TopChiller Water Chiller Machine Manufacturer and Supplier in China

Water Chiller Machine-An Ultimate Buying Guide by TopChiller.

Nowadays, many industries and commercial systems are using Water Chiller Machines.

The Water Chiller Machines are seeking the attention of many companies for cooling different products, machinery, or other industrial equipment.

It is a chilling machine that uses water to meet the cooling requirements of your Water Chiller Machine.

Many people are looking forward to this technology to improve the working of their applications.

But only a few people know about the proper working, structure, usage, and maintenance of a Water Chiller Machine.

This guide will help you to understand the Water Chiller Machine completely. It is a very useful, well-researched, informative, sequenced, and easy-to-understand guideline for you.

After reading this complete guide, you will be able to select, size, install and maintain a Water Chiller Machine for your application.

Before, you jump to other sections of this guide. It is necessary to know about the basics, working, and components features of the Water Chiller Machine.

What is a Water Chiller Machine?

Different industries use heavy machinery that generates a large amount of heat. It is necessary to dissipate that temperature to prevent sensitive devices and products.

A Water Chiller Machine is cooling equipment, which uses a refrigerant to lower the water temperature in a closed-loop system.

It uses a heat exchange process that transfers the refrigerant to the evaporator. The evaporator changes the refrigerant from liquid to gas state and the waste heat is released into the atmosphere.

A Water Chiller Machine uses absorption refrigeration, adsorption refrigeration, and vapor compression methods to remove heat from the water.

A Water Chiller Machine that uses an absorption refrigeration process uses a different number of a compressor. Its condenser can be either water-cooled or air-cooled.

A vapor compression, Water Chiller Machine uses a refrigerant as a cooling agent.

A Water Chiller Machine that uses absorption and adsorption refrigeration cycles requires a heat source for proper working.

It can be air-cooled, liquid-cooled, or evaporative cooler. But water or liquid chiller machine can perform more efficiently and have more benefits as compared to air-cooled chiller machines.

The Water Chiller Machine is commonly used by medium or large-scale industries, institutes, and commercial systems.

Water Chiller Machine Designed by TopChiller

What are the Working Principles of the Water Chiller Machine?

A Water Chiller Machine is used to dehumidify the air and cool down the heavy-industrial machinery and products. But the question is, how?

A Water Chiller Machine works on the basic principle of vapor absorption and vapor compression.

A Water Chiller Machine uses a vapor compression mechanical refrigeration process that is joined to the process water system through a device known as an evaporator.

Refrigerant is a chemical compound. It circulates through an evaporator, compressor, condenser, and expansion device of a Water Chiller Machine.

A thermodynamic process occurs in each of the above components of a Water Chiller Machine.

The evaporator acts as a heat exchanging device, in a way that heat stored by the Water Chiller Machine’s coolant flow, transfers to the refrigerant.

The heat-transfer process takes place, the refrigerant evaporates and starts changing from a low-pressure liquid into vapor form, while the temperature of the process coolant decreases.

The refrigerant of your Water Chiller Machine flows to the compressor. The compressor then performs multiple processes.

The condenser of a Water Chiller Machine re-circulates the water from the cooling tower to condense the refrigerant.

The condenser of a Water Chiller Machine ensures that the pressure in the evaporator must be low to absorb the required amount of heat.

Secondly, it is also responsible for raising the pressure in outflowing refrigerant vapor. It ensures that the temperature remains high to produce enough heat when it meets the condenser.

The refrigerant of a chiller machine then returns to a liquid state at the condenser.

Working Principles of the Water Chiller Machine

What are the Features of the Water Chiller Machine?

Apart from its working and its incredible benefits, it has some superior features given below.

• Energy-efficient

The Water Chiller Machine is highly energy efficient.

It uses water as a cooling agent. It highly meets the cooling method after passing through different processes in the Water Chiller Machine.

• Reliable and high-quality compressor

A Water Chiller Machine is highly reliable because of its manufacturing material and working techniques.

You can increase its lifespan with the help of proper maintenance. There is a complete section about maintenance guidelines.

The Water Chiller Machine has a durable and high-quality compressor.

• Easy to install

A Water Chiller Machine has the feature that you can install easily because of its design and packaging.

• Easy to maintain

You can easily maintain your Water Chiller Machine. It will optimize its performance.

• Auto Control panel

A Water Chiller Machine has a built-in automatic control unit which is crucial and helpful during any emergency.

• Easy to operate

A Water Chiller Machine is user-friendly and very simple to operate.

• Expansion valves

It uses a high-quality thermal expansion valve which helps the refrigerant to evaporate in the evaporator. It increases the volume of the pressure produced by the refrigerant.

• Multiple Compressors

A Water Chiller Machine facilitates its users with multiple compressor options.

• Data Logging

A Water Chiller Machine has another useful feature of data logging.

Portable Water Chiller Machine

What are the Main Components of a Water Chiller Machine?

A Water Chiller Machine is used in medium to large buildings and produces chilled water that is used to provide air conditioning.

There are many different types of Water Chiller Machines but mostly they all have the same main components.

• Compressor

It is the most important component of the Water Chiller Machine.

It is used to ensure the motion of refrigerant all over the process. It is located between the condenser and evaporator.

An electric motor acts as a driving force in it. You can place it internally or you can adjust it outside.

• Condenser

A condenser is used to remove the heat from the refrigerant and transfer it to the evaporator.

It is usually available in two types, i.e. water-cooled condenser and air-cooled condenser.

• Expansion Valve

The expansion valve increases and expands the volume of refrigerant. This helps the refrigerant to get heat in the evaporator.

The expansion valve is available in different types; the common type is used mostly in the thermal expansion valve.

• Evaporator

An evaporator receives the heat from your application and passes it to the refrigerant to send it to the cooling tower.

It is placed exactly between the compressor and expansion valve. When the heat extracts the water will start cooling.

The chilled water is then generated throughout your application to start air-conditioning and then your application resends the water to the evaporator with the heat and it repeats the same cycle.

• Power Unit

The power unit also plays a very important role in the working of a Water Chiller Machine.

It is used to control the electricity supply to all the components of the Water Chiller Machine.

• Water Boxes

In a Water Chiller Machine, the water boxes are mounted to the condensers as well as evaporators. It is responsible for keeping the flow continuous.

It also separates the inlet from the exit point. A water box of a Water Chiller Machine mostly has one or more entrances and exits.

It depends upon the number of cycles in the condenser and evaporator.

• Control Unit

The control unit in a Water Chiller Machine monitors the performance and efficiency of a Water Chiller Machine.

It is highly responsible for making settings and adjustments if something is not working the way it should.

The Control unit has an alarms facility. It immediately shuts the system in any emergency condition.

Water Chiller Machine Cooling Towers

What are the Benefits of the Water Chiller Machine for your Application?

• Environmental friendly 

Refrigerant is used: in Water Chiller Machines instead of toxic chemicals; that’s why it is safer for users.

• Quiet/Silent Operation

It does not have ducts and vents like air-cooled chillers due to which it does not produce noise. The Water Chiller Machine starts without any noise.

The water inside the system flows fluently, which does not cause any noise pollution. Fast and noise-free operation is important in buildings/environments such as educational institutes, Hospitals, and noise-less, areas.

• Energy Saver

The Water Chiller Machine is energy-efficient, as it transfers heat more efficiently as compared to air chiller machines. It is 20 to 100 times better than air chiller machines.

You can save money by using a Water Chiller Machine due to its energy efficiency benefit.

• No Open Space Needed

Just like air chiller machines, it does not need an open space for operation. You can fit without the limitations of open air.

If you don’t have an open area or your company is in a congested area. where there is no open space available, then this will be ideal open for you to select a Water Chiller Machine.

• Longer Lifespan

Water Chiller Machine has a longer lifespan if compared to air chiller machine because they are not fixed outside. So the elements like heat, ice, and snow do not affect them like air chiller machines.

Energy Saving Water Chiller Machine

How to Determine the Capacity of your Water Chiller Machine?

First of all, you need to perform this basic calculation. If you want to calculate the capacity of the Water Chiller Machine.

• The volumetric flow rate of water into the evaporator of your Water Chiller Machine
• The incoming and required water temperature for your application.

You can determine the capacity of your Water Chiller Machine by using the given four-step process;

• First, calculate the material-specific heat, Δ T and Δ
• Now you need to calculate and MC ΔT.
• After that, convert the results into tons to get the capacity of your Water Chiller Machine.

Additionally, Then you can check out the properties of water for the following.

• The density of the water at the average temperature by using (inlet temperature +  required outlet temperature)/2
• The Specific Heat Capacity of the chilled water of the Water Chiller Machine at the average temperature by (inlet temp + outlet temp)/2

What are the Industrial Applications of the Water Chiller Machine?

A Water Chiller Machine provides constant temperature, constant current, and constant pressure.

An Industrial Water Chiller Machine is used for industrial processes and applications. It is being used in different medium and large-scale industries.

Electronics Industry: 

Water Chiller Machine applied in the electronic industry on the production line is used to balance the molecular structure and the electronic components.

It can highly enhance the qualification of electronic components in the electronic industry.

Plastic Industry:

Water Chiller Machines in the plastic industry can control the temperature during the molding process of plastic. As a result, a product will have better finishing.

Electroplating Industry:

The electroplating industry is using a Water Chiller Machine to control plating temperature.

It is also used to make the plating parts smooth and to increase their density.

A Water Chiller Machine summarizes the plating cycle and improves the quality of product and production efficiency.

Machine Tool:

A Water Chiller Machine applied in the machine tool helps to control the temperature of the oil pressure system.

It is used to improve the lubrication process. It stabilizes the oil pressure and oil temperature in the application.

Construction Industry:

A Water Chiller Machine installed in the construction industry provides the coolant for concrete and provides a suitable molecular structure for the construction process.

It is very effective to improve, the quality of concrete.

Vacuum Coating Industry:

A Water Chiller Machine can be used: for cooling vacuum coating by controlling the temperature in the vacuum coating machine.

It also provides well-qualified plated parts in the vacuum coating industry.

Food and Beverage Industry:

You can use a Water Chiller Machine in the food industry for good cooling when the food is ready to adapt to packing requirements.

You can also control the temperature of fermented food products.

Pharmaceutical Industry:

The pharmaceutical industry is widely using a Water Chiller Machine to control drug temperature and medical equipment.

This industry is continuously making progress in technological innovations to serve the pharmaceutical section.

Ultrasonic Cleaning Industry:

In an ultrasonic cleaning industry, a Water Chiller Machine prevents the volatilization damage that occurs by expansive cleaning agents.

Water Chiller Machine is Famous for Food and Beverage Industry

How to Choose the Right Water Chiller Machine for your Application?

The selection of a Water Chiller Machine entirely depends on your applications, so by keeping the following few steps in your consideration you can select the best water chiller plant as per your requirements.

1: Figure out the Heat Load Requirements of your Application

First of all, calculate the heat load of your application or activity because this factor plays an important role in the selection of a Water Chiller Machine, choose only and only Water Chiller Machine that can meet your heat load requirement.

In the places or buildings where the heat load is greater the more efficient the water chiller is required to be used.

2: Identify the Coolant Type, Temperature & Flow Rate

The next step which you keep in your mind is that what type of coolant you are going to use for your Water Chiller Machines.

And how fast the coolant absorbs the heat from its surrounding, as you know that water has different characteristics than oil

3: Inspect the Installation Environment

The third point that you need to keep in your mind is the environment where to install your chiller machine.

So always choose a water chiller which is suitable for your environment.

You know that some Water Chiller Machines can perform better even in the worst environmental conditions but these Water Chiller Machines are too expensive, so by analyzing your environment and budget.

4. Final selection 

Now as the final step, you have to analyze the water chiller curve and compressor curve the Water Chiller Machine which you are going to choose, its curve should be within specified limits.

You can use trend analysis techniques to finalize the selection of a Water Chiller Machine that may be suitable as per your requirement.

How to Size Water Chiller Machine for your Application?

You can size your Water Chiller Machine according to the requirements of your application.

The size you need for your Water Chiller Machine is based on the total amount of heat your application is producing.

It also refers to the additional power to adjust the temperature under different loads.

Normally the manufacturer of the Water Chiller Machine you are going to buy will give you the complete heat removal information and figures.

If still, you don’t know the method for calculating the size of your Water Chiller Machine, here is a formula is given below;

• In the first step, you need to calculate the temperature Differential (? T°F)? T°F = Inlet Water Temperature (°F) – Required Water Temperature
• After that, Calculate BTU/hr.BTU/hr. = Gallons per hr x 8.33 x ?T°F
• Then, figure out the tons of cooling capacityTons = BTU/hr. ÷ 12,000
• Now, Oversize the chiller by 20%Ideal Size in Tons = Tons x 1.2

Hence, you will have the ideal size of your Water Chiller Machine for your application.

How to Install your Water Chiller Machine?

Here are some steps which must be followed: to install the Water Chiller Machine, for optimum performance of Water Chiller Machine.

1. Installation Environment

The Water Chiller Machine should not be installed closer to the fireplace or heating environment and the site temperature where the installation is recommended should not exceed 45 degrees Celsius.

The environment should not have any corrosive gas or any other corrosive chemicals, dust, and dirt.

2. Construction of the Foundation

The compressor is an essential part of the Water Chiller Machine, is consists of non-moveable parts, and for the installation of the compressor, a foundation or base is to be built where the compressor is going to be fixed.

The foundation must be strong enough to bear the compressor load; the size of the foundation should be as prescribed in the manufacturer manual.

3. Unpacking of Equipment

In this process, carefully unpack the equipment as per instructions given in the manual.

Check all the components, and parts are available as per the list and contact the supplier in case of deficiency also check for any damage and report to the supplier if any.

4. Installation of Equipment on Foundation

Before installation, make sure of the availability of all the tools, equipment, and crane.

First of all, install the shock pad and bolt now carefully lift the equipment with the help of a crane and place the Water Chiller Machine on the bolts and fix it by using washers and bolts.

Caution:

Always lift the machine from marks for lifting marks otherwise damage to equipment or serious injury may cause.

5. Piping and Wiring

After successful installation, your Water Chiller Machine’s main unit carries out the piping and electrical wirings as per the standard and procedures specified in the installation manual.

Finally, debug the installation and carry out the operation check out of the system. All installations are done under the supervision of classified experts.

Water Chiller Machine Solid Foundations

How to Maintain your Water Chiller Machine?

Following steps may be taken for the maintenance of your Water Chiller Machine.

1. Maintain a Logbook Record

Maintain a complete logbook consisting of all the history and inspection records of that particular Water Chiller Machine.  All the events that took place should be recorded.

2. Cleaning of Tubes and Pipes

Due to continuous flow of water sometimes the tube or pipes of Water Chiller Machines become contaminated and this decreases the efficiency of the machine,

so it is suggested that these tubes and pipes may be cleaned as directed by its manufacturer.

3. Condenser Water is treated to Avoid Scale and Corrosion

All the components involved in the condenser water loop required some sort of water treatment to avoid scaling and corrosions.

The scaling and corrosions in the machine or pipes slow down the process of heat transfer, so this inspection must be carried out once a year.

4. Lower Entering Water Temperature

You can reduce the temperature of the water entering the condenser;

You can improve the efficiency of our water chiller, sometime the operator lowers down the chilled water setpoint that may overcome air handler deficiency like a dirty coil.

This cure will allow your Water Chiller Machine to work harder to meet the required cooling standard.

5. Analyze Compressor Oil

The lubrication oil sample used in the compressor must be sent for spectrometric analysis to a well-reputed lab once a year.

The time replacement of lubrication oil will enhance the life of the compressor.

6. Check Motors and Starters

All the motors and starter gears, pulleys, and belts are inspected for their proper functioning if something is out of order repair or replace it for the smooth running of your chiller machine.

Water Chiller Machine Cleaning

FAQ of Water Chiller Machine.

1. How a Water Chiller Machine removes Extra Heat from your Application?

During the process of cooling, the refrigerant is evaporated with the help of an evaporator heat is absorbed by the refrigerant.

After this refrigerant is compressed with the help of a compressor this it will go through the condenser where extra heat is removed.

2. What is the Difference between Vapor Compression Water Chiller Machine and Absorption Water Chiller Machine? 

Vapor compression, Water Chiller Machine, and absorption Water Chiller Machine are different from each other in a way; that how refrigerants are changed into the liquid, in absorption Water Chiller Machine change.

While on the other side a vapor-compression chiller requires a metering device to convert gas into a liquid.

3. How Air-cooled Chiller Machine different from a Water-cooled Chiller Machine?

In an air-cooled chiller, a ducting system requires to cool down the hot air. so these are used in small or medium buildings

While the water-cooled chillers require an additional water tower to compress the air. This type is used for large buildings.

4. What type of Cleaning Services is required for the Water Chiller Machine?

Different types of preventive and corrective maintenances are required to be performed on a Water Chiller Machine as prescribed by the manufacturer.

For example, six months or one-year inspections for optimum performance of the Water Chiller Machine. It is necessary to remove any contamination, minerals, from ducting, and pipes.

5. How to know that, which Water Chiller Machine is best?

If you are going to buy a Water Chiller Machine. Must make a feasibility report based on your requirement and budget.

For a selection of chiller machines, must consult some experienced technicians and also calculate your area of the building.

6. What is the Environmental Plus Point of Water Chiller Machine?

The use of water as a cooling agent is a safe and cheaper way. It is a natural resource and it is non-toxic none plosive, and easily available as compared to using other chemicals.

7. How much water is consumed for the Cooling Process in a Water Chiller Machine? 

No water is consumed during the process of cooling because it is a closed-loop cooling system.

Once the system is filled with freshwater that is approx. 60 to 80 liters it is kept on circulating in the chiller machine.

8. What should be the Quality of Water used as a Cooling Agent in the Water Chiller Machine? 

No extra hygienic or high-quality water is required for this purpose.

Simple and ordinary water can be used for this purpose but it should be kept in mind that no hard water or rainwater should be used to avoid scaling in the Water Chiller Machine.

9. What happens if Pressure is too High in a Water Chiller Machine?

A very high-pressure rate in a water machine can result in a leakage in the thin aluminum and condenser pipes.

It is also a sign that the process has enough amount of refrigerant when you experience a very high temperature.

10. What is the Difference between Chilled Water and Condenser Water in a Water Chiller Machine?

Chilled water absorbs the heat from your application during the process.

And condenser water removes the heat from your application and ejects it into the atmosphere.

100% Quality Tested Water Chiller Machine