TopChiller Modular Air Cooled Chiller Manufacturer and Supplier

Modular Air Cooled Chiller-An Ultimate Buying Guide by TopChiller.

An Ideal Modular Air Cooled Chiller is a highly recommended cooling device for an industrial HVAC system.

Modular Air Cooled Chiller features easy Installation, specificity, durability, maintenance, high capacity, and redundancy.

The Modular Air Cooled Chiller is a super-compact industrial chiller, specifically designed to build a complete system with multiple chillers, connecting them in series (Multistage) or parallel configuration.

When you choose a Modular Air Cooled Chiller for your application, a lot of preparations are required to install the unit as well as maintenance.

The following guide will help you to purchase and install it in your industrial HVAC system.

In this guide, you will surely learn about how to customize your system to accommodate your Modular Air Cooled Chiller and your facility’s HVAC requirements.

What is a Modular Air Cooled Chiller?

The Modular Air Cooled Chiller is an air conditioning unit that uses air as a cold & heat source and water as the refrigerant carrier.

Various air side units such as fan coil unit, air handling unit are integrated with Modular Air Cooled Chiller to form a central air conditioning system.

Installation of EC motor is driven condenser fan, and low sound fan blade in a Modular Air Cooled Chiller produce a very low noise level and vibration.

A Modular Air Cooled Chiller works with high energy efficiency and water quality efficiency and offers superior redundancy to single machines.

The environment-friendly, it has complete cooling/heating functions and various specifications due to its binding with basic modules of any supported combination.

The attachment of Modular Air Cooled Chiller with different modules is available for different models, including 66kW, 100kW, and 130kW.

At most, the 8 modules can be connected in parallel, providing combination products ranging from 66kW- 2080kW.

It is easy to install, with advancements as no cooling water, simple pipelines, moderate cost, short construction period, it works efficiently.

In computing, plastic manufacturing, ice making, and air conditioning industries a Modular Air Cooled Chiller has its wide applications.

Modular Air Cooled Chiller

What are the Components of a Modular Air Cooled Chiller?

A Modular Air Cooled Chiller has the same basic components as another chiller with minute changes and some other additions as given below.

• Hermetic Compressor
• V-Shaped Condenser
• Saw-Shaped Condenser Fan Blades
• Efficient Shell and Tube Heat Exchanger/Evaporator
• High Precision Electronic Expansion Valve
• Microprocessor Control Unit
• Multiple Protection Functions, Providing Safety and Reliability

Hermetic Compressor

A Modular Air Cooled Chiller is equipped with highly efficient, reliable, and silent compressors with internal overload protection.

The compressors implement hermetic type to eradicate operating noise and vibration in a Modular Air Cooled Chiller.

V-Shaped Condenser

The v-shaped condenser is reinforced with a metal frame and triple anti frosting features in a Modular Air Cooled Chiller.

It avails the unit with higher structural stability and rust resistance as well as heat exchange efficiency. The V-shaped condenser has a low tendency to dust accumulation and frosting in winter.

Small loss of pressure, smooth drainage, and higher reliability are also the key features of a v-shaped Condenser.

Saw-Shaped Condenser Fan Blades

The saw-shaped condenser fan blade offers large air volume, high durability, and high air supply efficiency with low noise are used in a Modular Air Cooled Chiller.

Efficient Shell and Tube Heat Exchanger/Evaporator

The waterside efficient shell and heat exchanger used in the Modular Air Cooled Chiller is of helical baffle type.

The heat exchanger has better heat transfer performance and resistance to freezing than the plate heat exchanger.

The refrigerant circuit is factory brazed and emptied before being accurately charged with R22 to ensure the best operating requirement.

Each refrigerant circuit is furnished with a carefully sized thermostatic expansion valve.

High Precision Electronic Expansion Valve

The electronic expansion valve achieves 480 regulating range, improves the optimum efficiency of each component, and ensures the optimum condition of system operating pressure and temperature.

Microprocessor Control Unit

A microprocessor control unit is being used in a Modular Air Cooled Chiller for performing functions as current detection, Compressor communication, standardization, convenience, and universality.

The USB interface is also attached to facilitate later-stage maintenance and upgrade of the control function.

Multiple Protection Functions, Providing Safety and Reliability

The Modular Air Cooled Chiller has a large number of safety protection features that ensure the safety of units and systems.

The water flow switch and multiple anti-freezing program designs are installed in a Modular Air Cooled Chiller to protect the unit and system for better working.

A Variety of Hermetic Compressors for Modular Air Cooled Chiller

How Does a Modular Air Cooled Chiller Work?

• A Modular Air Cooled Chiller uses an air cooling system to release extra heat out of a system for cooling purposes.
• To play and start the process, need to prepare the machine for working and make settings for play after installation.
• After the play, fill out the refrigerant in the storage tank. Mostly glycol or the mixture of glycol and water is used as a refrigerant. The refrigerant flows out of the storage tank and is moved towards the compressor.
• The Compressor applies a force on the refrigerant, compresses it, and increases the volume of the refrigerant.
• The compressor increases the pressure on the refrigerant to move ahead.
• Consequently, with high-pressure reinforcement, the speed of the refrigerant increases and it passes speedily and straight from the evaporator section/heat exchanger section of the Modular Air Cooled Chiller.
• At the evaporator/heat exchanger section refrigerant take up the heat that has been collected by the evaporator from the environment /system where you want to produce cooling.
• The heat exchanger/evaporator section has a large number of piping systems filled with chilled water. As chilled water circulates in tubes absorbs heat from the system.
• As soon as enough heat gets absorbed by chill water, it moves towards the evaporator from the tubing.
• Evaporator has refrigerant, transfer heat from water to the refrigerant. After absorbing heat refrigerant changes into a gaseous state from a liquid state.
• Now refrigerant has enough pressure to flow straight towards the condenser of Modular Air Cooled Chiller.
• In the condenser section, the refrigerant will transfer heat to the coolant, (air) of the condenser.
• Coolant will take it towards the cooling tower or to the environment and get rid of the access heat from the system.
• After heat release, the refrigerant moves from the condenser to the expansion valve. At this point refrigerant has no more heat, again converts into the liquid state with the help of an expansion valve.
• After liquefaction, the refrigerant becomes ready for the next cycle and moves towards the compressor.
• Microprocessors maintain communication among compressors of multi chillers if a Modular Air Cooled Chiller has more than one chiller system.

Modular Air Cooled Chiller Working

What are the Key Features of a Modular Air Cooled Chiller?

• Low installation costs due to complete testing of each unit and their function testing at the factory.
• Distribution of the weight of Modular Air Cooled Chiller units at support points
• Easy access to the lifting points during installation
• Factory testing
• Each unit of Modular Air Cooled is tested, vacuum tested, evacuated, and charged with refrigerant requested.
• Factory test bench facility proceeded as per instructions and design conditions specified by the customer.
• Before shipment, each unit rechecking a Modular Air Cooled Chiller for pressure and refrigerant charge control.
• High Capability of a Modular Air Cooled Chiller to install up to ten (10) modules together to reach capacities up to 600 tons.
• Flexible end-to-end and side-to-side configurations of a Modular Air Cooled Chiller
• Offers footprint flexibility for challenging installations
• Factory-installed compressors on rubber isolation mount for quiet operation
• Compressor acoustic hoods availability
• Sound isolating cabinets available for sound-sensitive applications
• Variable speed compressors
• V-shaped condensers and Condenser fan
• Hydronic pump package installation
• High Energy efficiency, moderate cost, and reliability
• Low refrigerant charge
• Intuitive, factory-installed microprocessor-based controller for compressors communication
• Microchannel heat exchanger (MCHE) condenser coils (Standard uncoated or optional e-coated coils) availability
• Highly efficient, dual circuit brazed plate heat exchangers offering best performance at both full and part-load conditions.
• Operational high performance from -20°F to 120°F (-29°C to 49°C) ambient temperature

Modular Air Cooled Chiller Brazed Plate Heat Exchangers

What are the Applications of a Modular Air Cooled Chiller?

A Modular Air Cooled Chiller has a wide range of applications due to its easy installation and efficient working.

In different services and industries, a Modular Air Cooled Chiller is being used nowadays. Here is some application where you can use them.

The Plastic Manufacturing Industry uses Modular Air Cooled Chiller for temperature maintenance, better quality maintenance of molded plastics, reducing costs, and manipulating environmental impact during plastic manufacturing.

Computer Room Air Conditioning Purposes are achieved by using a Modular Air Cooled Chiller as it releases heat from the system in electronics industries.

Ice Making Chiller System as a Modular Air Cooled Chiller has an ice making mode to use for skating rinks.

Landfill Gas Cooling System uses it where heat-producing in landfill is maintained through its processing.

Air Conditioning Industries use Modular Air Cooled Chiller for cooling effect.

Process Cooling Industries are a wide application where heat is released out from the system through processing refrigerant and coolant air.

Heat Pump Cooling purpose where heat is restored up to 60 degrees Celsius by using another condenser to reheat the coils by providing heat to leaving water by Modular Air Cooled Chiller.

Modular Air Cooled Chiller Applications

How a Modular Air Cooled Chiller is Different from a Modular Water Cooled Chiller?

The general working mechanism and components are almost the same as a Modular Air Cooled Chiller and Modular Water-cooled Chiller. However, they can from each other by following factors.

Capacity

A Modular Air Cooled Chiller can install up to ten modules together and reach capacities up to 600 tons while Modular Water Cooled Chiller has a Capacity range from 20 to 85 tons.

Cooling Effect

A Modular Water Cooled Chiller uses water to cool the environment around them, and a Modular Air Cooled Chiller uses air to cool a system.

Installation

A large space is required for the installation and it works with an ambient temperature from -29 to 40 degrees Celsius.

While Modular Water Cooled Chiller can install in small spaces having 4-degree calcium capacity evaporators.

Modular Water Cooled Chiller

What are the Benefits of Using a Modular Air Cooled Chiller?

A Modular Air Cooled Chiller uses non-ozone-depleting refrigerants. This feature reduces the impact on the environment, having some other advantages as given below

• Super compact design with maximum cooling capacity
• Low charge requirement of refrigerant gas
• High energy efficiency in operation
• The highest EER in all working environments
• High installation feasibility with remote condensation.
• High reliability with units built as a factory-mounted and testation in the factory.
• Microprocessor control for multiple compressors communication and self-diagnostics
• Plug & Play is easy to install and proceed
• The decrease in the cost of production
• Easy to maintain
• Water-efficient by recycling water and decreasing cost for water supply.

How to Size a Modular Air Cooled Chiller for Your Application?

To size, a Modular Air Cooled Chiller for Your application must consider checking out the cost, reliability, capacity, and installing area according to the needs of your application.

Size and Capacity

Check out the Incremental capacity you require for your application and then select the Modular Air Cooled Chiller accordingly.

It will provide a good balance between the building load profile and the available capacity steps of the chiller.

If the total load size is equal to 210 tons, then you can use 3 Modular Air Cooled Chiller of 70 tons, to size it for your application.

Location for Installation

Make sure to size a Modular Air Cooled Chiller according to the nature of the environment.

Manipulate the humidity and temperature of the environment for your application and then select it accordingly.

Modular Air Cooled Chiller has a wide range of ambient temperatures working efficiently from -29 to 40 degrees Celsius.

Reliability

It has great reliability for Industrial applications, as it ensures the continuity of working while replacing a chiller.

A Modular Air Cooled Chiller can combine with other modules for HVAC and give high reliability for choosing.

Installation

The installation is easy and environment friendly with a wide range of ambient temperatures to size it for your application.

Cost

A Modular Air Cooled Chiller is available in the market with different costs.

You should choose by considering budget and outcomes to select a Modular Air Cooled Chiller as it ranges from 1000 to 380,000 US dollars.

How to Install a Modular Air Cooled Chiller?

Shipping

A Modular Air Cooled Chiller is transported with a pallet. Each unit has been filled with refrigerant.

It is not necessary to fill it again with refrigerant for maintaining the proper level.

Inspection

As soon as you received Modular Air Cooled Chiller, inspect it for any damage that may occur in shipment and make sure that all the parts are received.

Storage of the Unit

If the Modular Air Cooled Chiller is not to install for the moment, it is strictly prohibited to load it.

 Location of the Unit

• Don’t install the unit in the courtyard, or other places which is narrow for the unit as narrow space will maximize the vibration and noise because of the echo.
• Space for access to air in front and sides of the equipment must be provided to document the unhindered flow of air to and from the unit.
• Install the Modular Air Cooled Chiller in such a way that hot air dispersed by the condensing unit cannot be drawn in again.
• Remove obstacles that block air intake or discharge from the unit.
• A place protected from direct sunlight, otherwise use sunshade for protection from storm and rain, put 5m high from the Modular Air Cooled Chiller.
• The location must not be vulnerable to dust or oil to protect the condenser coil from being clogged by the contaminant. It is advised that no flammable gas should be located near the Modular Air Cooled Chiller.

Handling

A Modular Air Cooled Chiller is skidded at the factory. Care should be made during handling to escape from damage to the unit and internal components.

A cable crane or lifter should be used to easily tramp the unit.

 Lifting Method

When it is going to be lifted, bind ropes to the suspension plates present on the top of the unit.

When it is lifted, the hook should be aligned over the center of gravity.

Care should be taken to avoid contact with the main unit while carrying.

It is essential to shield the Modular Air Cooled Chiller with the blanket so that the ropes may not injure the unit.

Installation Base

The Modular Air Cooled Chiller must be installed on a flat and level concrete foundation.

It can be conveniently installed on rooftops, terraces, and other proper places.

Refrigerant Installation is done after placing it in a specific Place.

Pre Heating Mounting for 24 hours before starting the Modular Air Cooled Chiller.

Power Supply Installation is done and starts the processing.

Use Fork Lifter to Relocate Modular Air Cooled Chiller

What are Factory Mounted Options for a Modular Air Cooled Chiller?

There is the following factory-mounted option for better operation of a Modular Air Cooled Chiller.

• Inverter water pumps are offered for 150/250/450 kPa.
• Power factor correction as about to cos phi 0.91
• Control panel electric heater with thermostat
• Phase failure protection system
• Gateway Modbus
• Soft-start (with only ON OFF feature for compressors)
• Automatic circuit breakers
• Air temperature kit for low outdoor (for operation down to -10°C)
• EC fans with high static pressure (100 Pa)
• Grilles for protection
• Special type condenser coils

Modular Air Cooled Chiller Water Pump

Which Accessories can be used in a Modular Air Cooled Chiller for Feasible Operation?

A Modular Air Cooled Chiller can use accessories for increasing the working efficiency as given below.

• A multi-manager controller in a modular configuration
• Sound absorbing jackets for compressors
• A Remote control display
• A Flow switch
• An Automatic water filling
• A Threaded strainer
• Water gauges to prevent leaks
• Rubber and spring anti-vibration mounts

How to Troubleshoot a Modular Air Cooled Chiller Problems?

When Your Modular Air Cooled Chiller fault is noted, instantly move to switch off the power supply to the unit and make contact with a local dealer to troubleshoot the fault.

Some simple troubleshooting tips are given below:

Compressor Malfunction (Alarm Lamp is on)

If a compressor of your Modular Air Cooled Chiller is not working, the Control system may be faulty or Compressor will be faulty. Contact a local dealer to troubleshoot the problem.

Noisy and Vibrancy

Due to dust in fan motor or Compressor fault by floor or wall cause noise and vibration in your Modular Air Cooled Chiller.

To troubleshoot this, clean the dust, call the local dealer, and Checkout the installation.

Fan Motor Cease Running

Fault in circuits or Overheat relay starting may cease working of the fan motor.

To troubleshoot this Check the circuit and repair it if necessary or Contact a local dealer.

Insufficient Cooling/Heating

Faulty Compressor, Impurity of the hydraulic system, Congested condenser coil, and Low charge on refrigerant in your Modular Air Cooled Chiller creates a problem in the production of cooling/heating in a system.

To troubleshoot this problem Contact the local dealer, clean the hydraulic system, clean the coil and add refrigerant to get the required charge.

Cycling Water Pump does Not Start

Stoppage of power supply, fault in Water pump motor or water pump may stop the cycling of water pump in your Modular Air Cooled Chiller.

To troubleshoot this Checkout power system, check and change the water pump if required.

Water Cycling Faulty

Gas entrance in the cycling system or dirt in the heat exchanger generates a fault in water cycling.

To troubleshoot this, liberate the gas and clean the heat exchanger.

The Unit does Not Start

Water flow switch and pressure switch fault in a Modular Air Cooled Chiller hinders it to start.

By checking water flow and by checking system pressure and putting those on the normal range may troubleshoot the problem.

How to Maintain a Modular Air Cooled Chiller?

For the maintenance and efficient working of a Modular Air Cooled Chiller, a user is directed to make records of a daily routine of all equipment and their operating date.

• Modular Air Cooled should provide with specific power supply. Current-voltage can fluctuate +10%.The automatic air switch should be used to maintain the power supply.
• Never apply the Knife switch unit to ensure voltage maintenance. Inverse phase protection devices are also installed to maintain the voltage set as 1.5 times of running voltage.
• At the very first application of your Modular Air Cooled Chiller, it should be preheated for 24 hours and do electrify, after that start it for processing.
• The host switches often do not do work. Mostly it can operate 6 times per hour. To compensate for this make sure that the electric control cabinet prevents humidity.
• Make sure to install it in an environment with proper ventilation. Heat exchangers on the airside should be clean on daily basis.
• An expansion tank should be used for a water system. During operational processing of Modular Air Cooled Chiller, maintain water flow. Make sure to clean the recycled water. Also, clean the filter regularly.
• Appoint a skilled person for daily records and maintenance.
• Modular Air Cooled Chiller cannot conduct refrigeration if the temperature of the environment is below 5 degrees Celsius. To overcome this and maintain the working make sure to conduct cryogenic refrigeration.
• Check if there is any abnormal noise produced when it is in operation. Stop the device and check the problem.
• Replace the damaged component with new to maintain the efficient working of the Modular Air Cooled Chiller.

Modular Air Cooled Chiller Maintenance

How can We Increase the Working Efficiency of a Modular Air Cooled Chiller?

You can increase the working efficiency of your Modular Air Cooled Chiller by improving its working conditions.

There are some key factors through which you increase the working efficiency

Maintenance of Taking Daily Records

Make sure of taking daily records about the operation of the Modular Air Cooled Chiller.

In this regard, you will know about optimum requirements of machine for working. Set optimum conditions for efficient working.

Proper Inspection

Move for the inspection of your Modular Air Cooled Chiller regularly to identify the problems that may occur in equipment on time and contact an expert to troubleshoot the problem.

Daily Cleaning

Sometimes a Modular Air Cooled Chiller slows down or stops processing due to dust accumulation in different parts. Make sure daily cleaning of the whole machine for efficient working.

Proper Maintenance

To increase the working efficiency, follow the maintenance schedule strictly.

Lubricate the machine equipment to prevent damage from friction.

Replace the broken parts of the device as soon as possible for maintenance and increase efficiency.

Optimizing all Operation

Follow the personnel of a Modular Air Cooled Chiller to install the optimum values of required fluids for increasing the efficiency of the device.

Modular Air Cooled Chiller Daily Inspection

FAQ of Modular Air Cooled Chiller

Q 1: How do multiple chillers work together in a Modular Air Cooled Chiller?

A Modular Air Cooled Chiller has multiple chillers working under one system as the microprocessor controller is involved in the communication of one chiller with the other during operation.

Q 2: Why Variable Speed Compressors are used in a Modular Air Cooled Chiller?

Variable speed compressors are used to control the speed and voltage at which the compressor works in a Modular Air Cooled Chiller.

By controlling the required speed, a power supply can be saved from wastage.

Q 3: How many Modular Chiller components can handle a Modular Air Cooled Chiller?

A  Modular Air Cooled Chiller can handle 12 chillers and 24 compressors for cooling purposes. It can use accessories for proper operation.

Q 4: What is the difference between a Cooling Tower and a Modular Air Cooled Chiller?

A Cooling Tower is used for cooling purposes as Modular Air Cooled Chiller.

It differs in its mechanical working, as cooling towers use fans that help to release heat.

While a Modular Air Cooled Chiller uses a compressor, evaporator, condenser, and expansion valve to release heat.

Q 5: Which best materials can be used for manufacturing a Modular Air Cooled Chiller?

Stainless steel and rubber are the best materials used for a Modular Air Cooled Chiller as stainless steel has corrosion resistance, tensile strength.

Rubber act as a sealer for designing a Modular Air Cooled Chiller.

Q 6: Which Quality Specifications should be followed by a good Modular Air Cooled Chiller?

EG quality certification, ELT, QSK, CE, and DIN quality certifications should be followed by a good Modular Air Cooled Chiller ensuring that it is safe for your application.

Q 7: How many system configurations are there for a Modular Air Cooled Chiller?

Two system configurations are included in a Modular Air Cooled Chiller, 1) Parallel system configuration and 2) series system configuration.

Q 8: Is there any limitation to using a Modular Air Cooled Chiller?

The vulnerability of some parts, high-quality water requirements and large weight index limits the working of a Modular Air Cooled Chiller.

100% Quality Tested Modular Air Cooled Chiller