chiller stops cooling or heating, you can troubleshoot it to see where precisely the issue lies.

For doing so, you need to become a full-time inspector. See everything connected with the Modular Chiller.

Check the wire, connector, fittings, etc. Is there any leakage? Do you hear the leaking voice of air, water, etc.?

Do all the inspections while the Modular Chiller is on so that the problem may be troubleshot easily.

Frequently check if the system is cooling over time or not. Use different electricity inputs to check if there is any problem with the socket.

If it still does not get detected, do not start the mechanic thing yourself but call an expert to troubleshoot and fix the problem.

Modular Chiller Inspection

FAQ of Modular Chiller

Which Type of Modular Chiller is best?       

Comparatively, the Water-Cooled Chiller is better than an Air-Cooled Modular Chiller. There are substantial advantages that are associated with Water-Cooled Modular Chiller.

The lifetime of a Water-Cooled Modular Chiller is more than an Air-Cooled Modular Chiller.

Therefore, Water-Cooled Modular Chiller is best according to its use relevancy.

Can a Modular Chiller be used for Heating?

A very cool and soft reply to this question is “Yes”. A Modular Chiller can be used for heating. There are some modifications needed to make it suitable for producing heat as well.

Which Refrigerant is used in Modular Chiller?

In a Modular Chiller, the refrigerant commonly used is R134 or R410a. This is a halogen-free gas that is incorporated in most of the Modular Chiller. This is suitable because it has a high rate of absorption.

What is Modular Chiller Capacity?

Modular Chiller capacity is the measure of the extent to which it can add the cooling effect in a system. Modular Chiller Capacity of air-cooled type is 500 tons. However, there is Modular Chiller with 1000 tons also.

What is the Formula for Calculating the Modular Chiller Capacity?

After getting to know all of the metrics, we then apply the formula of chiller capacity, that is,

Q = ṁ x Cp x ΔT

Modular Chiller capacity can be determined by putting the values of m, Cp, and ΔT in the above equation.

What is Delta T in Modular Chiller?

Delta T that is denoted as ΔT is the temperature difference before and after cooling. For example, if the temperature is 90 F before the cooling and it drops to 50 F after cooling then delta T will be 40 F.

How is the Modular Chiller Load Calculated?

There is a specific formula that experts use to calculate the load of the Modular Chiller. The formula is as follows,

A Load of Modular Chiller = Q (British Thermal Units – BTUs / h) / the number of BTUs per ton.

How Long a Modular Chiller Lasts?

The life span of a Modular Chiller is different according to its type. Water Cooled Modular Chiller has a longer life span than the Air-Cooled Modular Chiller. Their life span ranges from 10 years to 25 years. Similarly, where the system is installed, is it safe, or is it vulnerable to damage dust, and heat determines the life span.

Can We Use Modular Chiller for 24 Hours?

Modular Chiller can run for 24 hours but it is recommended to use one Modular Chiller for 12 hours and turn it off and turn on the second Modular Chiller. However, if there is only one Modular Chiller then turn off the Modular Chiller for half an hour after every 12 hours of working.

What Type of Modular Chiller is More Efficient?

Although, both types of Modular Chiller work in a very efficient way, Water Cooled Modular Chiller is more efficient than the other is.

What Causes a Modular Chiller to Trip?

A Modular Chiller can trip due to low refrigerant. It can also be due to low or no water flow. The mud coating of tubes of the evaporator and ant freezing can also result in the tripping of the Modular Chiller.

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