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How do Chillers Work? Expansion Valves

Home / Chiller Basics / How do Chillers Work? Expansion Valves

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How do Chillers Work?  May 2020

Expansion Valves  April 2020

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Tags : chiller evaporators Category : Chiller Basics  February 2020
 January 2020
chiller expansion valves
 December 2019
chiller liquid line solenoid valves  November 2019
 October 2019
chiller refrigerant discharge pipes
 September 2019
chiller refrigerant latent heat  August 2019
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  June 2019
chiller refrigerant liquid pipes
 May 2019
chiller refrigerant mass �ow rate  April 2019
 March 2019
chiller refrigerant saturation

chiller refrigerant suction pipes

chiller refrigerant superheat

direct expansion chiller evaporators

�ooded chiller evaporators

In this article we are going to explore: how do chillers work-

expansion valves. They are also referred to as a metering
device, as they control the �ow of refrigerant into the
evaporator. Read below for an insight into the 4 main types
that are used on chillers…

How do Chillers Work -

Electronic Expansion Valves
This is a refrigerant control which uses a mechanical valve
operated by a step motor. A step motor opens the valve
according to the number of steps in between the closed
and the open positions. This step motor is controlled by a
program in the chiller controller…

On Board Comparator
Every engineer has a comparator app on his phone and a
set of comparator sliders in his tool case. The controller
has sensors �tted to the evaporator and an in built
comparator for the refrigerant which runs through the
system. The comparator is a scale which compares the
pressure of the refrigerant to the corresponding saturation
point. Saturation point is another way of describing the
boiling point of the liquid refrigerant.

Superheat
The above algorithm is needed to decide the position of
the step motor. A pre programmed amount of superheat
(the temperature above saturation) is programmed into
the controller. This prevents compressor failure due to
liquid refrigerant slug back.

E�ciency
Because the above is controlled by a step motor and a
microprocessor, the superheat is closely controlled to as
low as 1°C. A low superheat value is one of the factors
which contributes to a machine running more e�ciently.

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How do Chillers Work -

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Solenoid Expansion ValvesTranslate
This is a very simple expansion valve. It is just a solenoid
valve �tted into the liquid line which is operated by a
solenoid coil. The control of this valve is very similar to the
above. The di�erence is that the program works out how
long to keep the valve open and how long to keep it shut.

How do Chillers Work - High

Side Float Expansion Valves
The photo shows this type of valve as used on an ammonia
chiller. This kind of chiller is a �ooded system where all of
the refrigerant is stored in its liquid phase on the low side
of the system. As load increases: more refrigerant boils o�
in the evaporator- it is sucked into the compressor-
discharged into the condenser and then arrives as a liquid
at the �oat valve. When the chamber in this valve �lls, it
lifts a �oat inside which is made of steel. The �oat operates
a switch which sends volts to the liquid pipe solenoid valve.
When this valve opens, it lets the liquid in the �oat
chamber to pass into the evaporator. Having done this, the
�oat drops back down and the valve closes again. The
closing of the valve maintains the pressure di�erence
between the high side and the low side of the system.

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How do Chillers Work -

Thermostatic Expansion
Valves
There are 4 forces acting on a TEV: the power element v
spring and liquid line pressure v suction pressure. The
expansion valve has been designed to balance these
forces.

Power Element
A bulb is �tted to the suction pipe near to theRight click is disabled!
compressor.
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This bulb is charged with the same refrigerant that is
running in the chiller system. It is connected to the power
element using a capillary tube (photo at the top of the
page) When the temperature rises in the evaporator, liquid
refrigerant boils o� in the bulb, this forces a diaphragm to
open in the power element.

Spring
A needle located on the outside of this diaphragm pushes
the spring down. This opens the expansion valve and lets
more refrigerant through.

Liquid Line Pressure

The liquid line is the inlet to the expansion valve and
carries the refrigerant arriving from the condenser.

Suction Pressure
The pressure drop on the far side of the expansion valve is
maintained by the sucking action of the compressor.

Mass Flow Rate

The above allows for a high mass �ow rate when the
evaporator warms and a lower mass �ow rate when the
evaporator cools.

Liquid Line Solenoid Valve

To prevent refrigerant passing into the evaporator during
o� cycles, a liquid line solenoid valve is often used. This
type of system usually pumps the evaporator down before
the compressor stops. Shortly before the compressor
starts back up again, the liquid line solenoid valve opens,
the pressure increases in the evaporator and then the
compressor starts.

Equalizing Line
This is usually a copper pipe which connects the expansion
valve to the far side of the evaporator. It compensates for
the pressure drop across the evaporator. It also detects the
pressure of the suction pipe at the same location of the
sensing bulb. This allows the TEV to accurately adjust the
superheat.

Hot Gas Bypass

Some chillers, like laser chillers, require a very close control
of setpoint. Sometimes the deadband can be as narrow as
0.2°C. If the compressor were to stop and start all the time
to achieve this- it would fail very quickly. Therefore, a hot
gas bypass can be used to allow the compressor to carry
on running when the chiller achieves setpoint. A solenoid
valve opens which allows the discharge hot gas to bypass
the expansion valve and return to the suction. It can open
and close as many times as needed to achieve a very close
control, while at the same time allowing the compressor to
run normally.

How do Chillers Work -

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Expansion Valve Flash GasTranslate
 This is the term that describes that portion of the liquid
refrigerant which, in any expansion valve, instantly
evaporates after it passes through. When this happens, the
absorption of latent heat cools the remaining liquid
refrigerant in the evaporator to the required saturation
temperature.

Related Articles:
How Do Chillers Work

Chilled Water System EEV Service

Chiller Maintenance Company

Planned Preventative Chiller Maintenance

How do Chillers Work? Compressors

Hit the Tags at the top of the page to navigate your way to
our extensive library of further reading on this subject.

Read more about thermostatic expansion valves at the

Danfoss website

ABOUT AUTHOR

Maximus Chillers
Maximus Chillers for centrifugal, water cooled, air cooled and
ammonia chillers

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