Whatever Type of Air Chiller,
TopChiller Can Fulfill the Chiller Solution for You.

TopChiller: Your Best Air Chiller Supplier and Manufacturer In China

Air Chiller is also called air-cooled chiller, air chiller system, or air chiller unit.

Air chillers can absorb boring heat from the process water, and the heat is then transferred to the air around the air chiller unit.

This type of air chiller system is mostly used in all applications where the additional heat it discharges is not a factor.

Air chiller is often practical to use the excess heat to warm a plant during the winter, thus providing additional cost savings.

Air Chillers were designed and manufactured by TopChiller with a cooling capacity from 1.65KW to 202KW and an adjustable temperature control range of 5℃ to 30℃。

This kind of air chiller is equipped with branded Copeland from the USA, Danfoss from France or Denmark, Sanyo or Panasonic from Japan.

The above all branded hermetic scroll compressors are all available depending on clients’ detailed requirements and working conditions.

You will find TopChiller has 3 or 4 refrigerant circuits for air chiller models from AC-25AD to AC-60AF depending on the chiller refrigeration capacity.

Based on the above models, each air chiller machine circuit can work or stop independently for air chiller safety and energy saving consideration.

All air chillers made by TopChiller features easy operation, steady running, reasonable design, high quality, and best refrigeration performance.

All Types of Air Chillers

Each air chiller manufactured by TopChiller has a big volume stainless steel buffer tank and a built-in water pump allowing for easy installation and high flexibility.

All the water piping systems inside the air chillers are stainless steel material to make sure the circulating water is clean without rust.

For the air chiller evaporator, there are some options for different processing requirements

For types of air chiller evaporators include a built-in water tank as the open-loop system and shell & tube type heat exchanger or brazed stainless steel plate heat exchanger as the closed-loop system.

For air-cooled type condenser of air chiller, generally use the aluminum fin with the copper tube that has big volume air blowers.

For refrigerant charged inside air chillers, there are R22, R407c, R134a, R410a, or R404a for your options.

But please note: if refrigerant R134a charged air chiller, it can be installed at the working temperature range from 55℃ to 60℃ .above the ambient temperature without any high-pressure alarm special for Middle East countries like UAE, Saudi Arabia, or other high ambient temperature countries.

Ultimate Guide to Selecting Air Chillers

1. What Is An Air Chiller?

Chillers can be classified into two main types, air chillers, and water chillers.

Both types of industrial chillers have similar systems to cool process water. The big difference lies in how the systems remove the extracted heat.

To have in-depth knowledge of what they are, how they work, their applications, strong and weak points, regular maintenance and troubleshooting will help you make the proper choice——— in selecting the right air chiller for your applications, whether you are building a new factory, or upgrading your facility, or extending your production lines.

But today you will get the full information on air chillers on this page.

An air chiller is a closed refrigeration system for cooling water by running refrigerant through its four main components- compressor, condenser, evaporator, and thermal expansion valve

An air chiller is characterized by expelling heat in the air-cooled type condenser by the cooling fans on top of it, instead of by a water tower in the case of the water chiller.

Air chillers have applications both in commercial sectors and industrial sectors, but in this article, we shall focus on industrial air chillers.

Air Chiller Working Diagram

In an air chiller, the refrigerant (in vapor form) absorbs heat from the process of water circulating in the tubes inside the evaporator.

And then the refrigerant vapor is drawn into the compressor, where it is pressurized, with the result of turning into high-pressure high-temperature vapor.

After that, the vapor is sent to the next link-the air-cooled condenser.

In the air-cooled condenser, the refrigerant vapor is condensed and transfers its heat up to the ambient air around the air chiller.

After the refrigerant is highly pressurized and cooled, it goes through an expansion valve to further reduce its high temperature.

At last, the refrigerant enters the evaporator of the air chiller again to perform its duty of cooling and thus complete the operation cycle.

Air chillers are widely applied in large equipment to cool down the overheated parts or systems.

Types of air chillers, classified by the cooling capacity, could be portable air chiller and stationary air chiller; air chillers are classified by compressors, could be piston type air chiller or screw-type air chiller; once classified by sealing type, could be open type air chiller, semi-open-air chiller, and close type air chiller.

Air chillers are preferred by industrial processors for their compact size, high cooling efficiency, many conveniences in installation.

2. How Does An Air Chiller Work?

An air chiller is a closed system working in a repeated cycle that cools fluids. There are four major parts, evaporator, compressor, condenser, and expansion valve in an air chiller.

How does an air chiller work?

2.1 The cooling cycle of the air chiller

The air chiller cycle starts from a mixture of liquid and vapor refrigerant being released into the evaporator, moving around the tube bundles, creating low-pressure vapor that absorbs heat from the process water.

The process of water to be cooled is running outside the tubes. The refrigerant in the tubes absorbs the heat of the water.

And then the superheat vaporized refrigerant is taken to the compressor, where it is compressed into high-pressure vapor.

The high-pressure vapor is then pumped into the air-cooled condenser. In this condenser, heat is removed from the super-heat refrigerant to the relatively cool ambient by blowing air created by the fans.

The vapor is further condensed and cooled into liquid before it leaves the condenser.

The high-pressure liquid refrigerant then travels to the expansion valve, where its pressure drops and a small portion of the refrigerant boils off.

The boiling off helps to cool the remaining refrigerant to the desired temperature before it enters the evaporator to cool the process water again and repeat the cycle.

This is complete of the air chiller working diagram.

2.2. Major components of air chiller

As we can see from the above working diagram, for air chillers there are four major components including an evaporator, compressor, air-cooled condenser, and expansion valve.

Below we shall discuss these four major components in detail the functions and structures of each component in the air chiller unit.

Air Chiller major components

I. Evaporator

The evaporator of an air chiller is usual a barrel where heat is exchanged.

The refrigerant, in the form of a mixture of saturated liquid and vapor, travels through the evaporator tubing.

As the evaporator absorbs heat from the process water to be chilled, the refrigerant boils off at the evaporator outlet that is connected to the compressor inlet.

II. Compressor

Among all parts, the compressor is the key part of an air chiller.

The compressor in an air chiller is the source of refrigeration power. It creates a pressure difference to drive the refrigerant along with the whole air chiller system.

The compressor of the air chiller draws the overheated refrigerant from the evaporator and compresses it into a smaller space, putting it under high pressure and heat.

Though there are several designs of air chiller compressors-scroll type, screw type, and reciprocating types of compressors are most commonly used in air chillers.

Every type of compressor has its advantages and disadvantages. It is connected either internally or externally to an electrical motor that provides its driving force.

Types of compressors：

a. Scroll compressors

Scroll compressors are more commonly used in air chillers for industrial and commercial applications.

Hermetic Scroll Compressor Structure

b. Reciprocating compressor

Reciprocating compressors (also known as piston compressors) use pistons driven by a crankshaft to deliver gases at high pressure.

It is applied for delivering a small amount of refrigerant at very high pressure. Reciprocating compressors are classified in the category of positive displacement machines.

There are two main types, hermetically sealed type, and open-construction type. In hermetically sealed type, the motor and the compressor are directly coupled and installed in one compartment that is sealed to the atmosphere.

In the open construction type, the motor and compressor are installed in a separate compartment. Generally speaking, open construction has a longer service life, lower maintenance requirement, and higher efficiency.

c. Screw compressor

Screw compressors belong to the rotary type of compressors, which include vane, eccentric, gear, or screw type.

Screw-type compressors are more commonly used in air chillers for big cooling capacity. There are two screws, namely male and female, in a screw compressor.

They are fitted together in stationary housing. When the rotors rotate, the air is compressed by direct volume reduction between the two rotors.

Screw compressors have single screw and twin screw types. Each type has oil-free and oil-rejected designs. Twin-screw oil-rejected compressors are slightly energy-saving at moderate compression ratios.

They can operate at a compression ratio of 30. The compressors are available in both hermetic seal and open construction.

The advantages are compact in size, light in weight, quiet and vibration-free operation, high energy efficiency in both full and part load operation. The main disadvantage is the high cost.

Semi-hermetic Screw Compressor Structure

III. Air Cooled Condenser

The air-cooled condenser of an air chiller serves as a heat exchanger that rejects heat from the heated refrigerant to the ambient air.

The construction of an air-cooled condenser is similar to the outdoor unit of a home-use air conditioner.

A bundle of tubes arranged in fin-shape and the horizontal direction is surrounded by thin sheets of metal in the vertical axis.

The metal sheets distribute heat away from the tubes. Refrigerant runs through tube bundles. Fans blow air from the sides and force the air out from the top, taking away the heat and cooling down the refrigerant.

The heat reduction of the refrigerant causes the refrigerant to condense to liquid before it goes to the next link.

Air Chiller Condenser

IV. Expansion Valve

The thermal expansion valve is a pressure-reducing device playing a significant role in an air chiller.

After the refrigerant is condensed to a liquid, it passes through the expansion valve.

The expansion valve controls the amount of flash. The refrigerant boils into vapor and in this process; it reduces the pressure as well as temperature.

There are many types of expansion valves, among which the most commonly used are a thermal expansion valve, pilot operated thermal expansion valve, electronic expansion valve, fixed orifice expansion valve, etc.

3. What’s the difference between Air Chillers and Water chillers?

Both air chillers and water chillers are designed to remove heat from liquid or process water.

The difference lies in how they reject the extracted heat.

The applications, requirements on chilling and environmental conditions decide which the best chiller for the case is.

A thorough understanding of the difference between both types will help you make the proper decision on choosing between the two options.

3.1 Overview

Air chillers (air-cooled chillers) and water chillers (water-cooled chillers) have the same basic components as we mentioned in the above text: evaporator, compressor, condenser, expansion valve.

Refrigerant runs through a closed loop of refrigerating to cool fluid/process water.

The compressor provides the force to circulate the refrigerant through this loop, from the compressor to the condenser, through the expansion valve to the evaporator, and then back to the compressor.

How the condenser cools the refrigerant determines the key difference between the two types.

Air chillers have air-cooled condensers to cool the overheated refrigerant with ambient air.

The refrigerant is flowing through bundles of tubes mechanically assembled like closely spaced fins.

A fan or fans blow the ambient air through the tube bundles from the sides and cool the refrigerant running inside the tubes.

In contrast, water chillers or water-cooled chillers use water to cool the refrigerant in the condenser. The construction of water chillers is usually tube in tube, or tube in the shell, or plate type.

The water comes from a water tower to the condenser and then back to the water tower for the exchange of heat. Inside the condenser, water and refrigerant do not come in direct contact.

Refrigerant runs inside the tubes and water flows over the tubes and absorbs the heat, cools down the refrigerant to a designed temperature.

So the difference is using air or water to chill the refrigerant in the condenser. And a water chiller is featured by a water tower.

3.2 How to choose a suitable chiller between air chiller and water chiller?

We can’t tell you which one is better because numerous factors influence decision-making.

In different cases, you might find which chiller system is more advantageous than the other.

Understanding both air chiller and water chiller features in different aspects and consulting with professionals is advisable.

I. Environmental conditions
There are a few considerations on the environment when you install your air chiller, like ambient temperature and humidity condition.

A. Indoor conditions
Both air chillers and water chillers can be installed indoors.

But air chillers need ventilation to the outside. so that sufficient fresh make-up air allows maintaining the desirable ambient air temperature.

Water chillers, on the contrary, have no requirement for ventilation or fresh air, because they use water for cooling. So water chillers are typically installed indoors. They have to connect to the water tower outdoors though.

Air Chiller Indoor Installation

B. Outdoor conditions

Air chillers are more commonly installed outdoors.

In that case, the transfer heat rejected from the air-cooled condenser dissipates directly into the ambient air.

In the outdoor installation, proper configuration of the electrical control panel should be done of air chiller with consideration of the outdoor environmental conditions.

Water towers connected to water chillers should be installed outdoors. Proper maintenance and water treatment are required for the water tower.

C. Temperature conditions

Water chillers do not rely on ambient air for cooling, so the high-temperature environment does not influence its operation.

But air chillers must have a requirement on ventilation and the ambient air temperature has a great impact on its cooling effect, thus ambient temperature is an important factor to consider when you make the choice.

D. Installation Space

Generally, an air chiller needs a bigger space for installation compared with a water chiller with the equivalent capacity.

Especially in big cooling capacity air chillers, we must consider having enough space for air chiller installation.

In case if you don’t want the installation of the water tower for a water chiller, then an air chiller is a good idea.

E. Water source
In an area where a water source is scarce or water cost is expensive, air chillers would the best choice.

Water quality and water treatment are also factors to be considered when you choose an air chiller because sometimes air chiller will be used near the seaside/island or using seawater and brine.

If so, the air chiller will use non-corrosive heat exchangers for the critical water sources.

F.Environmental impact

Air chillers’ expelling of hot air might cause an ambient air temperature to rise in the place where it is installed.

Sound is another issue that might have an impact on the environment. Air chillers operate with high decibels because of the fans.

If you need an air chiller used for a laboratory in a university or semiconductor industry,  Of course, you need to ask for a quieter air chiller with a low noise level.

II. Cost

In consideration of chiller cost, we have to look into both initial cost and operation cost.

Capital cost – In terms of machine purchasing cost, the air chiller is higher than the water chiller, especially when the user has a water tower in place.

Installation cost – In the case of indoor installation of air chiller, duck work, fans, and control for maintaining proper air temperature in the room may exist. For water chiller, installation, conjunction with the water cooling tower.

Operation cost – As water chillers use water to chill the refrigerant in contrast to air chillers using ambient air, and the wet-bulb temperature is usually lower than the dry-bulb temperature.

In this respect, water chillers are more energy-saving and thus cost-effective.

However, you have to consider the water cost, the cost of running a water tower, including regular monitoring of water quality, treatment of water, the operation of fans and pumps.

In areas where water cost is extremely high or water quality is poor or environmental conditions are negative and require high water treatment costs, then water chillers are less cost-effective than air chillers overall speaking.

III. Air Chiller Cooling Capacity

Generally speaking, water chillers have higher capacity available compared to air chillers.

Typically air chillers capacity can be up to 500 tons and water chillers up to 1000tons and could be higher in a customized order.

IV. Lifespan

In the case when air chillers are installed outdoors and water chillers installed indoors, water chillers will last longer, because of a lack of weather exposure.

You might have more specific and unique situations that might influence your final decision on selecting.

If you have any questions and puzzlements, the cooling engineering experts in TopChiller would always be available to help.

It is not an easy task to choose between air chillers and water chillers but TopChiller will provide you technical support and work with you in analyzing every single need to reach the best solution for you.

4. Air Chiller Industrial Applications

Air chillers are taking very important parts of industrial refrigeration are widely used in various fields.

In the industrial sector, most air chillers are used in the plastic process, die casting, laser industry, medical and pharmaceutical, machine tool, optical coating, thermal spray, water jet pumps and cutting machines, welding machines, brewery and distillery, food, and beverage industry, chemical, heat treating or induction, etc.

Now we shall discuss air chillers’ applications in some main sectors in the following text.

4.1 Air Chiller for Plastic Machinery

In the plastic industry, air chillers are used to cool the hot plastic that is injected, blown, extruded, stamped, rotational formed, or thermal formed.

Air chillers are also used to cool down the plastic process equipment, such as the hydraulic of the molding machine, gearbox, and barrel of the extruder.

TopChiller air chiller used for plastic blowing machines

I. Air Chiller for Injection molding

Air chiller cooling in injection molding is most commonly seen in plastic manufacturing. In the cycle of an injection shot, the cooling takes 80-95% of the cycle time.

Water cooling is the critical action that decides the product quality and whether the products can meet the target dimensions.

During injection molding, the plastic resin is heated to melted status and is forced into the mold. The remaining time of the cycle is to cool down the plastic until it can be ejected.

II. Air Chiller for Blow molding

Hollow plastic parts like bottles are produced by blow molding machines.

During the blow molding process, we must use air chillers.

Plastic resin is melted and formed into a tube-shape parison, clamped into a mold, and then compressed air is blown into the parison to form its desired shape.

In the later part of the process, the plastic has to be cooled so that the shape could be formed. Heat must be removed at the designed rate.

If the mold is cooled too fast or too slow, it might lead to deformation, poor plastic quality, or unqualified smoothness or brightness.

III. Air Chiller for Thermal forming

Thermal forming machines also need air chillers.

In thermal forming, a large sheet of plastic sheets is heated and made malleable, and then they are shaped with mold using vacuum pressure.

Same as the other plastic processes, maintaining the proper temperature is critical to production.

With too low temperature, the plastic will break or fail to shape in the mold; with too high temperature, the plastic will thin or tear in complex bends and shapes.

A reliable water cooling source from an air chiller is important for the manufacturing process.

IV. Air Chiller for Extruder&extrusion

Besides the above plastic machinery, air chillers are also widely used in the plastic extruder or extrusion line.

In a plastic extrusion machine, plastic is heated and forced through a mold to form a shape.

It is essential to maintain the right temperature to have an adequate flow rate.

Chilling and solidification of the plastic after it is extruded out of the mold is critical to have qualified products and an efficient production rate.

V. Air Chiller for Rotational Molding, Stamping, etc.

Air chillers can be also used in rotational molding, melted plastic is introduced into a large rotating drum.

The spinning drum sends the melted plastic into the mold cavities around the outer edge of the drum.

With rotational molding, you can create a complex shape which with other kinds of the plastic process you would have to manufacture and assemble every part.

In rotational forming, you also need to have optimal plastic chilling to guarantee efficient manufacturing.

4.2 Air Chiller for MRI, CT, and other medical equipment

Air chillers have a wide variety of applications in the medical industry including MRI machines, PET and CT scanning, and other medical equipment.

More and more advanced medical equipment needs a chilled water supply from an air chiller.

MRI, PET, CT, oncology linear accelerator, magnetic resonance imaging system, blood cooling system, lasers, and electron microscopes, etc all need air chillers in their operation.

Medical process chillers are very demanding as they do not cool a constant operating load.

The demand for chilling is cyclical. That is to say, the load ramps up quickly, and then dissipates equally fast. This is the unique feature of medical equipment chilling.

The medical process chiller has to handle the immediate shock of load surge and manage to maintain the chilling water at a stable temperature during the time.

4.3 Air Chiller for Anodizing and Plating

I. Air Chiller for Anodizing

Air chillers can also be used in anodizing equipment and process.

Anodizing is an electrochemical process that uses acid to convert the metal surface into a corrosion-resistant and wear-resistant anodic oxide finish.

As the anodizing process generates a huge amount of heat, cooling is a must, especially for hard coating processes.

So we will consider using an air chiller to maintain the water temperature in the Anodizing process.

II. Air Chiller for Plating

For the plating industry and plating process, air chiller plays an important role to provide cooling liquid.

Plating is the deposition of metals in solution onto a surface.

Plating is used for decoration purposes, corrosion resisting, improving IR reflectivity, radiation shielding.

Either electroplating or electroless plating requires a tremendous amount of heat that they have to be removed.

Air chillers are needed to efficiently carry out the duty. Temperature control is a very important part of the plating process.

Keeping the rectifier cool and the tank at a steady temperature is imperative to produce high-quality products.

4.4 Air Chiller for Food and Beverage Industry

Air chillers are widely used in the food and beverage process, including a brewery, winery, distillery, fermented craft beverage, potable water, bakery, yogurt, poultry, etc.

I. Air Chiller for Beverage

Air chillers are used for removing heat gained from the process of mixing, cooking, fermentation, after product pasteurizing and storage.

There are various factors that you have to consider in selecting a chiller: the temperature you need during the process, the brewhouse capacity, the quantity and volume of fermentation tanks, the quantity and volume for the bride tanks, etc.

There is no one-size-fits-all chiller for all applications. A customized chilling solution is of utmost importance.

II. Air Chiller for Food Process

In the bakery, yogurt, poultry, and other food industries, air chillers are needed to maintain the temperature in the processes or for storing.

4.5 Air Chiller for Laser Industry

An air chiller is a piece of necessary cooling equipment for the laser industry and laser process.

The laser has various applications in many sectors of industry, like high-speed and high-precision cutting, welding, perforating, medical equipment, etc.

To guarantee optimal performance and to extend the life of lasers, temperature control is important, in this case, the air chiller will provide steady cooling water for laser machines.

First, it is because the increased heat can cause an increase in wavelength, which might compromise the performance laser system.

Operation temperature can affect the beam quality, while in some applications strong beam focus is required. And lower operation temperature can ensure longer life of the components of laser systems.

So by water cooling from the air chiller, you can maintain the precise laser wavelength, achieve desired beam quality, reduce thermal stress to the laser system components and get higher output more efficiently.

4.6 Gold Melting Furnace

Air chillers can also be used for the gold melting machines.

In this gold melting furnace process, the air chiller can provide constant cooling water for the whole production temperature controlling purpose.

Superb Electromachinery Co., Limited is a professional precious metal melting and casting machine for gold and jewelry.

If you have such an inquiry, please send me all your requirements.

4.7  Air chiller for other applications

Air chillers have many other applications, including pharmaceutical, plasma cutting, thermal spray, waterjet cutting, welding, etc.

Their processes always include heating and cooling. And for some reason, water cooling is vital in processing equipment protection or product quality guarantee.

Like in the pharmaceutical industry, the inherent chemical properties of pharmaceuticals, are sensitive to processing time and temperature exposure.

So a reliable air chiller is a must in the manufacturing process.

For more details, please contact the professional team of TopChiller to obtain the information you need.

4.8 Air chiller for the food industry

We specialize in designing and manufacturing air chillers for the food and beverage industry.

Our food processing air chillers are used in a range of settings, including in frozen yogurt shops, bakeries, wineries, breweries, and much more.

TopChiller offers a variety of air chillers in sizes and configurations to meet any budget and cooling demands for the food processor and bakery applications.

For the best industrial air chillers for your commercial bakeries and more custom-designed food processing air chillers, please contact the TopChiller team.

5. Maintenance and Troubleshooting of Air Chillers

Maintenance and monitoring of air chiller regularly can prevent unexpected breakdowns and cause serious costs.

In the following part of the article, we shall give a guide on regular maintenance as well as troubleshooting when the air chillers have problems.

5.1 Maintenance

Maintaining a checklist of air chillers is the best way to detect problems and take preventive measures for the first time.

I. Check items weekly

A. Check air chiller oil level in oil separator sight glass
B.Check air chiller liquid line sight glass/moisture indicator
C. Check the refrigerant level in the evaporator sight glass while running full load for 10-15 minutes.
D.Record air chiller operating temperatures and pressures
E. Check air-cooled condenser coils for dirt/debris and clean as necessary

II. Check items every quarter

A. Check programmable operating setpoints and safety cutouts of air chillers. Assure they are correct for the application.
B. Check compressor and evaporator heater operation of air chiller
C. Check for dirt in the panel of the air chiller. Check door gasket sealing integrity.

III. Check items on a half-year basis

A. Check leakage of the air chiller.

IV. Check items every year

A. Take a sample of compressor oil, send it to the lab to check for acid, and change if necessary.
B. Disconnect power source and lockout. Check the tightness of power wiring connections.

5.2 Troubleshooting of air chiller

Even in the case that regular inspection and maintenance have been done, the air chiller’s performance might degrade over time.

So some basic troubleshooting skills would help save your time before you call the professionals for help.

If your air chiller has a problem, you can follow the following steps for troubleshooting.

I. Common problems:

A. The air chiller power isn’t on:

1) Check if the electrical supply voltage is proper or the line connection is loose;

2)Check if the main power phase connection is right (three-phase)

3) Check the electrical circuit breaker and fuse

4) Check if the power switch of the air chiller is “on”.

B. Not enough pumping force or insufficient refrigerant flow:

1) Check if the voltage is improper or fluctuating;

2) Check if process water/chilling water quantity is enough;

3) Check if the process line is stuck or restricted;

4)Check if the process valve is closed or partially closed;

5) Check if the process water/chilling water is temperature is as required;

6) Check if the refrigerant filter of the air chiller is blocked;

7) Check if the process piping is too small;

8) Check if the water pump inside the air chiller fails.

C. Not cooling or insufficient cooling:

1)Check the voltage is proper or not or fluctuating;

2)Check if the air filter or air-cooled condenser is clogged;

3) Check if the process water/chilling water temperature is the same as required;

4) Check if the process water’s/chilling water’s heat transfer properties are still normal;

5) Check if there is leakage of refrigerant of air chiller copper pipes;

6) Check if the ambient air temperature is too high;

7) Check if the evaporator of the air chiller has ice.

II. Consulting to chilling professionals

If you can’t identify the problem or solve the problems you find, please contact the air chiller supplier for professional advice.

TopChiller’s professional team will be glad to assist you in finding out the problems of air chillers and solve them for you.

Air chiller maintenance items

the safety protection of air chillers:

1 Check if the voltage is normal and the phase is missing.

2 Check and record the operating current of the air chiller.

3 Measure and record whether the high and low pressure and temperature control temperature are normal.

4. The normal high pressure of the air chiller is 1.5MPa / the low pressure is 0.45MPa4. M3/h

5 Check if the oil level and oil temperature are normal.

6 Check the air chiller compressor for abnormal sounds and abnormal vibrations.

7 Whole air chiller refrigerant system testing.

8 Air chiller overall testing and testing.

9 Check the water quality of the chilled water and cooling water regularly. When the water quality of the water source becomes dirty and turbulent, please replace the water source in time.

This is regular inspection and maintenance for the air chiller every month.

The annual maintenance of air chillers needs to be as follows:

1 Clean the air-cooled condenser (accumulate operation for six months)

2 Check the refrigeration oil and lubricant system and replace and replenish if necessary.

3 Check the support host circuitry.

4 Insulation test of compressor motor coil of an air chiller.

5 Check that the drier filter is normal, with or without clogging, and replace if necessary.

6 Check the amount of refrigerant and replenish the refrigerant in time.

7 Check and correct the high and low-pressure switches.

8Check and calibrate the thermostat.

9 Test run and total calibration, test whether the superheat is normal and whether there is abnormal sound in each part.

6. Why TopChiller Can Be Your Reliable Air Chiller Supplier?

TopChiller is the trusted manufacturer of air chillers for 20 years since 2003.

Our air chillers come with many innovative features built-in, such as automatic temperature stability, keeping the industrial process at peak conditions.

We also back our exceptional air chillers with superior service, ensuring that our customers receive fast and reliable service!

With 20 years of experience, TopChiller dedicated itself to manufacturing and supplying a wide range of air chillers from 0.8KW to 540KW.

TopChiller is seeking to improve all air chillers’ design and quality endlessly.

With our uncompromising attitude and ceaseless effort, TopChiller has become a leader in the air chiller industry, known for maintaining world-class quality standards, efficient air chillers, and competitive prices, and excellent before-sales and after-sales services.

We have been exporting to customers all over the world, supplying air chillers that are applied in various sectors of industry.

We fully understand the dynamics and intricacies of the different industries our special chillers serve and we offer optimum chilling solutions to meet the specific requirements of each case.

Air Chiller Installation in Customer Project Site

6.1 Air Chiller Advantages

Air chillers manufactured by TopChiller features below advantages:

I.Tailor-made machine design/chilling solution, with comprehensive consideration of your specific conditions and air chiller requirements
II.Advanced corrosion protection and rugged construction
III.User-friendly and easy to maintain
IV.Sustainable for heavy-duty and trouble-free
V.Manufactured and tested air chiller before delivery

6.2TopChiller Company Goals

I.Unprecedented air chiller quality and design, ceaseless pursuing perfection.
II.More safe, clean, environmentally friendly air chillers
III.Good service, communication, and customer trust

TopChiller is known for its high-quality air chillers, knowledge in special fields of industrial chillers, unbeatable presales, and after-sales customer support.

Our technical team is committed to handling all your special case conditions and requirements and is available on 7/24. We bring innovation to the business and benefit our customers.

Our effort is recognized by our customers worldwide. Choosing TopChiller, you are choosing a reliable air chiller supplier and a life-long friend.

Air Chiller Installed in Manila Philippines

Conclusion

If you need air chillers or any chilling systems/solutions for any cases, please inquiry TopChiller now.

Our chilling expert will guide you through the whole process from choosing, planning, ordering, installing, and operating the most suitable air chillers.

Time-saving, energy-saving, trouble-saving, cost-saving is what you would get if you choose to cooperate with TopChiller.

We are passionate, user-focused, detail-oriented, and most important experienced and professional air chilling experts.

It doesn’t matter if you investing in new facilities, replacing your old air chiller systems, entering a new field of business, we are always available to hear what you need, bringing your plan to reality.

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Air Chiller-The Ultimate FAQ Guide by TopChiller

Air Chiller is very common, particularly in small to medium size industries and office buildings. It is typically installed externally, either upon the rooftop or at ground level.

Air Chiller absorbs heat from process water, and the heat is then moved to the air around the Air Chiller. It is generally utilized in applications where the extra heat it releases isn’t a factor.

It’s often reasonable to utilize the excess heat to warm a plant throughout the winter, therefore providing extra cost savings.

If you are planning to buy an Air Chiller, you will get everything you want to know about it.

Let’s start it.

What is an Air Chiller?

Air Chiller depends on a condenser cooled by the environment air. So, Air Chiller may find common applications in small or medium industries where space issues may exist.

Air Chiller can be the most reasonable choice in situations where water is an issue.

Air Chiller can feature mechanical refrigeration cycles to draw surrounding air over a finned coil to condense the refrigerant.

The condensation of the refrigerant vapor in the air-cooled condenser allows the transfer of heat to the atmosphere.

Air Chiller System offers the significant benefits of lower installation costs. It requires simple maintains as compared to Water Chiller. It consumes less space, yet will generally reside outside the industry or an office.

It is well known Air Chiller doesn’t utilize cooling towers, rather they dump the heat into the surrounding air to remove the undesirable heat from the building or industry.

Air Chiller Manufactured by TopChiller

2-What are the Main Components of Air Chiller?

There are four major components.

• Evaporator

In the evaporator of the Air Chiller, chilled water is produced when undesirable heat is transferred into the refrigerant before it is taken care of into the condenser.

• Compressor

The compressor is the most significant part of an Air Chiller. Its main role is to circulate the liquid refrigerant in the tubes, and tube assembly. It is located between the evaporator and the condenser.

The compressor can be very noisy, normally a steady profound droning sound with an overlaying high pitch, hearing protection must be worn while operating the Air Chiller.

• Condenser

The condenser will assist in managing the refrigerant and decreasing it to its normal state after heat absorption.

The condenser is an arrangement of flat pipes inside the Air Chiller through which hot refrigerant runs. Air is transferred across the condenser to dispel unwanted heat.

• Expansion Valve

The Expansion valve will help in extending the air while delivering it from the Air Chiller.

It helps in making or keeping a constant movement of air through the whole Air Chilling.

Air Chiller Expansion Valve

3-What are the Types of an Air Chiller?

There are four types of Air Chillers based on different capacities and specifications.

Reciprocating Air Chiller, Scroll Air Chiller, Centrifugal Air Chiller, and Rotary Screw Air Chiller.

Below is the detailed introduction of these Air Chillers.

Reciprocating Air Chiller

It has an intake valve that will draw the refrigerant into the compressor inside an Air Chiller.

Aside from that, it has inner pistons that compress the refrigerant.

Because of the high pressure, the refrigerant will flow into the system through pipes consequently causing a cooling impact inside an Air Chiller.

Simultaneously, it absorbs enough heat from the Air Chiller, hereafter cooling the room.

It is fit for assisting and accommodating loads going from 30 tons to around 150 tons.

You can utilize various units, hence allowing appropriate adaptability of the whole Air Chiller.

It is an entirely reasonable kind of Air Chiller, yet you will pay more for getting proper maintenance done for it.

Aside from that, it creates a great deal of sound or noise through vibration and consumes and utilizes a high amount of energy.

Scroll Air Chiller

This is the smallest Air Chiller with the capacity of taking care and managing somewhere in the range of 5 and 150 tons of load.

Scroll Air Chiller has two spiral disks with one inconsistent rotation while the other is fixed.

It compresses the refrigerant at the focal point of the machine before forcing and pushing it back into the Air Chiller.

It has a compact design consequently making them the most effective and low maintenance cost.

Centrifugal Air Chiller

Centrifugal Air Chiller has an impeller wheel that will push the refrigerant against the cylinder divider chambers.

From that point forward, it will reduce the refrigerant thus prompting a constant cooling process.

Centrifugal Air Chiller has the capacity of taking care of and managing high volumes of refrigerants with moderately little compressive powers.

Centrifugal Air Chiller has the biggest load limit of around 2000 tons accordingly requiring load applications of around 300 tons.

In full mode operation, the Centrifugal Air Chiller is the most productive along with the low-cost value.

You may experience surge issues when you work with it at low operational limits.

Rotary Screw Air Chiller

Rotary Screw Air Chiller has helical rotors that are responsible for the compression of the refrigerants subsequently pushing it in the spaces inside the helical screws.

Rotary Screw Air Chiller is equipped for managing and taking care of between 20 to 1000 tons of load consequently putting it inside the mid-range limit.

It has not many moving parts and a high proportion of compression, hence making them very smaller. It is a quiet kind of machine that does not vibrate with undeniable degrees of dependability and productivity.

The expense of maintaining a Rotary Screw Air Chiller is extremely low even though it is expensive at the time of buying.

Reciprocating Air Chiller

4-How does an Air Chiller work?

Air Chiller manages and deals with a standard where the machine effectively absorbs extra heat from the process water.

From that point forward, Air Chiller will move the heat it absorbs into the surrounding air.

Indeed, before you buy it, you should see and get to know the proper details on how the Air Chiller functions.

Several steps are mentioned in sequence on how an Air Chiller performs and can be used.

Stage One: Evaporation Process

The tasks inside the Air Chiller start with the process of evaporation inside the evaporator.

Usually, the evaporator has an uncommon and unique sort of liquid refrigerant which typically flows over the group of the evaporator tube inside an Air Chiller.

The liquid will evaporate because of the quantity of heat that will consequently change its form to flow.

Stage Two: Heat Absorption

As that happens, inside an Air Chiller heat is frequently absorbed from the chilled water, which is consistently in constant circulation through the bundles.

From that point onward, the compressor will pull the refrigerant vapor directly from the evaporator and pump refrigerant liquid to the condenser.

The condenser will respond to the press and there will be a rise in the air pressure and temperature in an Air Chiller.

Stage Three: Condensation Process

While in the condenser tube, the refrigerant fluid or liquid will gather.

This will result in the arrival of heat internally for the cooling water or air inside an Air Chiller.

From that point forward, the high-pressure liquid will move into the evaporator from the expansion device.

As that occurs, the force of the refrigerant will decrease just like the temperature.

The process in an Air Chiller will proceed in a repeating style until it generates a chilling or warming impact in the room.

5-What are the Benefits of Using an Air Chiller for your Applications?

There are a lot of advantages and beneficial factors that can be appreciated.

Some of the factors that will have a huge positive impact on Air Chiller are mentioned below:

Affordability

Air Chiller is usually very easily affordable to buy and install because of the way that they have a couple of types of equipment which are already mentioned above.

Air Chiller is less expensive to install because they have less equipment.

Occupy Less Space

As compared to the Water Chiller, the Air Chiller will consume next to no space. This means it can easily be adjusted in a small space, no extra spaces are required for Air Chiller.

You can normally put it on the top of your building with no need of developing a mechanical space or storeroom.

Low Cost of Maintenance

You will likewise spend less during the process of maintaining and keeping up the Air Chiller as it has not many parts. The less the quantity of parts, the lower the expense of maintaining

On a similar note, it is less expensive, simpler to maintain, and does not require any water pump.

Air Chiller will work productively without the condenser water pump or cooling tower.

Whereas in contrast Water Chiller will require a water pump or cooling tower and is more expensive comparatively.

Simple Designs

Air Chiller has a straightforward ergonomic design and assembly, therefore, taking out the requirement for additional arrangements of pumps for the condensers.

Safety of an Air Chiller.

The Air Chiller takes out the requirement for liquid nitrogen or other refrigerated gases.

By doing this, it helps in removing the potential for suffocation, injuries, or different risks related to the compressed gas.

Easy connectivity

The Air Chiller does not require to be equipped with a cooling tower and is appropriate for use in regions where water quality is not acceptable.

The piping and channeling are basic, just two ice water lines and supply lines can be installed.

6- What are the Applications on Air Chiller?

Air Chiller is being used to cool down, applications buildings and manufacturing plant and utilized in a wide range of industries.

The Air Chiller can be centralized if there is a need or decentralized if the machines have their own Air Chiller.

There is likewise to have both centralized and decentralized Air Chiller at the same time.

You can utilize it in various applications to make a chilling impact consequently controlling temperature.

Here are the most numerous of the industries that will require and need the services of the Air Chiller.

• Construction Industry

You will require the Air Chiller to give enough heat just as chilling impacts inside various sorts of structures and buildings.

As a rule, you will notice the Air Chiller on top of various structures and buildings or inside a mechanical storeroom.

• Manufacturing Industry

You will utilize the Air Chiller in the manufacturing and assembling business to cool the environment that would produce suffocation from excessive heat.

Most manufacturing and assembling industries have Air Chiller on the outside to force impressive measures of cool air.

Air Chiller is Used in the Manufacturing Industries

• Medical Industry

The medical or clinical industries need the services of Air Chiller to assist with chilling and cooling down the insides of the medical clinic or interiors of hospital buildings.

Air Chiller makes the medical buildings to be as cool as convenient along these expanding the comfort level of patients.

• Warehousing Industry

All things considered, you will need and require the Air Chiller in warehouses or stockrooms to control the temperature conditions for the inventory storage of various items.

Air Chiller makes a cool environment that is positive for the inventory storage of various kinds of products in the warehouses or stockrooms.

It can utilize substantially more areas, for example, domestic and industrial areas.

Likewise, Air Chiller can be utilized for the safety of electronic devices, fine arts, power amplifiers, and so on from the heat.

7-How to choose the right Air Chiller for Your Application?

You need to make an appropriate choice of your Air Chiller to have accurate ventilation inside your industrial or modern application.

This is possible just with a proper choice rule while picking an Air Chiller. Here are the key advances that you need to see while you are going to buy them.

Great quality Air Chiller is designed, manufactured, and planned by a high-standing Air Chiller Industry.

We are an expert Air Chiller manufacturer and supplier who can plan and make all sorts of Air Chiller to satisfy your cooling needs reasonable for your applications.

• Determine the Load of Heat

In the first place, you ought to recognize a load or power of heat inside the application settings before picking an Air Chiller.

The more noteworthy the heat load inside your application settings, the greater the sort of Air Chiller you need.

• Determine the Type of Coolant

You should give close consideration to the kind of coolant you will utilize in the cooling procedure inside it.

In this situation, the kind of coolant that we will utilize is air, which will help in the exchange of heat through the system.

• Determine the Installation Environment

You will select the Air Chiller installation climate by taking a look at the access to the proper air ventilation.

Much of the time, you will install it outside the building or structure for legitimate access to free-streaming air.

If you have a mechanical room, at that point you should have appropriate ventilation that allows the free progression of air.

• Look at Air Chiller Performance Curves

Withstanding the above-mentioned, you must likewise take a look at the presentation of Air Chiller before you settle on a decision.

You will relate the performance curves to the application necessities to have proper and accurate evaluations of its productivity.

• Final Selection

With all the above elements considered, you will feel free to settle on a decision on the sort of Air Chiller you need.

Chose a Suitable Coolant for your Air Chiller

8-How to size an Air Chiller?

We can’t overstate the worth of choosing an accurately sized Air Chiller.

Bit small Air Chiller won’t efficiently cool down your industrial applications. An oversized one will turn out at great cost.

At the point when you select an Air Chiller of the suitable size, you can rely on several years of dynamic cooling.

You can determine the Air Chiller size by adopting the following points:

First of all calculate the temperature difference between the inlet temperature of the cooling medium and the necessary temperature of the cooling medium, to discover the value of ΔT°F.

Secondly, calculate the cooling capacity in BTU/hr by placing the values in the formula below:

BTU/hr = Gallons/H x 8.33 x ΔT°F

Thirdly convert the value of BTU/H into tons by dividing it by 12000.

At the end calculate the perfect size of your Air Chiller in tons by oversizing it by 20% as;

The perfect size of your Air Chiller according to your requirements is = Tons x 1.2.

Air Chiller Sizing Formula

9-How to Install your Air Chiller?

Installation of your Air Chiller is a simple job. Follow these steps for installation.

• First of all, choose the proper location for the installation. Choose a suitable location to provide proper cooling to the whole area. Make sure that the installation zone is free of obstacles.
• Make particular location vibration proof. Use vibration-proof pads, and rubbers.
• When installing it on the ground make sure that the ground is extra thick and can bear its load.
• After the arrangements of location and ground setting put your Air Chiller on its location.
• Unpack all parts and check all parts for damage, or broken parts.
• Assemble all the parts.
• Connect it to the power and turn it on. Check the operational parameters and primary setting according to your industrial need.
• Check its operational performance in the first 15 minutes and when you are sure everything is ok, start your Air Chiller for your industrial application.

Air Chiller Installation

10-How to Maintain your Air Chiller?

You need to maintain or keep up the industrial Air Chiller to maintain the best performance consistently.

Appropriate maintenance support is an assurance that it will serve for quite a long time.

• All things considered, you should have a proper timetable that you need to follow to keep up or maintain the Air Chiller.
• Essentially, your support timetable will detail the time stretches for cleaning and greasing up the Air Chiller.
• You need to clean the Air Chiller to dispose of the residue that may stop up the frameworks consistently.
• Aside from that, you need to grease up the moving parts routinely to decrease grating and harm inside it.
• At last, you ought to review the Air Chiller consistently to distinguish broken parts for substitution purposes.

Air Chiller Maintenance

11-How to Increase the Working Efficiency of Your Air Chiller?

You can easily increase its working performance by taking care of its components.

Here is a portion of the variables that you can consider expanding the working efficiency of your Air Chiller.

Variable Retrofit Speed

You ought to consider the variable retrofit speed to help in the arrangement of energy-saving freedoms.

You should, in any case, be very careful with different parts of the systems to guarantee there are no harms.

Notwithstanding that, it is imperative to keep an eye on the variable now abilities of the Air Chiller to improve proficiency.

Run Multiple Parallel Devices

Running the Air Chiller parts equal will help in saving enough energy, consequently expanding its productivity.

A portion of the systems that you can pipe in equal incorporate system pumps and cooling fans.

Running a greater amount of the equipment will help in maximizing the surface region of heat move at the working focuses.

Increment Temperatures of Supplies

You can expand the temperatures inside the stock system to build the dehumidification measure.

12-How to fill Refrigerant into Air Chiller?

With actual instruments or tools and secure materials, filling refrigerant inside the Air Chiller is an exceptionally straightforward procedure.

The process starts by checking the air levels within the Air Chiller system to decide the measure of air to add.

From that point onward, you will find the attractions valve which you will use to fill enough air into the Air Chiller.

When you have it, you ought to continue to open the valve and cleanse the procedure of the air inside.

You will do this by linking various shades of tubes to the assigned focuses to perform extraordinary capacities.

You must be extremely mentally active so as not to allow entry passage of humidity inside the Air Chiller as that would cause great harm.

From that point onward, you ought to guarantee that you close all the valves on the Air Chiller manifold gauge.

Interface the yellow house to the channel of the refrigerant and guarantee that the lines do not have air inside.

With that under wraps, you will continue to open the refrigerant cylinders to allow entry of air into the Air Chiller.

At long last, you will cautiously remove the close valves.

Air Chiller Refrigerant Filling

13-What Safety Measures should you consider when using an Air Chiller?

When utilizing the Air Chiller, it is critical and very significant to examine the safety of the Air Chiller parts.

Air Chiller components should be protected from low refrigerant temperatures, high condensing, or low oil pressure.

A portion or features of the safety controls you must know about include:

Capacity Controls

It is responsible for the support of temperatures, particularly of the chilled water.

Refrigerant Flow Controls

You will set it in correspondence to the pressure you are utilizing inside the Air Chiller components.

Aside from the two, you should likewise view different sorts of mechanical controls for high protection.

Notwithstanding that, the Air Chiller can consequently close down on the off chance that the above safety features neglect to work.

Wear Gloves Before Operating your Air Chiller

14-What is the difference between Air Chiller and Water Chiller?

Air Chiller:

There are particular differences between the Air Chiller and a water chiller. Air Chiller is outfitted with condensers that use surrounding air to decrease refrigerant temperatures.

Fans are utilized to constrain the air over tubing containing refrigerant and subsequently remove heat from it.

The cooled refrigerant utilized in Air Chiller would then be able to be flowed through the industrial process to achieve a cooling impact.

Water Chiller:

On the contrary, the water chiller takes advantage of the high heat capacity of water to ease refrigerant chilling.

The coolant utilized in the water chiller is a combination of water and glycol which is flowed in a sealed tubing network.

Cooling happens when the chilled refrigerant is gone through a heat exchanger that interfaces with the industrial process.

Warmed coolant is then gotten back to a cooling tower or refrigeration unit which wipes out procured heat in expectation of another pattern cycle of cooling.

Water Chiller

FAQ of Air Chiller.

1. What Refrigerant is suitable for Air Chiller? 

An Air Chiller that cools down the Industrial applications and processes uses R-410A, R-404A, R-407C, and R-134a.

2. Do Air Chiller Needs Cooling Towers?

No, Air Chiller doesn’t need a cooling tower.

3. What is the Heat Load of an Air Chiller?

The amount of heat generated by the industrial machines during their normal operation is called the Industrial Air Chiller heat load.

Its unit is BTU (British thermal unit). One BTU is the amount of warmth or cooling that increases or decreases the temperature of 1 gallon of water to 1 degree Fahrenheit.

4. What is the average life span of an Air Chiller?

The average life span of an Air Chiller is 15 to 20 years. But, the way you treat and how much you use your Air Chiller plays a key part in affecting its average life span.

5. What varieties make the Installed Air Chiller better than the Mobile Air Chiller?

An Installed Air Chiller is far better than the mobile Air Chiller because it is bigger and offers better capacity. It can deal with several, flexible, and large process loads and is more reliable in any industry.

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