TopChiller Water Chiller System Manufacturer and Supplier in China

 Water Chiller System-An Ultimate Buying Guide by TopChiller.

A Water Chiller System is a large piece of machinery that is used to remove heat from a process.

It is used to cool medium and large-sized buildings. It is also used to provide cooling for multiple adjacent buildings.

With modernized conception and compatible design, Water Chiller System occupies minimum space and is used worldwide for its reliability, productivity, and efficiency for industrial process cooling purposes.

This article will guide you about the placement, operation, service, and maintenance of your Water Chiller System and ward off all your worries about this bulky machine.

This guide will provide you with the bulk of information about the Water Chiller System.

Let’s start it.

What is a Water Chiller System?

Water Chiller System is a specific type of cooling machine that is used in a variety of industrial applications where water is circulated through process equipment to remove the excess heat from it.

The Water Chiller System is globally used to maintain the temperature of the process due to its critical structure for some special required industries applications.

Water Chiller System provides cooling to a particular process by using chilled water to absorb heat from a process. Then it removes heat from the water through the refrigeration cycle.

Water Chiller System acts as a centralized cooling system that provides cooling for an entire building.

This is because it is often more practical to centralize Water Chiller System in one location rather than installing several cooling systems in many different places.

Water Chiller System Designed by TopChiller

What is the Working Principle of a Water Chiller System?

A Water Chiller System uses the principle of compression and absorption of a liquid such as water and converting it from one state to another in its operation.

We know a Water Chiller Unit is a water cooling refrigeration machine.

It consists of a pumping system that circulates cool water from a Water Chiller System to the process.

The Water Chiller System cool fluid removes heat from the process and the warm fluid returns to the Water Chiller Unit. A Water Chiller System contains a chemical compound, called a refrigerant.

There are many types of refrigerants. The Refrigerant is selected according to the applications depending on the temperatures required for your applications.

But all types of refrigerants work on the basic principle of compression and phase-change of the refrigerant from a liquid to a gas and back to a liquid.

In the refrigeration cycle, the process of heating and cooling the coolant and changing it from a gaseous state to a liquid and back again takes place.

The refrigeration cycle starts with low-pressure water entering the evaporator.

In the evaporator, heat from the process water increases the temperature of the refrigerant.

The refrigerant changes its state from a low-pressure liquid to a low-pressure gas.

The low-pressure gas enters the hermetic scroll compressor where it is compressed to high-pressure gas.

The high-pressure gas enters the condenser.

The atmospheric air or condenser water removes heat to cool it to a high-pressure liquid.

The high-pressure liquid travels to the expansion valve, which controls the amount of liquid refrigerant entering the evaporator. Then the refrigeration cycle starts again.

There are two types of condensers used in the Water Chiller System based on the types of condensers.

• Air Chiller System
• Water Chiller System

An air-cooled condenser uses the atmospheric air to cool and condense the hot refrigerant gas back to a liquid state. Whereas water is used to condense the refrigerant in water-cooled condensers.

Water Chiller System Working Principle

What are the Features of a Water Chiller System?

The Water Chiller System has many attractive and user-friendly features which distinguish it from an ordinary chiller and make it stand out from the crowd.

Water Chiller System has compatible and highly flexible model than facilities user and maintains the required temperature for your applications by rejecting heat outside the environment.

One of the leading features is that it contains a variable speed motor that is designed and programmed in such a way that it adjusts its voltage according to the compressor load.

Its prime feature is that it doesn’t waste your electricity by supplying extra voltage to its compressor. It reuses the power and saves your electricity consumption.

In this way, a Water Chiller System helps you to save a lot of money you spend on energy consumption.

Water is used as a coolant has more advantages over another coolant. A water leveling system is used to adjust and monitor the level of water and it helps to maintain it and don’t let it increase more than the specified limit.

Water corrodes the metal plate. It causes rusting of several components.

To overcome this problem, a Water Chiller Unit uses non-reactive metal-plated plates as a heat exchanger to prevent corrosion and rusting in its internal parts.

A Water Chiller System uses the programmable logic controlled system to control its various operations like speed, voltage, water level, and temperature. It has different sensors to monitor different levels and situations.

For example, it has a water level sensor and a pressure level sensor. Pressure sensor to monitor and precisely control high and low pressure.

With the help of micro-channeled condenser coils, the condensation power of your Water Chiller System boosts to the next level.

These coils are made up of aluminum and copper these are the top preferred non-reactive metals widely used to prevent corrosion.

They are used not only for their non-reactive properties but also have the best heat exchanging properties as well.

Aluminum has perfect value for emissivity to store and transport heat from one part to another. Small-sized and lightweight coils provide high-quality heat transfer and high durability of compressors.

Stainless Steel Body Water Chiller System

What are the Main Components of a Water Chiller System?

A Water Chiller System has the following main components:

High-Quality Evaporator:

It plays a crucial role in a Water Chiller System. The condensation pressure of refrigerant drops to the evaporation pressure to place it in the liquid receiver.

It precisely monitors the flow of refrigerant entering the evaporator.

The chilled water produced in the evaporator is moved to the Water Chiller System and passes through the pump.

The pump pushes it to a building or process where cooling is required.

Water in the Water Chiller System absorb all the heat from the environment and return to the Water Chiller System at high temperature.

When it leaves the Water Chiller System it gives up all its absorbed heat. This cycle repeats.

These heat leaves are transferred via refrigerant to the condenser.

Suction Service Valves:

A Water Chiller System consists of a suction service valve that controls the amount of water entering and leaving the unit.

Hermetic Scroll Condenser:

A condenser is a device that works on the principle of condensation. Condensation simply means converting gas into a liquid state.

It is one of the essential parts of the refrigeration unit of your Water Chiller System. It condenses the refrigerant back into a liquid form.

But a Water Chiller System uses a specific type of compressor known as a Hermetic Scroll Compressor which contains both compressor and an electric motor are confined in a single unit.

Hermetic compressors are best where maintenance of the system is difficult to achieve.

It compresses the refrigerant that is water to high pressure and sends it out to the condenser.

It adjusts its cooling when a low or high temperature is required.

Plates Coated with Stainless Steel Material.

These plates are, heat exchangers. It is the place where most of the cooling takes place.

Stainless steel has many unique properties that make it useful as a heat exchanger.

It is one of the best metals to resist rusting and corrosion.

It protects the plates of the Water Chiller System from rusting and provides a long-life span.

Condenser Coils:

These are the cooling coils for the refrigeration system. They reject the heat taken from the inside of an environment outside that environment.

A Water Chiller System uses different types of condenser coils depending on your applications.

Some Water Chiller Systems use micro channeled coils that provide better transfer of heat.

Micro channeled coils are made up of an aluminum and plated coil that provides the parallel flow to the fluid. These coils contain water as a refrigerant or coolant.

The chilled water is transferred through the refrigeration unit to the pipelines connected with a heat exchanger surrounding a heated process.

These coils are the channel to transfer heat from the environment to outside that environment.

Pressure Pump:

A Water Chiller System uses a wide range of high-pressure water pumps with various water flow rates, pumps vary with your applications.

Water Chiller System Pump

What are the Applications of a Water Chiller System?

A Water Chiller System has a wide range of applications because it features few moving parts, high efficiency, superior reliability, and quality of service.

Applications of Water Chiller System in our Daily Life:

A Water Chiller System is very important in large buildings where cooling is required. It can provide maximum cooling to multiple buildings.

It is globally used to maintain the temperature in offices and industrial processes.

Bio-Pharmaceutical Industry:

Bio-Pharmaceutical Industry also needs cooling systems to maintain the temperature of the specimens, biological components of different animals, birds, and humans.

Bio-Pharmaceutical companies and the medical industry need accurate temperature control for the production of medicines and related products.

Chemicals and products used in medicine production need accurate and effective treatment control. It requires tough temperature control to control chemical reactions and produce desired results.

There are two types of chemical reactions:

Exothermic Reactions: these are the chemical reactions that release a huge amount of heat to the environment.

Endothermic Reactions: These are the chemical reactions that require heat and they absorb heat from the environment.

A chemical compound mainly depends on these two types of reactions so a pharmaceutical company needs to maintain a correct level of temperature in the laboratory to produce desired results.

A Water Chiller System is the best solution to their problems. It removes the excess heat from the environment or process and maintains the required level of temperature.

These are the reasons why pharmaceutical industries use Water Chiller systems.

Plastic Processing Machines:

Plastic processing machines produce a huge amount of heat and it is very important to remove this excess of heat from the environment or process.

Because this excess of heat can cause either damage to the internal system of your machines or can cause an explosion.

Water Chiller System is used to remove this excess of heat and maintain the required normal temperature.

Applications of a Water Chiller System in Food and Beverages:

The manufacturing industry uses Water Chiller Systems to remove heat from their processed products, like the plastic industry.

A Water Chiller System plays a vital role in maintaining the sustainability of the products.

Some products require a specific temperature to remain in good condition.

High temperatures can change the taste, consistency, and hygiene of some foods and beverages.

Beverages like juices, soft drinks, cold drinks, and vibe are served cold. No one likes to drink them at a normal temperature. They must be chilled and cold.

A Water Chiller System is used to maintain that level of water to ensure the quality of food and beverage.

What are the Benefits of Using a Water Chiller System for your Applications?

The Water Chiller System has a lot of benefits for industrial and commercial processes. Its major advantages are high efficiency, low power consumption, long service life, and easy operation.

The Water Chiller System is flexible and can have many different configurations, it can be installed indoors, outdoor.

Water Chiller System has a unique and profitable feature that they can have different compressors and refrigerants depending on the cooling capacity and the efficiency needed.

In short, Water Chiller Systems are perfectly customizable options it allows the users to choose different options and accessories for the needs of a specific application.

A Water Chiller System has full protection devices like water alarms and high-temperature alarm functions.

These alarms are quite helpful for users to monitor their Water Chiller System and detect any problem easily.

According to the U.S. Energy Information Administration, 15 to 20% of the energy used in commercial buildings is for cooling.

Water Chiller System is globally used in large organizations and buildings for cooling. Because of their unlimited benefits, reliability, and efficiency.

A Water Chiller Unit can be used for a variety of industrial and commercial applications for providing a steady cooling source.

Water Chiller System is Use for Big Industrial Manufacturing Units

What are the Common Problems that Affect the Performance of a Water Chiller System?

Some common mistakes affect the working performance, efficiency, and durability of your Water Chiller System.

You need to figure out solutions to these problems to ensure the best working performance of your Water Chiller System.

Sometimes your Water Chiller System doesn’t power up it does not necessarily mean that it is damaged.

It happens due to improper line voltage or loose connection. Always ensure a smooth and reliable flow of voltage.

Incorrect phase connection can also result in the shutdown of your Water Chiller System.

A blown circuit breaker or fuse will not allow it to operate. You have to replace them.

Improper or fluctuating line voltage will result in insufficient fluid flow.

Always make sure you have the right level of water in the reservoir for the proper operation of your Water Chiller System.

Close or partially closed process valve is one the most common mistakes that users do while operating a Water Chiller System.

Always choose a suitable coolant fluid for the temperature requirements of your application. If you will choose an unsuitable coolant it will affect the working performance of your Water Chiller System.

Don’t let your filters block. Clean them properly on weekends to ensure the smooth operation of your Water Chiller System.

Your Water Chiller System may show insufficient cooling due to improper or fluctuating line voltage and clogged filters of the condenser.

Refrigerant leakage is another common problem that results in insufficient cooling.

Avoid all these common mistakes. Your Water Chiller System will work smoothly.

How to Size a Water Chiller System for your Application?

Calculating the size of your Water Chiller System is not that much difficult. It depends on the requirements of your application.

Your application will define the size of your Water Chiller System. Usually, a large size is preferred in large buildings and industrial processes.

This is the general formula to calculate the size of the Water Chiller System:

• Calculate the temperature difference =incoming water temperature –chilled temperature required
• Calculate BTU/hr.
• Calculate the cooling capacity in tons. 1ton=BTU/hr. Divide by 12,000
• Oversize your Water Chiller System by 20%.
• Multiply the ideal size with 1.2.

You have the perfect size for your Water Chiller System for your application.

How to Install a Water Chiller System for your Application?

The Water Chiller System must be installed on a rigid ground surface. This surface must have adequate strength to bear the weight of your Water Chiller System along with water in it.

Location

A Water Chiller System uses water as a coolant when operating. Install it where any fluid leakage can not cause any damage to your environment. Although water leakage can not cause any hazard it may damage your surface.

Process Piping and Connections:

Your Water Chiller System has piping and connections to transfer fluid to and from the process. Carefully note the marks engraved on the piping.

The piping that is used to connect the hose to transfer fluid to the process is marked as TO THE PROCESS.

The piping that is used to connect the hose to transfer the fluid from the process back to the process is marked as “FROM THE PROCESS”. Use the mesh filter to enter the fluid into your Water Chiller System. It will protect it and help you to service and maintain your Water Chiller System.

Water Intake Connections:

Connect the hose marked as “water make-up” with the water source. Your Water Chiller System may have manual water intake connections or automatic water intake connections.

An automatic water intake connection will monitor the level of water in the tank when it is needed.

But if your Water Chiller System has manual water intake connections then you have to maintain the correct level of water in the tank.

Install a Valve Outside the Unit.

Always use backflow prevention devices to increase the efficiency of your Water Chiller System.

Your Water Chiller System has a label the mark “condenser water in” in the connections. Connect your water tower or city water with it.

The flow rate of water will be different for city water sources and tower water sources.

Use a strainer to transfer water to the condenser. It will filter the water for containments and protect the water regulator valve.

Accurate Voltage Supply:

Use an accurate required voltage supply. Follow the instructions of the installation manual for your Water Chiller System.

It should not exceed more or less than 10 percent of the limit provided for your application.

An extreme imbalance of voltage can cause damage to the internal system of your Water Chiller System. It may cause operation failure and safety risks.

Procedure to Turn on and Start your Water Chiller System:

Use clean water for operating temperatures of 48 degrees Fahrenheit to 80 degrees Fahrenheit.

Always use clean water it will improve the operation of your Water Chiller System.

Operating temperatures below this use a glycol water mixture.

It is recommended to use a Right Proportion of glycol as described by the manufacturers.

The excess of Glycol can also cause damage to your Water Chiller System and it will stop working or provide less efficient performance.

Water Chiller System Installation

How to Service and Maintain your Water Chiller System?

Afterward, the installation of your Water Chiller System is essential to service and maintain it to serve your purpose and to provide you best cooling system.

Proper maintenance and service of a Water Chiller System give you its output at the topmost level. It will also save your energy and maintenance costs.

• One of the major steps for its maintenance is to check your Water Chiller System for leakage and ensure that all components are properly functioning.
• Maintain a correct level of pressure as recommended by the manufacturers. It should not be too high or too low.
• Excessive loading results in damage and improper operation of motors and other components of the Water Chiller System. Always use terms and conditions to avoid such a situation.
• An unbalanced voltage supply can cause damage to the electrical circuits and the failure of the system. Choose a Water Chiller System having high quality and well-known circuit components mentioned above in their buying guides.
• Always make sure that flow sensors are on.
• Check the circuit breakers daily and replace the blown fuses and, damaged wires.
• Add high-quality lubricating oil once a week for the smooth working of the motor and reduce the wear and tear of its other components.
• Check all the wire terminals they must be properly connected.
• Check safety switch settings keep them on to avoid hazards and explosions.
• Cleaning the filters regularly will boost the speed and durability of your Water Chiller System
• Check the ratio of Refrigerant for the operation.
• Clean pump causing, cavities and impeller will increase the average life expectancy of your Water Chiller System.
• Turn off the Water Chiller System before cleaning. Don’t use a wire brush to clean its components, instead use a soft microfiber brush with high maneuverability and compatibility.

Water Chiller System Regular Inspection

How to Troubleshoot your Water Chiller System Problems?

Troubleshooting common and easily solvable problems don’t require much expertise but it is recommended to consult an expert or professional technician when you are dealing with complex problems.

Your Water Chiller System may not Start and Operate. Don’t get panic to figure out problem solutions. It is quite often observed that the Water Chiller System doesn’t start in the beginning.

It does not mean that your Water Chiller System is damaged or faulty.

Follow these instructions and you are good to go! Troubleshooting your Water Chiller System for better function and accurate results.

• A blown circuit breaker or fuse, loose wiring, or simply a power switch that’s been put in the “off” position could be the reason for not powering up.
• Determine whether the Water Chiller System is cooling. Check the temperature of the coolant at the Water Chiller System’s outlet to the process. It should be at an accurate Setpoint.
• If it isn’t at or near the Setpoint temperature, the evaporator might be iced up or the heat transfer properties of the coolant fluid might be deteriorating.
• Make sure that the pump is running. A closed or partially closed valve failed pump, inadequate coolant volume or process line restriction might be preventing the adequate flow of liquid through the process coolant loop.
• Check the process and environmental conditions. The load on the Water Chiller System might be too great due to changes in the process or the ambient temperature.
• Other conditions that can affect the Water Chiller System are heat removal capabilities include a change in the location of the Water Chiller System near other heat-generating equipment or farther from the process equipment.
• The distance between the process and the Water Chiller Unit should not be too large or too small.
• Loose, damaged, or missing insulation on the piping between your Water Chiller System and the process; or fluctuations in line voltage may also fail it.

Water Chiller System Troubleshooting

FAQ of Water Chiller System

1. How does a Water Chiller System Increase the productivity of your Business?

Water Chiller System is one of the most advanced technologies of refrigeration systems. It removes the heat from your industrial process and keeps your production smooth and steady.

2. What makes a Water Chiller System unique?

Water Chiller System uses a hermetic scroll compressor which makes it stand out.

The advantage of a hermetic scroll compressor used in a Water Chiller System is that it has fewer moving parts and less torque variation compared to the reciprocating compressor.

This advantage leads to a smooth and quiet operation of a Water Chiller System.

It enables the Water Chiller System to produce less noise as compared to other chilling systems. It has additional features over an ordinary chiller.

3. Why Service and Maintenance of a Water Chiller System are Important?

Maintenance plays a crucial role in the effectiveness and productivity of a Water Chiller System.

It helps the Water Chiller System to perform its operation smoothly.

Timely maintenance and service ensure a longer life span of your Water Chiller System.

4. How a Water Chiller System is Cost-effective?

Water Chiller System enables you to maintain the desired temperature and consume less amount of electricity.

In this way, a Water Chiller System is cost-effective because it saves your money.

It is a long-term investment solution that enables you to choose different options for your applications without any hustle.

5. Why water is used as the cooling liquid in a Water Chiller System?

Water is safe to use as a cooling liquid in a Water Chiller System. It is non-explosive.

It is an environment-friendly alternative for fluorinated gases that are harmful to the environment. It is non-toxic, easily, and freely available.

100% Quality Tested Water Chiller System