Whatever Type of Air Chiller,
TopChiller Can Fulfill the Chiller Solution for You.
- 20 years of air chiller manufacturing experience: TopChiller are specialized in air chiller manufacturing for over 20 years
- 18 months warranty time: Each air chiller or air chiller system manufactured by TopChiller covered 18 months warranty
- Famous brand spare parts: TopChiller using world first-class air chiller spare parts and refrigeration brands
- Technical support& Training service: After purchasing TopChiller can provide air chiller installation & commission guide
- 8 Hours troubleshooting: TopChiller promise 8 hours quick response to solve all air chiller error to customers worldwide
- Free air chiller design and quote: TopChiller give air chiller and air chiller system design"e free of charge within 12 hours
Why TopChiller Can Be a Reliable Air Chiller Supplier
Air Chiller: Your Premier Choice
Of Air Chiller Manufacturer and Supplier
Air chiller is one kind of air-cooled chiller that uses air-cooled condensers as the heat exchanger.
TopChiller is your professional air chiller manufacturer and supplier in China since the year of 2003.
As a leading air chiller supplier with 20 years’ experience, both portable air chiller, air chiller system, and air chiller unit manufactured from TopChiller has to be strictly checked after production and refrigerant charged before making a delivery to each refrigeration client.
This is more convenient for all air chiller end-users installation and operation when they receive TopChiller air chillers.
For all air chiller also has portable wheels that don’t require a water cooling tower, which is easy to install and remove.
High-quality air chiller designed and manufactured from TopChiller has some outstanding advantages as below:
1.TopChiller has an Extensive Air Chiller Lineup, The optimum air chiller model can be selected from an extensive product lineup for small to medium- to large-scale facilities for use in a variety of both commercial and industrial process applications.
2. Energy and Cost Savings, TopChiller air chillers are utilizing the latest refrigeration technology, TopChiller has achieved industry-leading efficiency and energy-saving operation for outstanding cost-saving performance. Our air chiller will save your money and cost.
3. Versatility, TopChiller air chiller delivers energy efficiency to a wide range of process cooling applications with a lineup featuring a full range of capacities for all working conditions and cooling requirements.
4. High Operation Efficiency, With meticulous attention to fine-tuning each facet of our air chiller operation, Air chiller from TopChiller offers high efficiency for unmatched performance and economical operation.
5. The body structure of TopChiller air chillers is a galvanized steel cabinet with baked enamel powder or pre-painted finish on exterior panels passes 500-hour salt-spray test in accordance, this makes our air chillers stay strong and long service time outdoor installation.
6. The air chiller is all in one package solution and factory-charged with environmentally friendly refrigerant (R407c, R134a, or R-410A) and all necessary refrigeration spare parts along with chiller before delivery to your hand.
7. The air-cooled fin condenser installed in air chiller uses freshwater nano-aluminum foil to enhance anti-corrosion performance, good heat transfer effect, easy cleaning and maintenance, and convenient installation.
8. Each air chiller has full protection devices including Hermetic scroll compressors and outdoor fan circuits are protected by circuit breakers or fuses, high and low-pressure protection/compressor overload protection, electronic expansion valve and Self-contained controls including transformer.
9. Our air chiller has microcomputer control, built-in comprehensive intelligent monitoring, and protection, including motor temperature control, phase sequence monitoring, manual reset lock, oil temperature monitoring, accurate temperature control within ± 1℃ temperature difference.
10. The air chiller body structure is made of high-strength steel plate after plastic spraying, and the most advanced patented technology is used for high-precision processing to ensure that it will not rust in acid and alkali gas.
11. Standard warranty time, All the air chillers manufactured from TopChiller have one year from start-up or 18 months from shipment on all other parts, and Extended warranty packages available. This is the no worry about after-sales service for you to choose TopChiller.
We all know air chillers play important parts in modern industries during the production process. Air chillers are widely used in various industrial applications, they can supply cooling water for the industrial process constantly.
Air chillers manufactured by TopChiller can precisely control the temperature requirement from the modernized machinery production, and it will greatly improve the production efficiency and product quality.
Air chillers are widely used in various industrial applications, like plastic industry, electrons, plating, chemical industry, ultrasonic wave cooling, printing, welding thermal spray, vacuum furnace & other small-medium scale processes cooling.
TopChiller having 20 years of experience in making air chillers since 2003. Air-cooled chiller from TopChiller is the best partner and process cooling solution for your modernized industry.
As a leader of air chiller supplier and manufacturer over 20 years, TopChiller offers a wide range of standard industrial air chiller, air-cooled chillers, portable air chiller, air-cooled chiller system, air chiller unit which can be found in following specification tables, but standard air chillers may not always fit your unique refrigeration requirements.
TopChiller has exported thousands of air chillers, air chiller units, and air chillers systems every year.
All these air chillers are exported to the Philippines, Australia, New Zealand, Malaysia, Singapore, Indonesia, Chile, Mexico, Costa Rica, Brazil, Argentina, Colombia, South Africa, Nigeria, Saudi Arabia, Dubai, Spain, Italy, etc.
If you are looking for a reliable and high-quality air chiller manufacturer?
If you want to buy a new air chiller from a professional air chiller company?
Please do not hesitate to contact our application specialists as they can suggest an air chiller that is customized to meet your unique air chiller needs.
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.
In fact, air chiller is often practical to use the excess heat to warm a plant during the winter, thus providing additional cost savings.
Air Chillers designed and manufactured by TopChiller with cooling capacity from 1.65KW to 202KW and adjustable temperature control range 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 having a big volume stainless steel buffer tank and 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 of air chillers on this page.
An air chiller is basically 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 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 reducing 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?
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 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 repeats 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
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 connected to the compressor inlet.
Among all parts, the compressor is the key part of an air chiller.
The compressor in an air chiller is the source of the refrigeration power. It creates pressure difference so as 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 a 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 have the ability to 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 cool 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.
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 there are numerous factors that influence decision-making.
In different cases, you might find which chiller system 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 has no influence on 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 making 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.
Air chillers’ expelling of hot air might cause an ambient air temperature to rise in the place where it is installed.
The sound is another issue that might have an impact on the environment. Air chillers operate with high decibel 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.
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 cost, then water chillers are less cost-effective than air chiller 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.
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 so as 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 the 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 so as 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 controlling 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 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.
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, of them 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 on a regular basis 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.
Maintain a checklist of air chillers is the best way to detect problems and take preventive measures for the first time.
I. Check items on a weekly basis
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 on a quarterly basis
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 on a yearly basis
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 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 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
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.
We work whatever it takes to ensure you receive the best service throughout our engagement. So hesitate no more, call us or send us an air chiller inquiry online.
Air Chiller Complete FAQ
While searching or using an air chiller, you must have some questions or problems with the air chiller. I believe this complete FAQ guide will make you know more clearly about air chiller.
Let’s have a look at the below items:
What is an Air Chiller?
What are the Basic Components of an Air Chiller?
What’s the Difference Between Air Chiller and Water Chiller?
Which type of Chiller is Best? Air Chiller or Water Chiller?
Which Refrigerant Gas is Used in Air Chiller?
What is the Working Principle of Air Chiller?
How do You Install an Air Chiller?
What are the Regular Maintenance and Checklist of Your Air Chiller?
How Do You Troubleshoot an Air Chiller?
Which Industries Air Chiller Applied?
Why TopChiller is Your Best Air Chiller Manufacturer and Supplier?
1. What is an Air Chiller?
Air chiller sometimes also named air-cooled chiller or air cooling chiller. An air chiller is a refrigeration system that can cool the fluids including water, oil, brine, glycol water from a higher temperature to some certain temperature, then feed these coolant fluids to a facility’s system to achieve the cooling effect.
For an air chiller, there are four main refrigeration parts including evaporator, compressor, condenser, and expansion valve. An air chiller works by absorbing the heat from processed water.
2.What are the Basic Components of an Air Chiller?
The main components for an air chiller are the Compressor, Condenser, Evaporator, Expansion Valve, Power Panel, Temperature Controlling System.
The compressor is the heart of an air chiller, develops pressure variation to stir the refrigerant around. There are mainly four types of compressors such as a screw, centrifugal, reciprocating, and scroll.
The condenser is one kind of heat exchanger that works as a heat remover from the chiller that was generated by the evaporator.
The evaporator is another heat exchanger situated between the compressor and the expansion valve and it works as a collector of unwanted heat from the refrigerant and cooling fluids.
The work of an expansion valve is to increase the refrigerant dropping its pressure and amplifying the volume. Air Chiller manufacturers variant types of expansion valves such as electronic, thermal, fixed orifice, and pilot-operated thermal expansion valve.
The controlling system is accumulated on the air chiller and its main work is to observe the diverse aspects of the performance of the air chiller and also manage these things by altering.
3.What is the Difference Between Air Chiller and Water Chiller?
Some people are puzzled about air chiller and water chiller.
An air chiller has a condenser that is cooled by the environment air. The air chillers are preferred for small or medium installations but lately, the quality improvement in their structure, allows the user, in modular type, for large installations also. An air chiller is preferred especially in cases that there is not enough water or the water is very expensive.
The water chillers have water-cooled condensers connected with cooling towers and are usually preferred for medium and large installations where there is the sufficiency of water. In addition, they are also preferred in cases that are demanded the constant performance of the system, independently of the ambient temperature (industrial air conditioning, air conditioning of digital systems, etc), because the capacity of the water chillers is not affected by the ambient temperature fluctuations.
4. Which type of Chiller is Best? Air Chiller or Water Chiller?
Air chiller or water chiller? Which is the Best for you?
- Air Chiller
- An air chiller is more easy operation and maintenance than a water chiller
The air chiller does not need to install a cooling tower
Air chillers are portable cooling solutions for facilities with space constraints.
- Water Chiller
Water chillers are generally more efficient than air chillers.
A water chiller has a quieter operation than an air chiller.
Air chiller and water chiller are suitable for both small-scale and commercial-scale cooling.
Portable solutions are available for facilities with space constraints.
5. Which Refrigerant Gas is Used in Air Chiller?
There are many different kinds of refrigerant gas in the market?
But how to select the most suitable one for your air chiller? this is a big question.
Common Types of Air Chiller Refrigerants including:R22,R134a,R407c,R410a and R404a.
Freon 134A. As a refrigerant, it possesses completely stable thermal characteristics, has low toxicity, and is non-corrosive and non-combustible. It is widely used in air chiller and water chiller.
Additionally, R134A HFC has minimal ozone depletion potential with a near-zero GWP. Despite being considered relatively safe and environment-friendly.
R22 is a long history refrigerant, which is most widely used before. But R22 refrigerant will phase out soon due to it takes harm to the environment ozone layer.
R410a refrigerant For general purpose air chiller, R410A is a zeotropic mixture of hydrofluorocarbons that can be employed. It does not have harmful effects on the ozone layer and is becoming more popular as R22 refrigerants are being phased out. But R410a is high-pressure gas for your air chiller and other refrigeration systems.
R404a is another refrigerant that specially used for a low-temperature refrigerant is required for air chiller, then R404A should be considered. This is a hydrocarbon blend that can be used in various commercial settings such as an air-cooled low-temperature chiller or glycol chiller.
R407C is suitable for residential & light air conditioning and air chiller. It was chosen to replace R22 by many new equipment manufacturers and is also used in medium-temperature refrigeration systems.