Analysis of the operation of air-cooled chillers with variable-speed fans for advanced energy-saving-oriented control strategies

Air-cooled chillers are extensively employed to meet cooling demand in commercial and tertiary sectors. To enhance their performance during part-load operation, variable-speed drives have been integrated into compressors and condenser fans. In existing systems, condenser fans are either operated at a fixed speed or modulated to maintain a predetermined condensing pressure or temperature difference between the refrigerant and outdoor air. In the search for increased efficiency, it is worth investigating innovative control strategies aimed at minimizing energy consumption. A preliminary mapping of chiller performance at different fan speeds, loads, and operating conditions is required to achieve this goal. In this respect, this paper investigates the operation of air-cooled chillers equipped with variable-speed condenser fans, both in the case of constant- and variable-speed compressors. An ad hoc matrix test is adopted to cover appropriate ranges conditions, in terms of load and outdoor air temperatures. Performance maps are developed for a 50-kWc chiller using a 1-D simulator. As the main findings, it may be stated that (i) in the case of the variable-speed chiller, the energy efficiency ratio increases almost linearly with fan speed, resulting in an 8.8% increase when increasing the speed from the nominal to the maximum; (ii) in the case of constant-speed chillers, the system exhibits a different behavior with the cooling capacity and the energy efficiency ratio increasing with the fan speed between 380 and 980 rpm and then decreasing (slightly or sharply, at full and part load respectively) with fan speed between 980 and 1280 rpm, and a percentage increase of EER in the range 7.8–45% is observed. Also, the sensitivity of such results to the system design is investigated, analyzing a chiller equipped with a larger condenser that resulted in achieving minimum energy consumption at an optimal 980 rpm fan speed. Finally, for a constant-speed chiller serving an office building in the Mediterranean, the proposed fan control strategy could yield an electricity saving of up to 12.1% compared to the base case, confirming the potential for energy savings through optimized and system-tailored management of condenser fan speed.