Air Cooled Screw Chiller

TopChiller: Your Professional Air Cooled Screw Chiller Supplier

Air-cooled screw chiller equipped with semi-hermetic screw compressor also called air-cooled screw compressor chiller.

An air-cooled screw chiller is always used for large cooling capacity applications.

Each air-cooled screw chiller manufactured by TopChiller featuring full protection devices including screw compressor overheating protection, low-temperature protection, high/low pressure, anti-freezing, phase-missing, anti-phase with overload, water flow switch, and startup latency.

Various refrigerants such as R134a, R407c, R410a, and R404a are all available depending on the screw chiller working condition, application requirements, and ambient temperature.

Besides the above features, all air-cooled screw chillers designed and manufactured by TopChiller also have an optional function for special requirements including soft-starting, economizer for higher efficiency.

Each air-cooled screw chiller with complete stainless steel nonferrous chilled water circuit for high water quality requirement, electronic expansion valve, and remote control for monitoring the screw chiller working status.

As we all know screw-type air chillers play very significant roles.

Most air-cooled screw chillers are widely used for various industries applications such as HAVC, big building&hotel air conditioning, central chilled water supply, chemical processing, die casting,food&beverage processing, pet food, pharmaceutical, plastic processing, automotive, energy&power project, packing, and printing.

Based on the required chillers cooling capacity or refrigeration capacity, we have one screw compressor chiller and dual compressors chiller for your optional:

As a professional air-cooled screw chiller manufacturer, TopChiller aims to provide air-cooled screw chillers with stable quality, operation efficiency, and energy savings.

It is suitable for air conditioning applications, industry-type process cooling, and large-scale district heat source systems.

Helpful Resources To Know More About Air Cooled Screw Chillers

What Is Air Cooled Screw Chiller?

Air-cooled screw chillers are a water cooling system in which air is used to cool the temperature of the device and improve the production efficiency of the machines.

As there is no need to install a complicated water cooling system and it’s easy to install and highly efficient, air-cooled screw chillers are more environmentally friendly compared to other kinds of chillers.

Nowadays, more and more companies are paying attention to energy conversation in their business production so air-cooled screw chillers have played a key role in cost savings.

In the marketplace where all kinds of screw-type chillers can be found, air-cooled screw chillers are widely accepted and popular in factories, shopping malls, hotels, office buildings, and other public places that require cooling systems.

How Does an Air Cooled Screw Chiller Work?

Air-cooled screw chiller earned its name for being equipped with a screw compressor.

The working principle of an air-cooled chiller with a screw compressor is like this:

The screw compressor will release high temperature, high-pressure gas into finned tube condenser, then this air-cooled condenser will condensed refrigerant liquid will flow into a component named liquid container.

The high-pressure liquid coming from the liquid container will be cooled by the heat exchanger in the gas-liquid separator.

After that, the liquid continues to go through the expansion valve and enters the shell and tube evaporator to get cooled and turn into refrigerant vapor featured by low temperature and low pressure.

When the refrigerant vapor enters the gas-liquid separator again, the refrigerant gas after being separated will be sucked into the compressor.

It might be easier to understand its basic idea if we follow the refrigerant alone to look at where it flows and how the process completes a cycle:

The refrigerant vapor is sucked in and compressed by the compressor, and then is released to the condenser where it’s condensed into a refrigerant liquid.

Afterward, it will pass through the expansion valve into the evaporator to get vapored. The refrigerant vapor will go back to the compressor again for the next cycle.

Now let’s take the whole air-cooled screw chiller apart and look at its key components closely.

Key Components of an Air Cooled Screw Chiller

Before this article, let’s have a look at the air-cooled screw chiller video we finished in the TopChiller factory.

You will get a general idea about this kind of air-cooled screw chiller.

1. Screw Compressor
For air-cooled screw chiller, we are using Hanbell brand or Bitzer brand semi-hermetic screw-type compressors.

This type of screw compressor is most crucial among all components in an air-cooled screw chiller as it works as an engine in a vehicle.

The role of the screw compressor is to compress the low pressure, low-temperature gas into a high pressure, high-temperature gas, and then transfer the gas into the finned tube condenser.

A screw compressor is a type of rotary compressor that consists of one or two screws.

The advantage of a screw compressor is that it can compress air by screw action and compress it continuously and stable.

TopChiller® air-cooled screw chillers are featured by semi-hermetic double screw compressors. Each compressor is highly efficient and can be managed by the unit controller to modulate the capacity.

2. Oil Separator
A certain amount of oil will be released when the compressor compresses the refrigerant.

After the oil leaves the compressor, it will circulate throughout cooling components and hinder heat transfer, and even reduce the capacity of the evaporator and condenser.

The oil separator is to make the oil disconnected from the refrigerant, which can minimize the amount of oil flowing in the cooling system.

Therefore, it is particularly important to prevent oil from getting more and more in the chiller.

Oil separators in TopChillerr® air-cooled screw chillers are smaller in size and have fewer moving parts, which make them more effective in the removal of oils in the refrigerant and also lower in terms of failure rates.

A double screw compressor integrated with an oil separator maximizes the efficiency of the air-cooled screw chiller.

3. Evaporator

For the air-cooled screw chiller, we are using a closed shell and tube-type heat exchanger.

The shell and tube evaporator is designed to collect the waste heat from the outside and transfer it into the refrigerant.

The cooling process begins with the evaporator, whose tubes contain some kind of liquid refrigerant.

In a shell-and-tube evaporator, the liquid refrigerant at low pressure enters the shell and flows through the tubes, absorbing heat from higher-temperature water that flows through the tubes.

When the water has reached a particular temperature, it will send the heat back to the refrigerant in the evaporator and get evaporated.

In the meantime, the water temperature cools down when the heat is extracted by the refrigerant.

Generally, the evaporator is installed between the compressor and the expansion valve.

At TopChiller®, air-cooled screw chillers are equipped with shell and tube heat exchangers, these high-performance shell&tube evaporators have some advantages:

• New grooved tubes geometry
• Delta T up to 10℃
• Optimized for variable flow operation

All are selected for R22, R407c, R134a, R404A refrigerants, and many other applications.

4. Condenser

Condensers in air-cooled screw chillers can harness the air around to cool down the hot refrigerant which flows through the tubes.

In a typical air-cooled screw chiller, the condenser will condense the hot, high-pressure refrigerant vapor flowing through the tubes to a liquid.

Then the condenser is used to lower the temperature of the refrigerant below the saturated condensing temperature, which enhances the refrigeration effect and improves system capacity eventually.

The condenser coils are usually made of copper tubes and aluminum fins and are assembled in the form of W to offer a larger heat exchange surface.

TopChiller is always using the last generation of microchannel condensing coils. They are features below advantages:

•  Long service life aluminum alloy
• Reduced refrigerant charge
• Several coating options are available

5. Expansion Valve

Expansion valves expand the refrigerant before it enters the evaporator.

Air-cooled screw chillers usually use either electronic expansion valves (EXV) or thermostatic expansion valves (TXV).

Thermal Expansion Valve

TXV is very common and it has one side attached to the pressure of the refrigerant and the other side is connected to the sensing bulb, which is installed near the outlet of the evaporator

The expansion valve reduces the pressure of the liquid refrigerant, which makes the liquid temperature getting lower.

The heat molecules inside the refrigerant can spread out when the refrigerant leaves the orifice of the expansion valve.

The liquid refrigerant gets cold under a massively reduced pressure and it will get access to the evaporator after leaving the expansion valve.

6. Cooling fan

Each air-cooled screw chiller with 6 units to 22 units of air cooling fans. These cooling fans play a very important role to spread boring heat out when the air-cooled screw chiller working.

These high-performance fans with below advantages:

• Increasing the overall installation efficiency
• Available static pressure up to 200Pa
• Variable speed brushless motor available as an option

The Difference Between Air Cooled Screw Chiller and Water Cooled Screw Chiller

Both air-cooled screw chiller and water-cooled screw chiller are composed of a compressor, an evaporator, a condenser, and an expansion valve.

They work under similar principles to finish the heat transfer but they use different components to cool the condensers.

Water-cooled screw chillers use water consumption whereas air-cooled screw chillers need air ventilation.

As mentioned above, when a chiller comes with a screw compressor, it will be named a screw chiller.

Therefore, there are screw compressors for both kinds of chillers.

However, the air-cooled screw chiller is noteworthy as it has the following advantages compared to a water-cooled screw chiller.

1. Smaller Occupation Area

When we take an air-cooled screw chiller alone, it is bigger than a water-cooled screw chiller.

However, a water-cooled screw chiller requires installing a cooling tower, pumps, and other necessary components, which will make the whole set of a water-cooled chiller take up more space.

And as a result, an air-cooled screw chiller requires a smaller area of occupation.

2. Easier Operating System

As there is no need for a water cooling system, air-cooled screw chillers have simplified the cooling system.

What’s more, the company managers do not need to hire workers to install the cooling tower, pumps, and pipes.

In a society where labor costs are getting higher, it’s a key issue to keep the daily maintenance and repair costs running low.

Without the components in water chillers, air-cooled screw chillers will bring the companies to cost savings on the labor.

3. Less Impact on Building Appearance

For most water-cooled chillers, a cooling tower is a must for a water cooling system.

The cooling tower is often installed inside the building, which not only creates a negative impact on the building’s appearance but also is disharmonious with other objects on site.

Architects oftentimes are opposed to the use of cooling towers, as they think cooling towers are harming the atmosphere inside the construction.

An air-cooled screw chiller, instead, generally will not exceed 3 meters in height and is much shorter than a cooling tower.

This is why air-cooled screw chillers are more popular in constructions where appearance is a key factor for the business.

4. Lower Cost on On-Going Maintenance

Water-cooled screw chillers are less expensive than air-cooled screw chillers in terms of product cost and operating expenses.

However, when it comes to expenses on cooling towers, water pumps, pipes, and water processing, etc.,

the investment in water-cooled screw chillers will bring fewer benefits than air-cooled screw chillers in the long run.

Let’s have a deep look at the difference between an air-cooled screw chiller and a water-cooled screw chiller:

1. The air-cooled screw chiller and water-cooled screw chiller structures comparison

The air-cooled screw chiller unit adopts air cooling mode (fan cooling); the water cooling chiller unit adopts cooling water cooling mode, and the water pump plus cooling tower and circulating pipeline cools the unit.

From the perspective of water-cooled installation, it can be divided into two types: built-in water cooling and external water cooling.

For the built-in water cooling, it is mainly composed of a radiator, a water pipe, a water pump, and a sufficient water source, which is destined that most of the water-cooling heat dissipation system has a large volume and requires a sufficient space inside the chassis.

Therefore, the air-cooled screw chiller unit only needs an air-cooled condenser or a fan.

Water-cooled screw chillers need to be equipped with cooling towers, pumps, and circulation lines. The water-cooled type from the structure is more complicated than the air-cooled type.

The air-cooled screw chiller is suitable for areas where the water source is located in a tight area.

It is more advantageous to use an air-cooled chiller unit for a refrigeration system with longer annual operating hours.

The annual comprehensive cost of the air-cooled refrigeration unit is lower than that of the water cooling system.

However, if the water cooling system is managed and the water supply is controlled below 3%, the annual cost of the water-cooled screw is lower than that of the air-cooled screw chiller.

2. Advantages and disadvantages of water-cooled and air-cooled screw chiller

Disadvantages of water-cooling chiller:

For open-type cooling circulating water system, since the cooling water absorbs heat, it is in contact with air, CO2 escapes into the air, and dissolved oxygen and turbidity increase in the water, causing four major problems in the cooling circulating water system: corrosion, knot Scale, algae breeding and sludge.

If the water quality is not treated, the refrigeration equipment will be seriously damaged, and the heat exchange efficiency will be greatly reduced, resulting in a waste of energy.

Therefore, it is very important to carry out corrosion inhibition, scale inhibition, sterilization, and algae treatment on the system water.

Disadvantages of air-cooled screw chiller:

The air-cooled screw chiller cooling capacity is slightly higher than that of the water-cooled screw chiller, but the annual comprehensive cost of the air-cooled screw chiller is slightly lower than that of the water-cooled chiller.

The results of the technical and economic analysis show that it is reasonable to configure air-cooled condensers for medium and small chiller units.

The longer the annual running time of the air-cooled screw chiller, the more favorable it is to adopt an air-cooled screw chiller.

In summary, The initial investment of an air-cooled screw chiller is relatively high, and the power consumption per unit of refrigeration capacity is also slightly higher than that of water-cooled units.

However, the annual comprehensive cost of an air-cooled screw chiller is the same as that of water-cooled units.

The longer the annual running time of the chiller, the more favorable it is to the air-cooled screw chiller unit.

The initial investment recovery period of the air-cooled screw chiller compared with the water-cooled screw chiller is shorter.

The amount of water replenishment of the water-cooled screw chiller is an important factor affecting its cost.

Strengthening maintenance management and reducing water consumption are important aspects of reducing the cost of a water-cooled screw chiller.

Industrial Applications of Air Cooled Screw Chiller

Air-cooled screw chillers are very popular refrigeration equipment that can provide steady and reliable water cooling sources for both industrial and commercial usage.

For air-cooled screw chillers used in a variety of industries for process cooling and here are some typical examples of how they can be helpful for production.

1. Printing

The printing industry involves a variety of products ranging from newspapers, postcards, to packaging goods.

Many products can be found in our daily life when it comes to paper products. Digital printing, an already thriving sector of the market and there is growing momentum for this industry.

Digital printing refers to the process of printing from a digital-based image directly to another type of media.

A picture, document, or another kind of digital format is received from a personal computer and then sent to a printing device where it’s processed and placed on any desired material.

TopChiller® air-cooled screw chillers have been serving the printing industry for years.

In the printing industry, air-cooled screw chillers are used to dissipate the heat created by the heated printing rollers in the process of friction.

Air-cooled screw chillers are also able to cool the paper when it comes out of the ink drying ovens.

Air-cooled screw chillers can help companies save costs as they can be used to control temperatures in presses and rollers to reduce the chances of stretching and bleeding.

In doing so, the production time is reduced and the manufacturer will be able to produce more printed products every day and achieve more profits.

2. Cement Cooling

Cement is usually mixed with water to form the material known as concrete whose temperature is to a great extent determined by the water used in the chemical combination of cement aggregates and water.

Most of the application is for batching plants and other cement plants.

In the meantime, water gets more quickly evaporated at higher temperatures and if the temperature of the concrete is too high, more water will be evaporated.

Therefore, concrete cooling is required to cool the water before hydration.

TopChiller® air-cooled screw chillers are the perfect choice to regulate the temperatures of the concrete and ensure that problems will not arise from hot concrete.

Temperature-controlled concrete is required for the large-volume pouring of viaducts.

Large hydropower dams, nuclear power, and high-rise building foundations.

During the concrete mixing process, the internal volume of the concrete hydration heat increases, especially the heat generated by the stirring under high-temperature conditions is higher.

In the subsequent curing or low temperature, the interior of the concrete will be caused by thermal expansion and contraction.

The volume is reduced, and cracks usually occur in this process.

Therefore, the initial pouring temperature of the concrete should be low, reaching the limit temperature of the building design unit, thus ensuring the quality of the project.

In this condition, you must install the air-cooled screw chiller for your cement plant.

Coldwater from the air-cooled screw chiller is used in the construction to cool the concrete.

3. Plasma Cutting

Plasma cutting is used on different kinds of materials such as aluminum and stainless steel.

In plasma cutting, the plasma cutting torch is a big heat source as it’s usually the power leads, which contained a metal cable inside and the cable can conduct a great amount of electrical current.

A lot of heat will be generated and the heat has to be removed to prevent the hoses from melting.

The air-cooled screw chillers supplied by TopChiller® are a suitable water cooling partner for plasma cutting machines.

An air-cooled screw chiller can control the temperatures of the production devices and keep the cutter at the required temperature all the time to secure the quality of the products coming out of the machines.

4. Plastic machinery

Plastic machinery is also another important application for air-cooled screw chillers.

Air-cooled screw chillers are also widely used in plastic processing and plastic machinery including plastic injection molding, plastic extruders, and extrusion lines, blowing molding machines.

The function of using an air-cooled screw chiller is to provide the cooling water flow rate for cooling the plastic mold temperature down to make sure the product quality and production efficiency.

TECHNICAL, INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS

1. SUMMARY
Air Cooled Screw Chillers are the products developed by Shenzhen TopChiller Co. Ltd.

Air-cooled screw chiller series models adopt Bitzer brand semi-hermetic screw type compressor, famous refrigeration parts, and electrical control elements from the world.

These series air-cooled screw chiller have features of impact design, reliable control systems, economical and flexible installation.

The computer control system increases precision and reliability. It may regulate energy multi-steps to make output cooling energy to best match practical running load.

Therefore this air-cooled screw chiller runs in the best economical state. Pre-set operating mode and program realize the air-cooled screw chiller to run in energy-saving all the time.

The computer may also connect the network system to realize building management control automatically.

An air-cooled screw chiller having an integrity structure saves the cooling tower and reduces construction investment.

It is suitable for various hotels, shopping centers, and office buildings central air conditioning systems and textile industrial, chemical industrial, metallurgy industrial, pharmacy and electrical power, etc.

2. WORKING PRINCIPLE AND TECHNICAL DATA IN AIR-COOLED SCREW CHILLER

2.1 WORKING PRINCIPLE OF AIR-COOLED SCREW CHILLER
Cooling circulating compressor absorbs low-pressure, over-heated refrigerant gasify from dry type evaporator and changes the refrigerant into high-temperature.

High-pressure, over-heated refrigerant gasify, and radiates heat energy into ambient, then refrigerant is condensed into the liquid status and passes by the expansion valve.

After throttling refrigerant drops pressure, then goes into dry type evaporator to absorb heat energy and is absorbed by compressor again to finish one circulation.

Cooling system working principle of series air-cooled screw chiller shows as an appendix:

Air-cooled screw chiller is an integrity structure with modular structure design, condenser upside-down M layout.

The screw compressor, dry type evaporator, receiver, cooling pipes, and accessories arrange on steel foundation uniform.

The electrical control box is at one end of the unit, the flange connector for the refrigerant inlet locates the side of the machine.

The shell of the air-cooled screw chiller is made of high strength pained steel plate with a nice look and long service life.

Please note the air-cooled screw chiller is suitable for outdoor installation in atrocious weather.

The side of the unit has high/low-pressure meters, a semi-piston type compressor has an oil-pressure gauge.

2.2THE FEATURES OF THE AIR-COOLED SCREW CHILLER

2.2.1Wide capacity range:
1)The various air-cooled screw chiller with a range of cooling capacities from 180KW – 1730KW;

2)Each screw circuit has cooling only and cooling (heating) type;

3)Air-cooled screw chillers are integrity and optional modular structure;

4)Each air-cooled screw chiller circuit has a regular computer control type and luxury computer control type;

5)Provide optional components of the auxiliary electrical heater, build-in water pump, and paddle flow switch, etc. according to customer requirements.

6)The air-cooled screw chiller may use no-standard refrigerant.

It may be low water temperature type glycol for air-cooled screw chiller, or double refrigerant unit, air-cooled compress condensing unit, etc. Please contact us for details.

2.2.2The air-cooled screw chiller has high efficiency, less energy consumption, and low operating fee features.

TopChiller imports brand high EER semi-hermetic crew type compressor ( Handbell or Fusheng as standard), Bitzer from Germany are also available. Condenser, and cooling accessories from the world and adopt advanced technology in air conditioning and control.

High-quality process equipment and testing center to ensure the air-cooled screw chiller has energy-saving and reliable features.

2.2.3Air cooled screw chiller protection components
The air-cooled screw chillers have a thermal protection switch, overload relay, high/low-pressure switch, paddle flow switch, and delay-starting protection devices to ensure the unit runs under safety, reliable working condition and unit are easy to maintain and repair.

2.2.4Optional modular design
Multi-modular air-cooled screw chillers adopt module combined structure to increase the screw chiller’s flexibility in transportation, installation, adjustment, and maintenance and reduce the fee for transportation, installation, and air-cooled screw chiller maintenance.

2.2.5Super low noise, operating quietly. And optional low noise cabinet for screw compressor
1)A semi-hermetic screw compressor has operating steady, low noise, and fewer vibration features.

2)A brand condensing axial fan is used in the screw chiller unit. The blades and exterior rotor motor are designed integrally.

The structure of the air-cooled screw chiller is simple with good air dynamic features and to ensure the fan works under low noise and high efficiency.

2.2.6 Advance control system, steady quality, and reliable features.
1)Micro-computer control intelligently, English display, and friendly interface. Operating information is clear at a glance.

2)High automatic management with complete features to realize unit start-up and shut down, timing control, water pump control, malfunction alarm, and self-diagnosis features.

The air-cooled screw chiller has an optional RS485/RS232 communication port and convenience for centralizing controlling and lone distance monitoring and long-distance control.

3)Micro-computer and electrical control elements are brand products and imported from the world. The air-cooled screw chiller has good quality and reliable features.

4)Micro-computer controller defrosts intelligently with accuracy and efficiency.

The controller of the air-cooled screw chiller also has self-diagnosis, energy management; anti-freeze, and operating mode automatic control abilities.

The air-cooled screw chiller has protections of high/low pressure, anti-freeze, oil temperature, overload, phase sequence, and water lacking to ensure unit run safety.

2.2.7Nice outline
1)Air-cooled condenser of this screw chiller with upside-down M shape layout to improve space using ratio, heat exchange area of an air-cooled condenser and to reduce the unit overall size.

2)The air-cooled screw chiller components and system pipes layout is reasonable.

3)The shell of the air-cooled screw chiller is pained with static treatment.

The color of the shell may design by the customer when the order is placed. The stainless steel plate is also available for the shell.

2.2.8Save outdoor space.
1)The air-cooled screw chiller may install on the roof of the building, ground, or other location, where does not need the equipment room.

2)This air-cooled screw chiller uses a highly efficient heat exchanger. It adopts outdoor structure design and system matching with small volume, lightweight, and less area occupied.

2.2.9Easy to maintenance
1)The installation of the air-cooled screw chiller is flexible. It can control at the job site and long-distance

2)Air cooled screw chiller with a pen-type structure is convenient for maintenance and reduces service space.

2.3TECHNICAL DESCRIPTION OF AIR-COOLED SCREW CHILLER

2.3.1Refrigerant: R22/R134a/R407c

2.3.2Nominal cooling working condition:
1)Condenser inlet temperature DB 35 ℃, WD 24 ℃.
2)Evaporator inlet temperature 12℃, outlet temperature 7 ℃

2.3.3Nominal heating working condition:
1)Condenser inlet temperature DB 7 ℃, WD 6 ℃.
2)Evaporator inlet temperature 40℃, outlet temperature 45 ℃

2.3.4Fin type air-cooled condenser
1)Fin type air-cooled condenser adopts imported high purely, seamless screw thread copper and special aluminum fin after mechanical expanding joint closely. It ensures fin-type condenser work in the best efficiency.

2.3.5Tube in tube type evaporator
1)It is a tube-in tube structure with newly developed fire-proof and water-proof material as heat preservation. The water-side working pressure may reach 2.0 MPa.
2)There is PVC engineering plastic breakwater inside of the evaporator with strong anti-corrosion ability. Chilling water circuitous goes up and down to increase tumble effect, and heat exchangeability.
3)Adopt new technology DAC weave interior screw threat, high efficient heat exchange tube to ensure good cooling characters.

2.3.6Semi-hermetic screw compressor
The air-cooled screw chiller uses an imported semi-hermetic screw-type compressor.

Comparing piston and scroll type compressors, the semi-hermetic screw type compressor has the following advantages:
1)Fewer accessories (Approximately 1/3 of piston compressor). The unit structure is a simple and long service life).
2)The unit EER ≥3.1W/W;
3)Screw type compressor may adjust the energy in the range of 25% – 100%. this is for energy-saving consideration

2.3.7Four-way valve
TopChiller air-cooled screw chiller adopts a famous four-way valve-like PE, so that solves reversing and system consume great problem exists in other same kinds of products.

2.3.8Condenser
1)Axial fan, protection grade reached IP55. long service ling and reliable.
2)External rotator and blades combined into integrity. Design compact, run in high speed and low noise.

2.3.9 Optional Heat recovery functions for free-living hot water
1) Partial heat recovery for free hot water.
2) Total heat recovery with multi-functions, and could be controlled.

F1 – F2 = Energy correction coefficient
FP1 – FP2 = Compressor power input correction coefficient
The performance data given refer to conditions with clean heat exchangers (fouling factor =1).

For different fouling factors, unit performances should be corrected with the correction factors shown above.

ETHYLENE GLYCOL SOLUTIONS
The use of ethylene glycol mixtures is intended to prevent freezing in air-cooled screw chiller heat exchangers.

The use of low freezing point mixtures causes a modification in the main thermodynamic properties of the units.

The major parameters affected by the use of glycol mixtures are the following:

Cooling capacity
Power input
Mixture flow
Pressure drop
In the table below are reported correction factors referred to the most common ethylene glycol mixtures.

CALCULATION EXAMPLE OF YOUR AIR-COOLED SCREW CHILLER
An example can help to use properly the coefficients reported in the table.
Suppose that a single air-cooled screw chiller presents the following performances at the nominal working conditions:

With a 30% glycol mixture these parameters will change to the following values, according to the correction factors:

CALCULATION EXAMPLE
Suppose that for a single unit performances should be required at the following conditions:
– Evap. in/out water temperature: 0/-4 °C
– Glycol: 30%
– Ambient temperature: 35 °C
For such a unit nominal performance (inlet/outlet water temp. 12/7 °C, ambient temperature 35 °C) are:
Cooling capacity: 184.9kW
Input power: 58.4 kW

Performances at the required conditions can be calculated as follows:
1st step:
Performances are calculated without taking into account the use of glycol mixtures.
Cooling capacity: 184.9×0.459 = 84.87kW
Input power: 58.4×0.774 = 45.2 kW

2nd step:
The use of glycol mixtures is taken into account (please refer to glycol correction factor tables). In our case we have (30% glycol):
Cooling capacity: 84.87x 0.973 =82.58kW
Input power: 45.2×0.990 = 44.75 kW

5. Air Cooled Screw Chiller Dimension and foundation size recommended

6. ELECTRICAL CONTROL SYSTEM THEORY OF AIR-COOLED SCREW CHILLER
The electrical control system controls the cooling system by the thermal sensor.

Electrical protection devices and alarm systems act to monitor, protect, and alarm.
The electrical control system sees electrical drawings and
System wiring refers to wiring suggestions (Appendix 2) for detail.

7. INSTALLATION OF AIR-COOLED SCREW CHILLER
To act safely and avoid malfunction occurring, air-cooled screw chiller installation must be implemented by an experienced technician and carefully read the manual before installation.

7.1CHECK AND ACCEPT
After arriving, the user should check your air-cooled screw chillers as following documents

7.1.1 Random check if the package has documents below.
a. Certification. b. User manual. c. Warranty card. d. Package list

7.1.2Check the model, specifications, and accessories according to the packing list.

7.1.3Check if there is any damage or any missing accessories.

7.1.4Check if refrigerant leaks.
If there is any problem or question with your air-cooled screw chiller, please contact TopChiller or an agent right now, therefore the problem can be fixed as soon as possible.
Note: Please don‘t open the package of the unit until installation avoiding your screw chiller being damaged.

7.2TRANSPORTATION
Every air-cooled screw chiller passed strict inspection and testing to ensure performance and quality.

The user has to pay attention to handling the air-cooled screw to avoid damage caused by installation and transportation.

We advise the air-cooled screw chiller should be placed in the location where near the installing destination before unpackaging it. This air-cooled screw chiller should be placed upward, then transit unpackaged accessories.

7.2.1Lift hook
The air-cooled screw chiller has to be handled by a professional logistic company.

The handling method recommends below: Using two slings on the top of this screw chiller to support the steel cable preventing panel damage.

The intensity of the steel cable must be 3-times intensity more than the total weight of the unit. It doesn’t allow anyone to stay under the unit during the lifting hook.

The weight of the air-cooled screw chiller is on the nameplate.

Please refer to the figure below for the handling method.

7.1.2Installation of air-cooled screw chiller
1)Location and foundation (Foundation drawing as above)
The air-cooled chiller is an outdoor installation. It should be installed on the level up to the roof, ground, or other available places.

The foundation supporting should be two parallel U-steel or I-steel and installed on a flat base.

2)The space for maintenance and ventilation
This air-cooled screw chiller should have good ventilation. The minimum distance between objects should be equal to or greater than 1.5 meters.

Herringbone shed May be built up 2 meters high from the highest point of your air-cooled screw chiller if it allows.

7.3COOLING WATER SYSTEM (REFER APPENDIX III)
Each jointer of the pipe has a label. Please connect it according to the label.

7.3.1All pipes have to place jointer or flanges to the location where nearest the unit, so that uninstall easily when necessary.

7.3.2The connector of the cooling water inlet and outlet should use a vibration absorbs connector to avoid the machine’s vibration and pipe system damage.

7.3.3Water pipe system should install a paddle flow switch and interlock with compressor control to ensure enough water flow.

7.3.4Turn on the cooling water inlet/outlet valve and check if there is any leakage in the cooling system. In addition, there should be a discharge water valve at the water inlet, and a discharge air valve at the water outlet.

The air-cooled screw chiller is running, the valve handler has to be taken away to ensure the valve doesn’t close by mistake.

If the discharge water valve is open while the unit is running, the accident will occur with no water.

7.3.5Cooling water pipes have to be heat-preservation to avoid condensing water generated.

7.3.6The unit operation has to follow manual especially in the area where the temperature is below zero in winter.

1)Air cooled screw chiller is cooling only in summer and shut down in winter. After the unit shutdown, the water inside of the water pipe has to be discharged completely from the pipe avoiding pipe freeze to broken

2)If Air cooled screw chiller is a heat pump-type unit. If it works in heating only during day time and the water pump should be kept running at nigh.

It may work in heating mode at night according to water temperature to prevent the unit can not start up because of low water temperature. The anti-freeze precaution has to be taken in the chilling area.

3)In the area where the ambient temperature is below – 5℃, this air-cooled screw chiller should install an auxiliary water heater to endure the unit’s reliability.

4)In the area where the ambient temperature is below -10℃, It is not suitable to use a heat pump type chiller because of the low heating efficiency of the heat pump.

7.4WATER QUALITY CONTROL
Industrial water as a cooling water source has less furring.

The well water or river water as a cooling water source has more furring and even deposit as sand, etc., these can cause water flow reducing and freeze accidents in the evaporator, and so cooling water has to pass filter and soft by chemical substance before going into the cooling system.

The PH value, conductivity, chlorine ion, and sulfur ion have to meet TopChiller standard requirements.

The water purity standard
PH 6.5-8.0
Conductivity ≤200uv/cm（25°）
chlorine ion ≤50ppm
vitriol ion ≤50ppm
Total iron ≤0.3ppm
Alkali ion ≤50ppm
Total hardness ≤50ppm
sulfur ion None
Ammonia ion None
Sand ≤30ppm
Sodium-ion None

NOTE:
(1)Please not install this air-cooled screw chiller indoor. If you have to install it indoors, the minimum distance from the ceiling to the vent has to be equal to or greater than 1.5 meters, and enough airflow.

(2)The refrigerant charged is R22. It is no-flammable, no poison substance. Because the special gravity of R22 is heavy than air, it will spread and may cause people to strangle if leakage occurs. So good ventilation has to implement if your air-cooled screw chiller is indoor.

(3)If leakage occurs, stop the air-cooled screw chiller immediately, and contact repairing personnel. It forbids any lighter on the site. Because if R22 touches lighter, it will spread harmful gas.

(4)The air-cooled screw chiller has to be reliable grounded; the wiring has to be correct, tight.

8. TESTING-RUN AND ADJUSTMENT

8.1INSPECTION BEFORE RUNNING
Before adjusting the air-cooled screw chiller, TopChiller personnel have to regularly check the chiller unit and accessories to ensure unit quality. The check items refer to the below items.

8.1.1Inspection
Debugging personnel should check items according to sheet 1, if there is any unqualified item, modify it before entering the adjusting program.

8.1.2Water system operating
After time after time cleaning the water system and water quality meets the requirement, turn on two service valves that connect to the air-cooled screw chiller.

Filling water one more time, discharge it, and then switch on the water pump, confirm outlet pressure of water flow.

8.1.3The air-cooled screw chiller simulating the operation
If the condition of the air breaker of the compressor and the condenser is off, refer to the electrical principle drawing and < Electrical usage instruction >，tests actions on electrical parts and control logic (Note: If phase sequence error, the unit can not startup).

8.2TESTING-RUN
Under item

（1）normal condition, the test-run may take and method is as below.

8.2.1Adjust the cooling system flow valve carefully (or the unit inlet service valve), to make system water flow be 90% of water flow required by the nameplate on the unit.

8.2.2Switch on-air breaker of compressor and condenser, modify the setting-up value for temperature, after pressing the “ON/OFF” key (switch on/off key), the unit displays “On” state and then start the unit up.

If a malfunction occurs, the air-cooled screw chiller will shut down and display a malfunction message.

8.2.3Test and record items according to contents in sheet 3. If any abnormal occurs, press emergency off-key quickly to stop running (note: normal shutdown the unit does not allow to press this button). After analysis of the problem, do this procedure again.

8.2.4After testing-run 15 minutes, observe sigh glass and check if it is blue color, is an air bubble or steam, it does, please add refrigerant R22.

8.2.5After testing-run 30 minutes, the water temperature at the outlet reaches to prescriptive value, adjust the water flow to a nominal value, then set up outlet temper and dynamic different according to user load, and system actual instance to ensure the unit operates normally.

After the air-cooled screw chiller stops, wait for 10 minutes to restart.

The air-cooled screw chiller can not start and stop frequently.

Finally, check controllers setting values of the screw chiller t to finish the testing and inspecting.

Warning!
1)When cleaning the water system, the impurity water does not allow it to go into the dry-type evaporator. Please turn off the inlet valve of your air-cooled screw chiller, and turn on the outlet valve when cleaning the water system.

2)Before discharging water from the water system, your air-cooled screw chiller forbids starting up.

3)Water pump and paddle flow switch have to be interlocked, otherwise, the user takes full responsibility for any problem that occurs by lacking water.

4)During the test run, the interval of the unit has to be longer than 4 minutes.

9. Operating and maintenance
For ensuring the unit running for a long period, the air-cooled screw chiller should be tested and adjusted by TopChiller professional personnel or skills technicians under TopChillert’s expertise supervising daily operation and maintenance has to be done by trained air conditioning technicians.
The operator has to pay attention to the following components.

TYPE AND FREQUENCY OF SCHEDULED MAINTENANCE
All maintenance operations must be done by experienced personnel, qualified to work with conditioning and cooling systems.

Always switch off the air-cooled screw chiller to cut off the power supply before any maintenance work, even if the only inspection is involved.

To guarantee regular, efficient air-cooled screw chiller operation, it is advisable to schedule an overall inspection at regular intervals, to prevent irregular functioning which could damage the machine’s main components

PERIODIC CHECKS LIST

9.1MAIN ACCESSORIES
9.1.1Compressor: Observe discharge pressure, absorb pressure, oil supply pressure, and oil level, etc, If anything is abnormal, find out the problem, fix it.

The frequency of the screw chiller start and stop should be less than 6 times per hour, and each time the air-cooled screw chiller starts and run should be 5 minutes and more.

9.1.2Oil pressure difference control’s reliability ( for semi-hermetic piston-type compressor)。

9.1.3Electrical equipment: should be attention to working voltage, current, and phase sequence. For the contactors, check wire connectors, and see if there is an oxide or other reason to cause the problem.

9.1.4Control and protecting equipment: Don’t adjust any setting value at the job site.

9.1.5Regular check electrical wiring, if find out any loose connector, tight it up to the right way.

9.1.6Regular check electrical components, if find out any unreliable parts, replace right way.

9.1.7Pay attention to the electrical control box at any time for heating, It should have good ventilation. If the wire becomes aging, change it in time.

9.2LUBRICATION
The compressor has been filled with lubrication before leaving the factory.
9.2.1The operator has to monitor the oil level from the sight glass while the unit is running, Oil level has to be above the bottom of the sight glass; after shutting the unit down, the oil level should be above the middle of the sight glass.

9.2.2Every spring and fall is the maintenance season. if find oil color becomes black, or copper pieces in the oil, oxygenated impurity, the lubricating oil must be replaced with the same model after cleaning the oil filter, and bottom of the oil tank.

This job should be done under TopChiller’s expertise guide.

9.2.3When cleaning the oil filter should also clean the magnet which is under the oil tray.

9.3CLEANING DIRTY
After a long period of running, the inside of the pipe in the dry-type evaporator is accumulated calcium oxide or other mine substance. It conducts electrical consumption increase, discharge air pressure rising, and absorb pressure dropping.

9.4SHUT THE UNIT DOWN IN WINTER
When shutting your air-cooled screw chiller down in winter, the air-cooled screw chiller should be clean from inside or outside.

Refrigerant should be sucked into the condenser and then close the inlet gas valve and outlet liquid valves.

Cover your air-cooled screw chiller up to prevent dust, and make sure to tighten the pressure covers, valve nuts, and screw off the discharge water nuts.

In the ice-freezing area in winter, the water has to be completely discharged from the condenser to avoid freeze to split accidents.

9.5START THE UNIT IN SPRING
After a long period of the air-cooled screw chiller shutdown, the following preparation work has to be done first before restarting this air-cooled screw chiller unit.

6.5.1Inspect and clean your screw chiller completely

6.5.2Clean water pipeline

6.5.3Inspect pump, cooling tower, and adjustment valve

6.5.4Tighten all wiring connectors tightly

Note：
If the air-cooled screw chiller had been shut down for a long time, it should pre-heat compressor oil 24 hours before its startup.

Pre-heat time for lubrication of the compressor according to weather and ambient environment, but preheat time cannot be less than 12 hours.

9.6REPLACE PARTS
The replaced parts should be TopChiller’s parts; it does not allow to use of other manufacturer’s parts instead without TopChillert’s permission

9.7COOLING SYSTEM
6.7.1Filter net: Please check the absorbing filter net and make sure it doesn’t block when turning on the cooling system.

6.7.2Filling Refrigerant: When filling refrigerant, observe sucking and discharging pressure from sight glass. If there is any leakage, or replace the parts, air-seal testing is required. Filling refrigerants should be treated in two ways.

1)Because of leaking, there is no refrigerant left. Before filling refrigerant,
2)The cooling system has to be dry and vacuumed completely.
Turn on all valves.
Connect the vacuum between low pressure and high pressure.
The whole system is vacuumed by a vacuum pump.
The proper refrigerant amount and main technical data are shown on the nameplate. The refrigerant filling uses refrigerant filler.
The refrigerant filled by weight may be affected by ambient temperature. In this case, turn off the fluorine container valve temperately temporarily, let cooling water circulate in the evaporator, and startup the unit, at the same time, short-circuit the low-pressure controller temporarily.
Note: After filling refrigerant, re-connect wires back to normal!

3)Filling refrigerant
The refrigerant filler is connected to the low-pressure side filling connector, and connect the pressure gauge at low pressure and high-pressure side.
Make cooling water circulating, and startup the unit, short-circuit controller if necessary.
Slowly fill refrigerant into system, monitor absorb, discharge pressure value. The open degree of filling fluor in the valve should be in pressure between 0.15-0.2Mpa, It doesn’t allow to open completely.

Warning!
When inspecting leakage and airtight test, it forbids filling oxygen, ethane, etc., burnable or poisoned gas. This kind of gas may cause an explosion or dangerous situation.

9.8UNINSTALL COMPRESSOR
Please follow the below steps for uninstall.
6.8.1Turn off your air-cooled screw chiller power supply switch;
6.8.2Turn off service valves of the inlet and outlet of the compressor.
6.8.3Take off the connecting bolts of sucking, discharging flanges of the compressor
6.8.4Take off the power supply cable connection.
6.8.5Take off the fixing bolts of the compressor.
6.8.6Remove away the compressor.

9.9SYSTEM ANTI-FREEZE
If the heat exchanger of the evaporator or pipes freezes to break, it will result in serious leaking. This kind of damage is not on the guarantee. The user has to pay attention to three things.

6.9.1The air-cooled screw chiller stops and backups in low ambient temperature.

6.9.2If the temperature of the outdoor is below 0℃, the water in the evaporator should be discharged completely.

6.9.3The air-cooled screw chiller is operating
If the cooling water flow switch and low-pressure protection are unavailable, the water pipe may freeze. So that cooling water flow switch and unit control system should be interlocked.

6.9.4Maintenance
When the system pressure is under 0.4Mpa, the pipe freeze may occur, so the water in the system should be flow or discharge water completely.

Note:
1)Maintenance regularly
Your air-cooled screw chiller should be maintained regularly to ensure the unit operating in a good state.
2)Fireproofing
If there is a fire, the main switch should be off, use a fire extinguisher.
3)Prevent flammable gas.
The installation site of your air-cooled screw chiller should be far away from gasoline, alcohol, oil-made production, etc. flammable gas to avoid an explosion.
4)Operation panel and electrical control box
The operation panel is installed inside the electrical box. When operating, need to open the control box cover first. Be careful to avoid electrical shock.
5)Please don’t touch the discharge pipe avoiding to be burned. The temperature may reach 100℃ and higher.
(1)Don’t cool or heat the drink water and food.
(2)Malfunction
If there is any malfunction occurs, find out the cause first, and then restart the unit. In addition, if your air-cooled screw chiller has abnormal vibration and noise, please stop this screw chiller right away, find out the cause.
(3)Insurance
The fuse has to use in the allowed range, it forbids to use of iron wire or copper wire instead of fuse.
(4)Protection equipment
Don’t short-circuit the protected air-cooled screw chiller, otherwise, It will cause serious problems.
(5)The setting value has been set up before the unit delivery to users. The users don’t change it, otherwise, it will cause serious problems. Don’t touch any electrical components except the switch includes an emergency switch.
(6)The air-cooled screw chiller should manage by skilled air condition operators. Record relative data and analyze it to judge the operating situation.

10Malfunction analysis and trouble-shooting
Main malfunction and trouble-shooting of air-cooled screw chiller:

11. Warranty

24-months warranty time – for air-cooled screw chiller is warranted to be free from defects in material and workmanship.

If the defect appears within 24 months from the date of original installation, whether or not actual use begins on that date, then the product does meet this warranty.

A new or remanufactured part, at the manufacturer’s sole option, to replace any defective part will be provided without charge for the part itself; PROVIDED the defective part is returned to the distributor through a qualified servicing dealer.

THIS WARRANTY DOES NOT INCLUDE LABOR OR OTHER COSTS incurred for diagnosing, repairing, removing, installing, shipping, servicing, or handling of either defective parts or replacement parts. Such costs may be covered by a separate warranty provided by the installer.

THIS WARRANTY APPLIES ONLY TO PRODUCTS IN THEIR ORIGINAL INSTALLATION LOCATION AND BECOMES VOID UPON REINSTALLATION.

LIMITATIONS OF WARRANTIES – ALL IMPLIED WARRANTIES (INCLUDING IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY) ARE HEREBY LIMITED IN DURATION TO THE PERIOD FOR WHICH THE LIMITED WARRANTY IS GIVEN. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE MAY NOT APPLY TO YOU. THE EXPRESSED WARRANTIES MADE IN THIS WARRANTY ARE EXCLUSIVE AND MAY NOT BE ALTERED,
ENLARGED, OR CHANGED BY ANY DISTRIBUTOR, DEALER, OR OTHER PERSON
WHATSOEVER.

ALL WORK UNDER THE TERMS OF THIS WARRANTY SHALL BE PERFORMED DURING NORMAL WORKING HOURS. ALL REPLACEMENT PARTS, WHETHER NEW OR REMANUFACTURED, ASSUME AS THEIR WARRANTY PERIOD ONLY THE REMAINING PERIOD OF THIS WARRANTY.

THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR:
1. Normal maintenance as outlined in the installation and servicing instructions or owners manual including filter cleaning and/or replacement and lubrication.

2. Damage or repairs required as a consequence of faulty installation, misapplication, abuse, improper servicing, unauthorized alteration, or improper operation.

3. Failure to start due to voltage conditions, blown fuses, open circuit breakers, or other damages due to the inadequacy or interruption of electrical service.

4. Damage as a result of floods, winds, fires, lightning, accidents, corrosive environments, or other conditions beyond the control of the Manufacturer.

5. Parts not supplied or designated by the Manufacturer, or damages resulting from their use.

6. Electricity or fuel costs or increases in electricity or fuel costs from any reason whatsoever including additional or unusual use of supplemental electric heat.

7. ANY SPECIAL INDIRECT OR CONSEQUENTIAL PROPERTY OR COMMERCIAL
DAMAGE OF ANY NATURE WHATSOEVER. Some states do not allow the exclusion of incidental or consequential damages, so the above may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which may vary from area to area.

Why TopChiller® Can Be a Reliable Supplier for Air Cooled Screw Chillers?

1. Premium Quality and Excellent Performance of all models of air-cooled screw chillers

TopChiller® Air Cooled Screw Chillers are aimed to optimize the energy efficiency of the target devices.

And the use of such chillers will reduce operating costs and improve business profitability, effectiveness, and energy conversation.

By employing a semi-hermetic dual screw compressor, TopChiller®’s air-cooled screw chillers are energy-efficient and able to regulate energy performance levels from 0% to 100% for maximum electricity savings.

Working at high noise levels will affect the health of the workers and more and more employees opt for a quiet environment to work in.

It’s also crucial that companies should focus on noise reduction, especially in sound-sensitive workplaces.

With single main rotors and mufflers built inside, TopChiller® air-cooled screw chillers can reduce sound levels and vibration to the minimum when they are either running at part load or full load conditions.

2. A Comprehensive Range of Services

Since the air-cooled screw chillers are daily used in various industrial processes, it’s extremely important to ensure the chiller is operating normally.

If your air-cooled screw chiller gets out of order, it might result in a critical decrease in cooling capacity and even economic damages.

For each air-cooled screw chiller purchased from TopChiller®, its quality must be carefully checked before shipment to ensure the client will receive a satisfying chiller.

In the meantime, TopChiller® also provides a comprehensive range of services for pre-sales questions and after-sales issues, covering everything from product inquiries to maintenance support.

All clients can still expect professional and personal care and reliable services from our support team at any time.

TopChiller® has served customers from over 58 countries and regions. All of our air-cooled screw chillers come with a 24-month warranty and we are always to offer lifetime technical support to our valued clients.

Air Cooled Screw Chiller Technical Specifications

3. Certifications and Awards

All air-cooled screw chillers manufactured by TopChiller® are CE marked and comply with standards products sold in Europe.

In China, TopChiller® also earned a series of awards conferred by the government for energy-saving and technology innovation.

4. Customizable air-cooled screw chillers

As there are many industries and each industry may require air-cooled screw chillers of specific sizes and cooling capacities.

It’s very important to check if there is a standard air-cooled screw chiller model that just can meet your requirements and achieve maximum profitability for the production process.

At TopChiller®, we provide a wide range of air-cooled screw chillers and screw chillers also come with various specifications for the customers to choose from.

If you have a custom request for a nonstandard air-cooled screw chiller that can’t be found on our website, please contact us right away and we would be more than happy to help.

5. Fast delivery and careful shipment

If you purchase an air-cooled screw chiller from TopChiller, we give very fast delivery because for some often used or commonly used chiller models, we have stocks in our warehouse.

Even if the customized air-cooled screw chiller is based on your specific requirements, we also have all ready screw chiller spare parts.

The above ensures we can give you very quick delivery of your air-cooled screw chiller.

We always care about the shipment of your air-cooled screw chiller, please check below container loading of 200Ton air cooled screw chiller into 1*40HQ to Singapore seaport.

Conclusion

TopChiller® is committed to sustainable development and the concept has been integrated into our corporate culture.

The air-cooled screw chillers supplied by TopChiller® are energy efficient and suitable for printing, cement cooling, plasma cutting, and many other industrial applications.

The cooling capacity of our premium air-cooled screw chillers ranges from 30 Ton to 550 Ton and their operating sound levels are very low in all conditions.

TopChiller® air-cooled screw chillers are widely used by all kinds of industrial companies all over the world.

If your current chiller shows signs of aging and you are considering replacement, we are confident that you will find using our screw chillers will help you a lot with production efficiency and cost reduction.

With 20 years of experience in air-cooled screw chiller manufacturing, TopChiller is willing to provide all technical support to clients worldwide.

If you are searching for a high-quality air-cooled screw chiller manufacturer, Please do contact the TopChiller team to get an ultimate air-cooled screw chiller solution.

Air Cooled Screw Chiller-The Ultimate FAQ Guide by TopChiller

Obtaining an energy-efficient cooling system is essential to deal with the excess heat production in industries and buildings.

An Air Cooled Screw Chiller provides a cooling effect to the high-energy releasing industrial processes using mainly water.

The excess heat released from various industrial devices is essential to eliminate. Mostly, complex industries require installing such cooling systems for maintaining the temperature changes.

For better results, it is essential to understand the construction, working, applications, and maintenance of your chilling system.

Also, having good knowledge about how you can increase the efficiency of your Air Cooled Screw Chiller is essential to obtain the best results.

Hopefully, this guide will be helpful enough in providing detailed information about an Air Cooled Screw Chiller.

What is an Air-Cooled Screw Chiller?

The Air Cooled Screw Chiller is a closed refrigeration device that cools the heat produced by various machines, commonly used in different ads, as well as in industrial settings.

Air Cooled Screw Chiller is available in a variety of models and designs. This provides buyers with the best option for selecting the best one for their specific professional setup.

Air Cooled Screw Chiller is extremely powerful, lightweight, easy to use, high in demand, and is helpful to all systems.

Air Cooled Screw Chiller is used in a wide range of applications, including corporate offices, manufacturing plants, large construction sites, and any type of corporate or sporting event.

Air Cooled Screw Chiller Designed by TopChiller

What are the Components of Air Cooled Screw Chiller?

Air Cooled Screw Chiller system has an evaporator, expansion valve, refrigerant, internal piping, and controls, much like every other chilling system.

Air Cooled Screw Chiller is defined by their compressors, which use two helical rotors to propel and compress the refrigerant gas. Also, uses an electric motor, steam, or gas turbines to provide nearly constant flow output.

Moreover has a capacity range of 25 to 800 tones and acts most efficient when used with liquids that evaporate at higher temperatures.

In the construction of this unit, the screw, or helical compressor, is made up of two helical curved rotors: male lobes and female gullies. They’re contained in a stationary casing and switch at the same time.

The refrigerant gas is compressed and converted into gas as they rotate due to direct volume reduction between the two rotors.

The length of the compression path can be adjusted with a sliding vane on these compressors. Suction, compression, and discharge all happen in one straight line.

On the rotors, an oil lubricant also serves as a sealant. As the refrigerant flows through holes, the screw acts as a liquid separator, cooling the engine.

An Air Cooled Screw Chiller must be properly sized to work properly.

An Air Cooled Screw Chiller has long anti-recycle cycles and will shut down if there is no demand for cooling. This can also happen if the motors are open drive or running at fast, unnecessary speeds.

An Air Cooled Screw Chiller, on the other hand, can be reliable and effective for a variety of industrial and air conditioning applications when properly configured.

Air Cooled Screw Chiller Compressor

3. What are the Features of an Air-Cooled Screw Chiller?

• A high-performance compressor from a specialist manufacturer is used to ensure that the Air Cooled Screw Chiller is cost-effective and long-lasting, with minimal vibration and noise.
• A highly integrated motherboard is used, resulting in a powerful and reliable operation.
• An advanced control algorithm is used to properly control and prevent any stoppages in the working of this chilling system.
• To ensure that the operation is safe and efficient, a full safety security function is included.

• The peripheral equipment’s linkage control and remote monitoring functions ensure that it can operate safely and that operation and monitoring are easy.
• Choosing high-quality raw materials and fittings is crucial to ensure the amazing quality of an Air Cooled Screw Chiller.

4. What is the Difference Between Water Cooled Screw Chiller and an Air Cooled Screw Chiller

The condenser of an Air-Cooled Screw Chiller is cooled by the ambient air.

Moreover, it is typically used in small or medium-sized installations, but recent improvements in construction have enabled them to be used in large installations as well, in the form of modular Air Cooled Screw Chiller.

When there isn’t enough water or the water is extremely costly, an Air Cooled Screw Chiller is preferred.

Water Cooled Screw Chiller has a water-cooled condenser that is attached to a cooling tower and is typically used in medium and wide installations where water is available.

Furthermore, they are favored in situations where the system’s output must be consistent, regardless of the outside temperature (industrial air conditioning, air conditioning of digital systems, etc.

Since ambient temperature variations do not affect the capability of the Water Cooled Screw Chiller.

Water Cooled Screw Chiller

5. How Does Air Cooled Screw Chiller Work?

The basic operation of an Air-Cooled Screw Chiller is to circulate a refrigerant through a dissipated heap of tubes.

The evaporator, which holds the fluid refrigerant, is where the process begins.

With the aid of the tubes filled with water, this refrigerant transmits the virus to the surrounding area. With the aid of a circuit, the water is then chilled and siphoned.

Meanwhile, the Air Cooled Screw Chiller is cooled using a system that absorbs heat from various sources.

When the water reaches a sufficiently high temperature, it starts to radiate the warmth back to the refrigerant in the evaporator, resulting in vapors.

With the aid of a funnel, the vapor is forced to pass through the blower.

In this case, it’s a Rotating Screw Compressor, a form of gas blower that works against the Rotating Positive Displacement Mechanism’s premise.

This is the most up-to-date and safe method for applying pressure that is currently in use. In a small room, the blower puts the vapor under a lot of weight and heat.

The vapors have now turned into the extremely heated vaporized refrigerant, which is then sucked through the condenser.

The condenser is a collection of tubes in which vapor radiates heat into the surrounding air before reverting to a fluid.

The refrigerant passes through a development device, which reduces its temperature, and then the fluid returns to the evaporator to repeat the chilling process.

What are the Applications of Air Cooled Screw Chiller?

• Air Cooled Screw Chiller provides comfort and quality air-conditioning to be used in the chemical & pharmaceutical industries.
• Also, Engineering & Industrial industries may require such systems for acquiring proper temperature.
• Can be used in commercial & institutional industries, hospitals, and telecommunication industries.
• Usage in hospitals and various treatments including laser treatments, defense laboratory testing facility is suitable.
• Application in the welding engineering, blow mold machines, and also can be used in the aeronautical testing facility.
• Can be used in computer chip manufacturing, factory furnaces, the electroplating industry, and also the plastics processing industry.
• Various laboratory equipment’s such as the injection molding machine require using the Air Cooled Screw Chiller.
• Plays a part in maintaining the machines used in the food processing and the beverage industry. Moreover, the dye and pigment manufacturing processes also require these systems.
• Air Cooled Screw Chiller can be used in anodizing plants and various foundries.
• Applicable to be used in plasma spray machines for providing them with better operation.
• One of the major applications involves the usage of induction hardening machines.

Applications of Air Cooled Screw Chiller

 What Information of Air Cooled Screw Chiller is Included for Display?

The following information must be included in the display:

• Lockout of the compressor
• Low fluid flow is an issue
• Freeze defense that is cooler
• The thermostat and transducer aren’t working properly
• The temperature when entering and leaving is fluid
• Pressures in the evaporator and condenser
• Temperatures of the refrigerant in the system
• Hours of Air Cooled Screw Chiller operation
• Hours of compressor use
• The number of times the compressor has started is the number of times the compressor has started

Air Cooled Screw Chiller Display

8. How to Maintain Your Air Cooled Screw Chiller?

A periodic inspection program should be set up and followed, in general, to ensure proper operation at peak capacity and to prevent harm to system components.

The following information is intended to be used as a reference during the inspection and should be used in conjunction with listening to the compressor and following good electrical practices to ensure trouble-free operation.

Every circuit’s sight-glass indicator in the liquid line must be tested to ensure the glass is complete and clear.

Even if the device has a full refrigerant charge, the filter-dryer portion must be replaced if the indicator shows a wet condition and/or there are bubbles in the sight-glass.

Maintenance of compressors of the Air Cooled Screw Chiller does not need to be serviced regularly. A vibration examination, on the other hand, is an excellent way to ensure proper mechanical operation.

Compressor vibration means that maintenance is needed because it reduces the unit’s performance and efficiency.

A vibration analyzer should be used to inspect the compressor at or shortly after startup, as well as once a year.

The load should be kept as close to the rated load as possible when conducting the test. 40/48 is a test that, if done regularly, will alert you to impending problems.

A cartridge oil filter is included with the compressor. When the compressor is opened for operation, it is a good idea to replace the filter.

Air Cooled Screw Chiller Maintenance

9. What is Air Cooled Screw Chiller Control Options?

Minimum specifications for Air Cooled Screw Chiller controls are as follows:

• Permanent memory microprocessor (battery backup system not accepted).
• Power and control terminal blocks and supplies are separate.
• A separate 220-volt power supply for all controllers, relays, and control components is needed.
• Control switch that toggles between ON and OFF.
• Solid-state controllers that can be replaced.
• Suction, intermediate economizer, discharge, and oil pressures are measured using pressure sensors and transducers.
• Thermistors are used to track the temperature of the fluid as it enters and exits the system, as well as the ambient temperature outside.

10. What are the Electrical Requirements of Air Cooled Screw Chiller?

• The primary electrical supply for the device must enter via a single point (some Air Cooled Screw Chiller voltage/size combinations need two power supplies).
• The primary electrical power supply must be certified to work at 125 degrees Fahrenheit (52 degrees Celsius) ambient temperature.
• The unit must run on three-phase power at the voltage specified in the equipment schedule.
• Terminal blocks can be used to access control points. Factory control and power wiring will be mounted when the unit is delivered.

Air Cooled Screw Chiller Electrical Connection Establishment

11. How to Install your Air Cooled Screw Chiller?

Foundational requirements when installing the Air Cooled Screw Chiller on the top story of a house, be sure to take the planning and structure of the base seriously.

Avoid the strength and noise of the floor in particular. Before beginning installation, it is recommended that you consult with the building designer.

To prevent transmitting vibration and noise during the unit’s runtime and to ensure that the unit is level during installation, an anti-vibration pad should be mounted between the base frame and the base.

Where possible, use a shock absorber. If the Air Cooled Screw Chiller is to be mounted on the roof of a house, the vibration level must be kept to a minimum.

Installation space is needed. Allow enough space around and within the units for air circulation, service, and maintenance.

The following should be noted in areas where snow can accumulate during the winter season:

• Do not position the device under a house’s eave.
• Raise the base to account for the possibility of snowfall. (The base must be at least one meter higher than the maximum snow depth.)
• Do not position the device in a location where snow can accumulate.

If the unit’s heat-exchanger is directly facing the monsoon in a region where there is a heavy monsoon, provide proper maintenance.

Direct airflow occurs when the monsoon wind velocity exceeds the fan-blowing velocity.

As a result, the heat-exchanging mechanism will be influenced, lowering cooling capacity and, in some cases, causing malfunction.

The Air Cooled Screw Chiller is constructed with this in mind to reduce this phenomenon.

Even so, the heat-exchanger of the device should not face the monsoon to avoid unnecessary malfunction.

If the above condition cannot be prevented and a windbreak must be mounted, please do so.

Air Cooled Screw Chiller Installation

12. How to Troubleshoot your Air Cooled Screw Chiller Problems?

In a commercial building, an Air Cooled Screw Chiller helps to condition the air and creates the ideal atmosphere. The Air Cooled Screw Chiller is linked to a variety of issues, but the following are the most popular ones.

Oil failure

If there is a refrigerant leak that causes low oil in the Air Cooled Screw Chiller, the oil pump is impaired or there is low superheat, there will be an oil failure.

Low/High-Pressure Issue

In case of not enough water flow, tubes coated with dirt, broken capillary, lesser refrigerant, low – pressure issues can occur.

If the water-cooled condenser has an accumulation of minerals that affect the water quality, or if the condenser has little or no airflow, the Air Cooled Screw Chiller can experience a high-pressure problem.

The temperature of the cooling water tank, on the other hand, maybe over 80 degrees Fahrenheit.

Starter Trip or Blown Fuses

If the engine, wires, or compressor are over-amped or shortened, this may happen. The best approach is to search for shorts or grounds and correct them as required.

Freeze Stat

This can happen if the water flow is weak or if the thermostat is set lower than necessary.

Lack of Flow

If the pressure or flow switches in the water circuit do not receive the proper amount of flow, there may be a slow flow.

It is also possible that the water valve is turned off or that the water filter is blocked. The flow transfer paddle is usually broken in most situations.

The Air Cooled Screw Chiller is on, but it isn’t reaching the desired temperature.

The antifreeze could be destroyed or the evaporator could be iced up from the inside and the Air Cooled Screw Chiller is unable to handle the device load.

These are the most common problems that an Air Cooled Screw Chiller is known to have. Always be aware of how it operates and how to quickly detect and resolve any issues.

Loud Noises

If there is an imbalance in the system or if any components are blocking the free flow of air and water within the device, these devices will produce loud noises.

Any odd noises made by the device can be reduced with a well-balanced pressure flow.

Unpleasant Odors or Poor Indoor Air Quality

There may be an issue with the filter or a gas leak if there is a bad odor or the air quality in the building is low.

When sections of the unit overheat, the air filters become dirty, stagnant condensed water accumulates in the unit, or melting debris from the heat exchanger enters the ductwork, a foul odor is released.

Inspect the device as soon as possible to identify and correct any common errors. If you can’t identify the source of the odor, you can hire a specialist.

A defective motor, which should be tested multiple times during the year, may also affect the IAQ.

If the outside air temperature falls below a certain threshold, the compressor is turned off by the damper. These dampers tend to stick to each other if they aren’t washed and lubricated properly.

As a result, the cooling coils are overloaded, and the device is unable to cool itself.

Air Cooled Screw Chiller Troubleshooting

13. What are Safety Tips for the Air Cooled Screw Chiller?

When using an Air Cooled Screw Chiller, keep the following in mind for safety:

• Outside, and well away from the air inlet, a vent pipe and an air change pipe should be mounted.
• Verify that it is well ventilated. Use additional ventilation equipment if necessary to remove the refrigerant vapor generated by an accidental leak.
• Install an air detector to monitor the refrigerant vapor concentration in the air, if appropriate.
• Please carefully read the safety directions to ensure that all of the specifications are met. Please hold this manual in a safe place for future use.
• Make sure the controller is properly grounded and inspect it regularly.
• Unsuitable earthling can cause a sudden electric shock.
• Ensure that the solid and weak electricity are piped separately. Ensure that the wiring follows the wiring diagrams exactly. Make sure the voltage input of the isolating transformer is correct: AC380V 10%, 50Hz.
• Do not press the touchable screen with sharp objects, and do not press the screen too hard.
• The power supply cables and contact wires should not be pulled or distorted.
• To clean the dirt on the unit, do not use an acid or alkaline drug. Wipe the machine with a soft cloth dampened with clean water.
• If a fire breaks out, turn off the electricity immediately. Also, use a fire extinguisher made specifically for oil and electric fires.
• Moreover, it is forbidden to use the machine in a potentially explosive setting.

Wear Gloves Before Operating your Air Cooled Screw Chiller

14. How to Increase Efficiency of Your Air Cooled Screw Chiller?

To ensure effective heat transfer, keep the tubes clean:

The single most important factor affecting Air Cooled Screw Chiller efficiency is heat transfer.

Since a large chilling system may have more than five miles of condenser and evaporator tubes, efficient heat transfer is critical.

So, for an effectively working Air Cooled Screw Chiller, it is essential to keep the units, tubes, interior, and everything clean.

Treat Condensate Water: 

Both condenser water loops require proper water treatment. Scale, corrosion, and biological growth are all eliminated with this procedure.

If these elements are discovered in the method, the amount of chemical treatment applied to the water should be increased.

Analyze Compressor Oil: 

Send a sample of compressor lube oil to a laboratory once a year for a spectrometric chemical examination, which will reveal moisture content, metals, acids, and other pollutants that can affect efficiency.

High moisture levels can suggest a problem with the purge unit, which can reduce performance significantly.

Reduce Entering Water Temperature:

The performance of the Air Cooled Screw Chiller condenser system would be improved if the water entering the system is at a lower temperature.

When cooler water enters a device, it takes less energy to cool it to its usual operating temperature. Surging can also occur if the controlled temperature increases.

Maintain a Leak-Free System:

Three or four times a year, compressor leak checks should be conducted. A leak-free system is critical to an Air Cooled Screw Chiller system’s success.

Leaks in a system allow non-condensable, such as air and moisture, to enter the system, causing stress and corrosion. Hazardous refrigerants are also released into the atmosphere as a result of leaks.

Install VFD/VSD Drive in Chiller Motor:

Variable speed drives reduce energy consumption by syncing the workload and motor performance in Air Cooled Screw Chiller motors, which are also the single highest electrical load in a plant.

Variable speed drives also act as a soft starter, reducing the initial inrush current.

When it is powered by emergency backup power systems, this function is critical.

Maintain Proper Water Flow Rate:

Since too low a flow rate decreases Air Cooled Screw Chiller efficiency and leads to laminar flow, it must be carefully controlled.

Usually, the minimum flow rate is about 3 feet per second. A high flow rate, on the other hand, causes vibration, noise, and tube erosion. Usually, the highest recommended flow rate is about 12 feet per second.

Proper Insulation on Chilled Water Pipeline:

Insulation improves the productivity of the Air Cooled Screw Chiller facility. If the insulation is insufficient or the piping is not sealed, heat loss may occur, lowering the overall chilling plant quality.

Maintain the Charge of The Refrigerant: 

The amount of cooling an Air Cooled Screw Chiller can provide is determined by the amount of refrigerant it can pass through the compressor in a given amount of time.

It is important to keep the right amount of refrigerant in the system. Air and moisture, as well as leaks, reduce performance and system reliability.

Low refrigerant charge, which is normally caused by leaks, makes the compressor work harder and provides less cooling.

Purge Non-Condensable Gases:

Non-condensable gases such as air and moisture may leak into the Air Cooled Screw Chiller causing a lot of problems in the system’s normal functioning.

Chimney performance can be reduced by as much as 4% at 60% load and 7% at 100% load when using non-condensable.

Tubes are insulated by air, which prevents exchange and raises condensing temperatures, making the compressor work harder. The acid formation is aided by moisture, which can damage motor windings and bearings.

As these non-condensable are problematic for your Air Cooled Screw Chiller, their effect is reduced by installing purge units to the system.

Air Cooled Screw Chiller Routine Inspection

FAQ of Air Cooled Screw Chiller.

1. What is the average life of Air Cooled Screw Chiller?

The average life of an Air-Cooled Screw Chiller ranges from 15 to 20 years. However, the way you use and how much you use your Air Cooled Screw Chiller plays a major part in affecting this average life.

1. How Does an Air Cooled Screw Chiller Varies From a Scroll Chiller?

The Air Cooled Screw Chiller has a better part-load kW per ton efficiency as compared to the Scroll chiller. One thing to note is that an Air Cooled Screw Chiller has a single compressor.

1. What is the Efficiency of an Air-Cooled Screw Chiller?

The efficiency of an Air-Cooled Screw Chiller ranges from 0.7 to 0.8 KW/ ton which is greater as compared to a reciprocating chiller but lower than the centrifugal chiller.

This high-efficiency range is due to the 30 compressor ratios present in the Air Cooled Screw Chiller.

1. How Does the Compressor of an Air-Cooled Screw Chiller Vary from That of a Piston Chiller?

The compressor of an Air-Cooled Screw Chiller comprises two helical screws while the compressor of a Piston Chiller comprises pistons.

Moreover, the compressor of the Air Cooled Screw Chiller is more efficient and works at a lower temperature as compared to the Piston one.

1. What is the Hourly Performance Life of the Compressor of an Air-Cooled Screw Chiller?

The hourly performance life of the compressor of an Air-Cooled Screw Chiller ranges from 60,000 to 80,000.  Moreover, the way you treat this unit and how much maintained and efficient it is, influence this life.

1. Does the Air Cooled Screw Chiller Have a backward running compressor?

No, the screw compressors of an Air-Cooled Screw Chiller function only one way. The reverse functioning will cause a compressor failure problem, resulting in faulty operation.

1. What Oil to Add in The Compressor of an Air-Cooled Screw Chiller?

The Compressor oil 68 is the most suitable oil to add to the compressor of an Air Cooled Screw Chiller. So, if you want the best results, don’t try using other oils that are not recommended for use in this unit.

1. Do the Compressors of An Air Cooled Screw Chiller Run Constantly?

Yes, the compressors of an Air-Cooled Screw Chiller run constantly due to the better construction. But it is preferred to provide a certain pause rather than this constant working.

100% Quality Tested Air Cooled Screw Chiller