Whatever Type of Water Chiller,
TopChiller Can Fulfill the Water Chiller Solution for You.
- 20 years of water chiller manufacturing experience: TopChiller is a leader in water chiller manufacture with rich experience
- 18 month warranty time: TopChiller provide 18-month warranty for standard water chillers can extend to 24 months covered all water chillers
- Famous brand spare parts: Each water chiller from TopChiller using world-famous brand refrigeration spare parts
- Technical support& Training service: TopChiller can provide all clients water chiller installation and commission service
- 8 Hours troubleshooting: In case of any water chiller error or alarm, TopChiller will give a quick response within 8 hours to solve your water chiller problem
- Lifetime service: TopChiller promise clients to give all water chiller whole lifetime service free of charge
Why TopChiller Can Be a Reliable Water Chiller Factory
Water Chiller: Your Premier Choice
Of Industrial Chillers
A water chiller is also called water-cooled chiller or water to water chiller and water cooling chiller.
A water chiller is a mechanical device that can produce cold and chilled recirculating water for various industrial application use.
TopChiller® is your professional water chiller supplier and company with over 20 years of experience.
Water chiller designed and manufactured from TopChiller® equipped with USA Copeland brand, France Danfoss brand, and Japan Sanyo brand hermetic scroll compressors, have spare parts available from the world-famous refrigeration brands.
This water chiller from TopChiller company features a water-cooled shell & tube type condenser, stainless steel water tank heat exchanger as the evaporator, but shell & tube or stainless plate type heat exchanger option based on detailed requirements.
But compared with air chiller, water chiller needs to install a proper cooling tower and cooling pump to work together.
This is the biggest difference between a water chiller and an air chiller.
Each water chiller unit before delivery is charged with environmentally friendly refrigerant R407c, with R134a, R404a, and R410a, also available for different industrial applications and ambient temperature demands.
High-quality water chiller designed and manufactured by TopChiller features some outstanding advantages as below:
1.Environmental friendly – TopChiller water chillers are charged with HFC-R410A, R407c, and R134a refrigerants, which has no ozone-depletion potential and no phase-out schedule.
2. High Efficiency – Water chillers made from TopChiller are leading design and off-design efficiencies.
3.Compact Design – All water chillers are designed with a compact structure for ease of installation.
4. Reduced wiring costs –Our water chillers are with Lowest MCAs in the industry also maximize capacity on retrofit projects.
5. Low Operating Costs – TopChiller water chiller with rugged design for low maintenance costs and long design life.
As a leader of a water chiller manufacturer, TopChiller having a complete product range of water chillers including portable water chiller, recirculating water chiller, screw chiller, and other industrial water chillers.
All these water chillers are the best industrial cooling partner for your machines.
With the capacity to meet cooling requirements for a wide range of commercial and industrial facilities, get the performance you want from your cooling equipment with water chiller from TopChiller now.
For decades years, TopChiller has exported thousands of high-quality water chillers throughout world countries.
The cooling capacity from small 5ton, 10ton,15ton, 20ton, 25ton,30ton to middle size 40ton,50ton,60ton, and up to 100ton,120ton, 15t0n.
Our water chiller customers are the Philippines, Australia, New Zealand, Malaysia, Singapore, Indonesia, Chile, Mexico, Costa Rica, Brazil, Argentina, Colombia, South Africa, Nigeria, Saudi Arabia, Dubai, Spain, Italy, etc.
If you are looking for a high-quality water chiller supplier?
If you need a long-lasting water chiller for cooling your machine or plant process?
You are coming to the right water chiller factory.
As a professional water chiller manufacturer with rich experience in refrigeration, we have enough confidence to satisfy your special requirement on any water chiller needs.
Please do not hesitate to contact TopChiller sales to get the best price for your water chiller.
TopChiller: Your Leading Water Chiller Manufacturer and Supplier in China
TopChiller is a professional water chiller manufacturing company with 20 years of experience.
Compared with air chiller, water chiller should connect the circulation water pump and installed an external water cooling tower as the heat exchanger for a reliable working condition, performance, and high cooling efficiency.
This water chiller manufactured by TopChiller team is your reliable water cooling partner, can be widely used for a plastic injection molding machine, blow molding machine, plastic extruder, chemical industry, and many other applications.
Water chiller provides a constant chilled water flow rate to improve the development process and increase productivity.
As a leader in the water chiller field, all water chillers made by TopChiller® are all 100% tested and well packaged before delivery to make sure they are in perfect working conditions.
Each water chiller designed and manufactured by TopChiller has 12 months regular warranty time that covers the whole water chiller unit and all refrigeration spare parts.
As the most professional water chiller supplier with 20 years of experience, TopChiller® would like to give perfect water chiller solutions at competitive prices.
Please contact our engineering team to customize your water chiller solution for your business.
TopChiller is sure about your special water chiller requirements will be satisfied with our engineering department.
A Complete Buy Guide of Water Chiller from TopChiller
- Chapter 1: What is a water chiller
- Chapter 2: How does a water chiller working
- Chapter 3: The difference between water chiller and air chiller
- Chapter 4: Water Chiller Industrial Applications
- Chapter 5: Why TopChiller can be your reliable Water Chiller supplier
- Chapter 6: How to size a suitable water chiller for your machine
- Chapter 7: Water Chiller installation guide
- Chapter 8: Troubleshooting of water chiller
- Chapter 9: Maintenance of water chiller
Chapter 1: What is a water chiller
In the refrigeration industry, water chillers can be divided into the air-cooled chiller and water-cooled chiller.
According to the compressor types, a water chiller is divided into a screw water chiller and a scroll water chiller.
A water chiller is a kind of water cooling equipment, which can provide constant temperature, constant current and constant pressure for your applications.
Water chiller offered by TopChiller ranges from 2 Ton to 60 Ton in cooling capacity and the chilled water flow rate is up to 680 LPM.
Cooling water temperature can be adjusted automatically according to the requirements, the temperature controlling the range of water chiller by TopChiller is from 7℃ to 35℃，and water can be saved by long-term use.
Therefore, a water chiller is a kind of standard energy-saving equipment because it can save your water and cost.
More generally, you can always output chilled water with a lower temperature than the environment.
You can use it whenever you need to cool down. It can be cooled directly or by heat exchanged indirectly.
The water chiller consists of four main components: compressor, evaporator, condenser, expansion valve, so as to achieve the cooling effect.
In the industrial field, water chiller is one of the most commonly used refrigeration equipment. Water Chiller plays an important role in industrial refrigeration.
Many water chillers are controlled by microcomputers, which are easy to operate, high precision, a wide range of use and can accurately control water temperature.
At the same time, the perfect electrical protection system has the protection of phase absence, phase staggering, current overload, high and low voltage, compressor exhaust overheating, etc. to ensure the efficient operation of your water chillers.
Chapter 2: How does a water chiller working
The operation of the water chiller system is accomplished by three interrelated systems:
Water chiller refrigerant-cycle system, water cycle system and electrical automatic control system.
2.1 Water chiller refrigerant cycle system:
Let’s have a brief introduction of the water chiller refrigerant cycle system.
The liquid refrigerant in the evaporator absorbs the heat in the water and starts evaporating. It becomes gaseous and then is inhaled and compressed by the compressor (pressure and temperature increase), and then transported to the condenser.
The high-temperature pressure gaseous refrigerant releases heat through the condenser (water-cooled), condenses into liquid and becomes a low-temperature and low-pressure refrigerant after saving pressure by the thermal expansion valve (or capillary tube).
After entering the evaporator to absorb heat in water, a cycle process of refrigerant was completed. Refrigerants circulate in such a way that they constantly take heat away from the water and then reach the intent of cooling water.
2.2 Fundamental composition of your water chiller
The compressor is the core component of all water chillers, and also the power source of refrigerant compaction.
Its effect is to convert the input electric energy into mechanical energy and to tighten the refrigerant.
The condenser of a water chiller acts to output thermal energy and condenses the refrigerant during the cooling process.
After the high-pressure superheated vapor discharged from the refrigeration compressor enters the condenser.
it absorbs all the heat in the operation process, including the heat absorbed from the evaporator and the refrigeration compressor and in the pipeline, which is transferred to the surrounding medium (water or air); the high-pressure superheated vapor of the refrigerant condenses into liquid again.
2.2.3 Liquid reservoir
After the condenser, the Liquid reservoir device is directly connected with the discharge pipe of the condenser.
The refrigerant liquid of the condenser should flow into the reservoir in all directions so that the cooling area of the condenser can be fully utilized.
On the other hand, when the heat load of transpirator changes, the requirement of refrigerant liquid also changes.
At that time, the reservoir will play the role of adjusting and storing refrigerants.
Regarding the small refrigeration equipment system, the condenser is usually used to adjust and store refrigerants instead of the liquid reservoir.
2.2.4 Dryer filter
Dryer filter is another important part of a water chiller.
It is necessary to prevent moisture and dirt (oil, iron, copper) from entering the refrigeration cycle.
The origin of moisture is mainly the trace moisture contained in the newly added refrigerant and lubricating oil or the moisture brought by the air entering into the maintenance system.
If the water in the system is not cleaned, when the refrigerant passes through the saving valve (thermal expansion valve or capillary).
Sometimes the water will condense into ice due to the decrease of pressure and temperature, which will block the passage and affect the normal operation of refrigeration equipment.
2.2.5 Thermal expansion valve:
In a water chiller, the thermal expansion valve is a must refrigeration part.
The thermal expansion valve is not only a flow regulating valve in a refrigeration system, but also a saving valve in refrigeration equipment.
It is installed between the dry filter and evaporator in refrigeration equipment, and its temperature sensor is wrapped at the outlet of the evaporator.
Its primary effect is to make the refrigerant liquid at high pressure and normal temperature save pressure when flowing through the thermal expansion valve, and turn into low temperature and low-pressure refrigerant wet vapor (some are liquid, some are steam) into the evaporator， vaporize and absorb heat in the evaporator, and reach the intention of cooling.
Besides the above, the evaporator is another important heat exchanger for your water chiller.
The evaporator is a heat exchanger which absorbs the heat of the cooling medium by the transpiration of refrigerant liquid (actually boiling).
The evaporator of the water chiller functions in the refrigeration system is to absorb heat (or output cooling).
In order to ensure that the transpiration process can proceed steadily and durable, it is necessary to constantly use a refrigeration compressor to extract transpiration gas, in order to maintain a certain transpiration pressure.
Most water chillers used in the modern industry use refrigerant R22 or R134a and R407c, Refrigerants are active refrigerants in refrigeration systems.
Their primary effect is to carry heat and to achieve heat absorption and release when conditions change.
2.3 The water circulation system
In this part, we will know something about the water circulation in a water chiller.
The water circulation system is a pump that draws water from the water tank to the equipment that the user needs to cool.
After the heat is taken away by the chilled water from the water chiller, the temperature increases and then returns to the chilled water tank.
Chapter 3: The difference between Water chiller and Air chiller
To know more information about water chiller, firstly we should tell apart the difference between water chiller and air chiller.
The air chiller realizes the refrigeration function by refrigeration cycle cooling water of the chiller.
Because of the heat exchange between the fan and the air, therefore, air-cooled water chillers also use a fan, dust-proof net, and other heat dissipation components to carry out heat dissipation.
Air chiller can control temperature while maintaining stable performance, occupying small space, easy to move, easy to operate.
The water chiller cools the circulating water through the chiller’s refrigeration system and then delivers it to the equipment through the pump and the cooling water route.
The water chiller is relatively less affected by the environment, but the company needs a good quality water source for circulation cooling.
Due to the water tower, the water chiller occupies a large area, and the installation and maintenance workload is large.
The following are specific differences between the water chiller and the air chiller.
Because the heat exchange efficiency of water is much greater than the air exchange efficiency, the water chiller is more energy-efficient than the air chiller.
Compared with the water-cooled condenser with the same heat transfer capacity, the air-cooled condenser has a larger volume, more materials, and higher manufacturing cost.
The total cost of water chillers is still 15-20% lower than that of internal chillers even if the equipment cost of the cooling water system is added.
In addition, because the nominal power of the air chiller unit is larger than the nominal power of the water chiller unit, the cost in terms of power capacity increase and electronic control equipment is also high.
So if you require a big cooling capacity, you should go for a water chiller than air chiller.
The heat transfer temperature difference of the water chiller condenser is generally 4℃-8℃, while the air chiller has a heat transfer temperature difference of generally 8℃-15℃ in the same outdoor ambient temperature.
The temperature of the cooling circulating the water is lower than the outdoor air temperature, so the condensing temperature of the air chiller unit in normal operation is much higher than the condensing temperature of the water chiller unit.
So that the air] chiller unit consumes more power in refrigeration than the water chiller unit under the same cooling capacity.
3.3 Installation room
For water chillers, these chillers’ installation rooms should be provided to ensure that the normal operation and service life of equipment including water chillers and chilled water circulating pumps, and cooling tower equipment should be placed on the roof or outdoor floor of buildings.
It can be seen that, in the case that the building cannot provide enough room, the selection of air-cooled chillers should be a better way.
3.4 Operation cost
Because the water chiller operates at a lower condensing temperature, the refrigeration efficiency is high and the power consumption of the unit is small.
Generally speaking, compared with air chiller with the same refrigeration capacity, the overall power consumption of water chiller is about 25% lower than that of air-cooled units (including the power consumption of cooling water pumps and cooling tower fans).
3.5 Regular Maintenance
Shell-and-tube condensers used in water chillers have a low impact on heat transfer efficiency within a certain range of fouling accumulation, so the performance of water chiller units decreases slightly with fouling generation, and the cleaning cycle is longer.
The heat transfer efficiency of the finned condenser used in air chillers is greatly affected by the accumulation of dust.
The dust grids must be set before the fin tubes for heat dissipation, and frequent cleaning is required.
Because of the high operating pressure of air chiller units, they are usually installed outdoors, and the operating environment is relatively harsh.
Air chillers are inferior to water chillers in terms of maintenance and reliability.
Some tips of water chiller maintenance
1. Do not shut down the water chiller by cutting off the main power supply in case of an emergency.
2. When the water chiller fails to alarm and stop, first turn off the main power switch of the machine (the alarm lamp will be extinguished), and then check the cause of the failure.
The water chiller must not be forced to start before the failure is eliminated.
3. In order to prolong the water chiller life of the system and prevent the occurrence of safety accidents, a regular inspection must be carried out.
4. The water quality of the system should be treated. The high alkaline water quality will aggravate the corrosion of copper tubes and reduce the service life of heat exchangers.
The PH value of the water used is in the range of 7.0-8.5. 5. Keep the room dry, clean and well ventilated.
5. The daily operation, management and maintenance of your water chillers must be carried out by people with professional skills.
(It is dangerous to disassemble or inspect the water chiller unit when your water chiller is running, please note!)
6. Refrigerant gas leakage really happened with a water chiller, If this problem happens, we should recharge some refrigerant.
Please follow the below sequence:
Turn off the lid of the valve and connect the air pipe of the vacuum pump to the valve for vacuum pumping. The process takes about 1 to 3 hours.
After the vacuum is exhausted, the gas pipe of the refrigerant tank is connected to the needle valve and the refrigerant is added to the return pipe.
Monitor the change of electronic weighing and stop filling refrigerant when filling rated weight. (No liquid refrigerant in startup state) startup
Under the condition, the pressure of the high-pressure gauge is about 13-15 bars, and the pressure of the low-pressure gauge is about 3-5 bars.
Water-cooled chillers use shell-and-shell condensers, which accumulate scales on the inner side of heat transfer tubes for a long time, which affect their heat transfer effect.
The condensers should be cleaned regularly to keep your wate chillers working well.
If the cooling water has been treated as water purification, it is suggested to sterilize and remove algae with hydrogen peroxide, rinse ears with a high-pressure water gun, and then check whether there is scale.
Passivation is necessary after pickling. Passivation can be purchased for relevant treatment.
When the water chiller stops in the environment below 0 ℃ and is not used or stored, the pipeline should be disconnected, the front end of the water chiller should be improved.
And the water wrapped in the ice condenser should be discharged strongly and nearly as cold as that wrapped in the ice condenser.
Shell-and-tube evaporator is used in the water chiller. Scale accumulates on the outside of the heat transfer pipe for a long time, which affects its heat transfer effect.
Regularly cleans the evaporator to keep your water chiller good working performance. The evaporator is cleaned by cleaning the cold frost condenser. The scale is discharged from the drain.
Chapter 4: Water Chiller Industrial Applications
In most industrial applications, water chillers are used in a variety of industries to control products, mechanisms and plant machinery cooling.
Water chillers are commonly used for injection and blow molding in the plastic industry, metalworking cutting oils, welding equipment, die casting and machining, chemical processing, food and beverage processing, paper making, cement processing, vacuum systems, X-ray medical equipment, and power stations, analytical equipment, semiconductors, compressed air, and gas cooling.
Water chillers are also used to cool high-heat energy, such as nuclear magnetic resonance imaging and laser-specific engineering projects, and in hospitals, hotels and campuses.
Plastics industry: water chillers precisely control the mold temperature of various plastic processing, shorten the beer-plastic cycle, and ensure the stability of product quality.
Sometimes water chillers are used to cool down your finished plastic products.
Electronics industry: water chillers stabilize the molecular structure of electronic components in the production line, improve the qualified rate of electronic components, apply to the ultrasonic cleaning profession, and effectively avoid the damage caused by evaporation of precious detergents.
Electroplating industry: water chillers control the plating temperature, increase the density and smoothness of the plated parts, shorten the plating cycle, improve the output power, and improve product quality.
Machinery industry: water chillers control the pressure oil temperature of the oil pressure system, stabilize the oil temperature and oil pressure, extend the oil quality application time, improve the mechanical smooth power, and reduce wear.
Construction industry: water chillers provide chilled water for concrete, make concrete molecule structures suitable for building use requests, and effectively enhance the hardness and durability of concrete.
Vacuum coating: water chillers control the temperature of the vacuum coating machine to ensure the high quality of the plated parts.
Food industry: water chillers are used for high-speed cooling after food processing to make it accustomed to packaging requests. Others include controlling the temperature of fermented food.
Besides the above industrial applications, water chillers can be also served for some specific industries.
Please contact TopChiller water chiller expert to customize your water chiller.
Chapter 5 Why TopChiller can be your reliable Water Chiller supplier?
TopChiller, as the world’s leading water chiller manufacturer, we produce more than 5000 water chiller units annually and provides high-quality water chillers as our goal.
Here are some reasons why TopChiller can be your reliable Water Chiller supplier
5.1 Rich experience in water chiller and professional service team
Since TopChiller established in 1999, we have been accumulating experience in the field of water chillers to provide high-quality water chillers to customers around the world.
We have a skilled team is ready for providing all technical support all the time if you have any water chiller problem.
5.2 Using water chiller spare parts of internationally renowned brands
To ensure the high quality of water chillers, TopChiller uses internationally advanced compressors, such as USA Copeland, France Danfoss or Japan Sanyo, Germany Bitzer and Taiwan Hanbell.
We are also strict to control over every part, water pumps and condensers in water chillers can be configured according to specific requirements.
5.4 Extremely testing of all water chiller units before delivery to the customer
All water chillers will be strictly testing before delivery to clients.
Let’s have a look at the water chiller air tightness inspection, with experimental procedures and vacuum test indicators.
The water chiller has completed the airtight test before leaving the factory and is filled with 0.03 ~ 0.05MPa nitrogen for protection.
The site is determined by the following method to see if the unit is leaking. If it is not leaked, it can be avoided as a gas-tight test.
1)the pressure inside the water chiller is 0MPa or the pressure is lower than 0.03MPa, and it is determined that the water chiller unit has leaked;
2) After charging the water chiller, the water chiller unit is filled with refrigerant and leaked with a leak detector or an electronic leak detector.
When the water chiller finds a leak during the inspection, the airtight test shall be carried out according to the following procedure:
- Prepare nitrogen, add gas pipe and pressure reducing valve. Fill water chiller with nitrogen gas. When the pressure is 0.6~0.7MPa, close the intake valve and check the leak with the leak detection fluid to check all the leak points.
- Mark the leak point, find out the cause and make up the leak after the pressure is zero.
- After the completion, re-boost and check again. Do not pressurize the leak.
- nitrogen is boosted to the water chiller design pressure 1.28MPa, and the leak point is checked and treated.
- Pressure relief
- When it is confirmed that the water chiller has no leakage, the nitrogen in the water chiller unit is discharged. When the pressure is discharged at 0.3 MPa, the evaporator pressure transmitter valve is closed and the discharge is continued to zero.
After the water chiller airtight test is passed, the vacuum test is carried out.
The vacuum test process is as follows:
- connect the vacuum gauge to the water chiller.
- Connect the vacuum pump to the refrigerant charging valve of the water chiller, and require the pump to the unit to be as short as possible and the diameter as large as possible to reduce the airflow resistance.
- Open all internal shut-off valves of your water chiller.
- Evacuate to an absolute pressure of 500Pa or less (the factory requires an absolute pressure of 200Pa or less). Hold pressure for 2 hours, and the recovery is ≤200Pa (factory requirement ≤100Pa) is qualified. If the recovery is ≥200Pa (factory requirement ≥100Pa), it means that the unit has a leak point or the humidity inside the unit is too large. At this time, it should continue to vacuum for more than 2 hours to re-pressurize.
- After repeated several times, the water chiller is still unqualified, and the airtight test is re-tested and trapped.
Note: When adding fluorine, the vacuum of the water chiller should not exceed the absolute pressure of 500Pa.
5.3 Pre-sales and After-sales Service
Our sales and technical team provide you with free support throughout the day, providing most professional and just-in-time technical consults and water chiller solution for you.
When we get your water chiller inquiries, we will reply to you within 5 hours, 24-month warranty is provided for our products, and contact us at any time during chiller whole lifetime service
Chapter 6: How to size a suitable water chiller for your machine
A water chiller is a kind of refrigeration equipment that can provide chilled water for all industries to achieve the purpose of cooling.
It can control the temperature between 5 degrees and 35 degrees, and the low-temperature water chiller can control the temperature between 0℃ to -40℃.
In the selection of water chillers, we need to know exactly how much the inlet and outlet temperatures of chillers are, how much the flow rate is and how big the water tank is.
A water chiller with high quality is the guarantee of successful engineering design and has a long-term impact on the operation of the system.
Cooling water flow: refers to the cooling circulating water flow of the chiller that needs to be supplied when refrigerating equipment is used.
Cooling capacity: that is, how much refrigeration capacity is needed? The commonly used units of refrigeration capacity are Kcal/h, kw, etc.
Outlet-water temperature: return-water temperature or temperature difference between outlet-water and return-water: Outlet-water temperature refers to the temperature of chilled water，return-water temperature refers to the temperature of cooling water.
Some equipment with stricter heat dissipation requirements will have the temperature requirement of cooling water supply.
Outlet-water pressure: Because of the complex internal heat dissipation structure of some heat dissipation equipment, there is a certain pressure requirement for cooling water supply.
At this time, it is necessary to consider whether the rated outlet water pressure of the water chiller can meet this requirement.
Pump lift: If a single water chiller is used one-to-one, the pump lift should not be a problem.
If multiple water chillers are connected in parallel for the application of multiple cooling types of equipment, the resistance of the pipeline system should be taken into account, so as to calculate how many pump lifts need to be allocated.
Control adjustment requirements: generally refers to pressure control adjustment and temperature control adjustment.
Safety protection function requirements of water chillers:
A. Compressor delay starts protector
B. High and low voltage protection function
C. Inverse phase protection
D. Compressor overload protection
E. Antifreeze protection
F. Compressor overheats protection
G. Compressor frequent start protector and abnormal indicator lights and various protection switches.
Chapter 7: Water Chiller Installation Guide
Installation of water chillers (mainly is basic vibration isolation equipment): We are well aware that the installation of equipment must choose a flat and open place, chillers are no exception.
Before installing water chillers, many users will do a good job of foundation preparation and embedding four horizontal pad iron in advance.
Generally, the water chiller has four legs, which can be equipped with an adjusting padding plate with two adjusting threaded holes to adjust the level of the whole water chiller, and use concrete mortar to fill in the gap after adjustment.
After the mortar is dried, the adjusting bolt can be removed, the positioning bolt can be left behind, and the fixing measures can be taken for the water chiller.
Installation of water chiller pipes: mainly are the external water pipes of evaporator and condenser, if it is double-return water pipes, it is arranged on the same side.
If it is single-return or three-return water pipes, it is arranged on both sides, The inlet and outlet water of water chillers’ condenser and evaporator are from bottom to top.
water chiller water pipe cleaning: After installing the water pipe to the unit, the whole water system should be tested for leakage. After the leakage test is qualified, the water pipe can be cleaned.
When cleaning water pipes, we should first make sure the direction of the pump is correct. and open all the valves of the inlet and outlet pipes.
The pipes are full of water, start the chilled water pump and the cooling water pump, run continuously for two hours, stop the operation of the pump, drain all the cold water and cooling water, and clean the pump filters.
Chapter 8: Troubleshooting of Water Chiller
Each water chiller not only completes comprehensive performance testing before leaving the factory but also equips the unit with various safety protection devices,
such as phase protection, low water level protection, water flow switch protection, pump overload protection, compressor overload protection, high and low voltage protection, etc.,
so as to avoid secondary damage caused by the failure of your water chiller unit. When the unit fails to occur, the corresponding protection device will give a warning and stop the water chiller operation.
Trouble-shooting method: If the water chiller is used too long or not maintained regularly, some unexpected faults will inevitably occur. Here are some common troubleshooting methods.
8.1. Inverse phase
When your water chiller fails, it will be timely phase protection. The cause of the reverse phase is a reversal of the pump and compressor.
At this time, we can switch any two phases in the power supply phase line.
If the phase is absent, we only need to measure whether the three-phase power supply is normal with a multimeter to check whether the power supply line is broken.
8.2. The refrigerant is not enough and the indicator light is on
A. When the water temperature is above 5 °C, when the pressure of the low-pressure gauge is less than 2 kg/cm2, it means that the refrigerant is insufficient.
First, the place where the refrigerant is leaked is subjected to trapping treatment, and then the dry filter is replaced and the vacuum is refilled to fill the appropriate refrigerant.
B. When it is found that the leaking refrigerant is partially immersed in water, stop the operation of the water chiller immediately, remove the water in the water tank quickly, and handle the repair as soon as possible to prevent the compressor from inhaling water into the system and causing more serious damage.
8.3. Poor heat dissipation results in slow or non-refrigeration
When the condenser heat dissipation is poor, the compressor efficiency is low and the running current is increased.
When the air-cooled high pressure rises to 24kg/cm2, the water-cooled high pressure rises to 20kg/cm2, and the compressor is subjected to high pressure.
The switch protection trips, the compressor stops running, the heat dissipation is poor, the high voltage is overloaded and the fault code or fault indication is displayed.
At this time, please check whether the cooling tower circulating the water is normal, whether the cooling water temperature is too high, whether the cooling tower fan water pump is running, and whether the cooling water valve is running.
The above is normal, press the reset button or shut down and restart to running normally.
If high voltage overload occurs frequently, please arrange to clean the condenser as soon as possible.
8.4. Whether high and low pressure is normal
The second and third of the previous ones analyze in detail the pressure display of the compressor when the high pressure or the low pressure is abnormal.
Then when the compressor runs, the difference between high pressure and low pressure is small or equal, the compressor fails.
then we should check whether the value of the compressor itself is damaged or broken, and immediately stop running and notify the supplier to send someone to deal with it.
If you have any question in troubleshooting，please contact the sales engineer of TopChiller, we are very glad to help you solve those problems
8.5. Treatment of the insufficient refrigerant or refrigerant leakage
1. Fault phenomenon:
The cooling effect of the whole water chiller is poor, the outlet is only cool, and the pressure on the high-pressure side and the low-pressure side is low by the manifold pressure gauge.
(At the normal speed of the compressor, when the ambient temperature is about 35 °C, the low-pressure gauge index is lower than 1 kg. /cm2, the high-pressure gauge index is lower than 10kg/cm2), and the bubble flow is visible from the sight glass.
2. the cause or reason of the failure:
water chillers have refrigerant leaks that result in the insufficient refrigerant.
3. Processing method:
1) Use an electronic leak detector to detect leaks and repair or replace parts.
2) If the parts are not replaced, only the appropriate amount of refrigerant can be replenished; if the parts are replaced, the appropriate amount of refrigerating oil should be added as required, and the refrigerant should be added after the system is vacuumed.
8.6 Excessive refrigerant charged
1. Fault phenomenon:
The water chiller cooling effect is poor. When checking with the manifold pressure gauge, the pressure on the high-pressure side and the low-pressure side is too high (when the compressor speed is normal, the ambient temperature is 35 °C, the pressure of the high-pressure gauge is about 19 kg/cm2, and the pressure of the low-pressure gauge is 2.3. Kg/cm2 and no bubble flow is seen in the liquid mirror.
2. the cause of the failure:
Too much refrigerant is added to the water chiller, so that the refrigeration capacity cannot be fully utilized, resulting in poor cooling performance.
3. Processing method:
Connect the manifold pressure gauge in the system, and slowly loosen the low-pressure side manual valve of the manifold pressure gauge to make the refrigerant discharge slowly (can not be discharged from the high-pressure side.
Because the refrigerant will bring out a large amount of frozen oil from the high-pressure side).
Until the high and low side pressure is normal, at the same time, the clear flow of the refrigerant can be seen from the sight glass, and occasionally bubbles flow.
8.7 Refrigeration system mixed with air
1. Fault phenomenon:
The water chiller refrigeration capacity of the whole machine is reduced.
when the manifold pressure gauge is used, it is found that the high-pressure side pressure is high, and the low-pressure side pressure is sometimes higher than the normal value.
When the compressor speed is normal, the ambient temperature is 35 °C, the high-pressure side pressure Above 20kg/cm2; and the high-pressure gauge pointer has a swing;
on the other hand, many bubble flows can be seen from the sight glass.
2. the cause of the failure:
Air is mixed into the water chiller system.
Mainly after the assembly or overhaul, the vacuum is not complete; when charging the refrigerant or adding the frozen oil, bring the air into the system, or when the system is working under negative pressure, the air is mixed through the tight place.
After the air enters the refrigerant, it has a certain pressure, and the refrigerant also has a certain pressure.
In a closed container, the total gas pressure is equal to the sum of the partial pressures, so the high and low-pressure meter readings are higher than the normal value.
3. Processing method:
1) Release the refrigerant (discharged from the low-pressure side with a pressure gauge).
2) Check the cleanliness of the compressor oil.
3) Refill the refrigerant after vacuuming.
8.8 “Ice blockage” in the refrigeration system
1. Fault phenomenon:
The refrigeration system periodically cools down and then does not cool.
During operation, the pointer on the low-pressure side of the manifold pressure gauge often fluctuates between the negative pressure and the normal value.
2.the cause of the failure:
The refrigerant in the refrigeration system is mixed with water.
Since the moisture is incompatible with the refrigerant, when the refrigerant flows through the orifice of the expansion valve, the temperature suddenly drops, and the moisture mixed in the refrigerant is easily ice particles in the vicinity of the orifice of the throttle valve or near the hole of the valve pin are spherical or hemispherical.
When the ice particles are knotted to a certain extent, the throttle channel is blocked and an ice blockage is formed.
When the ice is blocked by ice, the refrigeration system can not work normally, and the cooling effect is obviously reduced, even without cooling.
At this time, the negative pressure occurs in the low-pressure gauge, so the temperature of the ice block rises remarkably, the ice particles blocked by the ice melt into water.
The ice blockage phenomenon disappears, the refrigeration system resumes normal operation, the refrigeration is good, and the low-pressure side pressure returns to normal.
After a while, the system blocked ice again and the system was not working properly.
3. Processing method:
1) Since the desiccant is in a supersaturated state, the reservoir with the desiccant must be replaced and 30 ml of frozen oil is added.
2) Vacuum the system and add a specified amount of refrigerant.
8.9 Dirty block troubleshooting
1. Fault phenomenon:
Poor cooling or no cooling.
When the water chiller is running, the readings of the high/low-pressure gauges on the manifold pressure gauge are all less than the normal values.
When the compressor speed is normal, the ambient temperature is about 35 °C, the pressure on the high-pressure gauge side is lower than 9 kg/cm2, and the pressure on the low-pressure side is at Negative pressure state), and there is frost or condensation on the pipeline before and after the filter and capillary.
2. the cause of the failure:
In the water chiller, dust adheres to or adheres to the filter at the inlet end of the filter, or the interface between the capillary and the filter makes a local throttling phenomenon at this position, and the temperature rapidly drops, causing condensation or frost.
3. Processing method:
1) If your water chiller frost on the inlet of the filter, and the intermittent airflow sound is heard, use the small wrench to gently tap the filter body, the airflow sound changes, and the filter and the capillary front frost layer melt, the filter can be judged.
The imported filter is clogged.
At this point should:
1 Remove the capillary, clean the filter and blow-dry, and reinstall. Or replace the filter
2 The vacuum is applied and the refrigerant is added to the specified amount.
Chapter 9: Maintenance of water chiller
Tips for maintenance of water chillers
1. If it is not an emergency, do not turn off the water chiller by cutting off the main power.
2. When the water chiller malfunctions and stops, first turn off the main power switch of the machine (the alarm light will go out) and then check the cause of the fault.
But do not force the water chiller to boot before the fault is eliminated.
3. In order to extend the life of the water chiller and prevent the occurrence of safety accidents, regular inspections must be carried out.
4. The water used in the water chiller should be treated with water.
The high alkaline water quality will intensify the corrosion of the copper tube and reduce the service life of the heat exchanger. The PH value of the water used is in the range of 7.0-8.5.
5. Keep the water-cooled chiller machine room dry, clean and well ventilated.
6. The daily operation, management and maintenance of the water chiller must be performed by professionals with professional skills.
(It is dangerous to disassemble or inspect when the water chiller is running, please be careful)
During the normal operation of water chillers, it is unavoidable that dirt or other impurities affect the refrigeration effect.
Therefore, in order to prolong the service life of water chillers and make the refrigeration effect more stable, regular maintenance should be done to ensure the operation quality of water chillers and improve production efficiency.
Check regularly whether the voltage and current of water chillers are stable and the sound of a compressor is normal.
If it is a semi-closed compressor, check regularly the oil quantity. Normally, it should be more than 2/3 of the window.
When the water chiller works normally, the voltage is 380V and the current is normal in the range of 11A-15A.
Regularly check whether the refrigerant of the water chiller has leakage: refer to the parameters indicated on the high and low-pressure gauges on the front panel of the main unit.
According to the temperature (winter, summer) temperature changes, the water chiller pressure display is also different.
When the water chiller is working normally, the high pressure shows 11-17kg, and the low pressure shows 3.5kg-5kg.
Check whether the water-cooled chiller is normal, whether the cooling tower fan and the sprinkler shaft are working well, and whether the water replenishment of the water tank of the water chiller is normal.
Water chillers should be replaced with new water for 3 months. If it cannot be replaced, add a rust remover.
All Water chillers should be cleaned once every six months and cleaned once a year. The main cleaning parts include: cooling tower, cooling water pipe and condenser to ensure better cooling.
When water chillers are not used for a long time, circuit switches such as pumps, compressors and general power supply of cooling towers should be switched off in time.
Water chillers need to be connected with cooling towers and circulating pumps to achieve refrigeration effect.
In order to ensure the quality of circulating water, Y-type filters can be installed at the source of water, and algaecide and scale remover can be added to the cooling towers to avoid impurities entering the pipeline affecting the operation of the unit.
Cleaning Method of Condenser Pipeline
Cut off the power switch.
Close the cooling water inlet and outlet ball valve.
Remove the front panel of the water chiller.
Remove the fixing screw and remove the round cover plate. A copper pipe can be seen. Please use a copper brush to clear it back and forth.
Filling the refrigerant
Unscrew the lid of the liquid thimble valve and connect the air tube of the vacuum pump to the liquid thimble valve for vacuuming.
This process takes about 1~3 hours.
After the vacuum is completed, the gas pipe of the refrigerant tank is connected to the liquid addition ejector valve, and the refrigerant is added to the return gas pipe.
Monitor the electronic weighing change and stop the refrigerant when filling the rated weight. (It is strictly forbidden to charge liquid refrigerant in the on-state).
Under the state of being turned on, the high-pressure gauge shows the pressure: 13~15bar; the pressure gauge of the low-pressure gauge shows the pressure is about 3~5bar.
The water chiller adopts a shell-type external condenser. After a long time of use, the inside of the heat transfer tube accumulates scale, which affects the heat transfer effect.
The condenser should be cleaned regularly to keep the water chiller in good working performance.
If the cooling water has been treated with clean water, it is recommended to use the hydrogen peroxide to sterilize the algae, and then wash the ear with a high-pressure water gun to check the water.
After pickling, it must be passivated, and a passivating agent can be purchased for related treatment.
When the water chiller is not used or stored in an environment below 0 °C, the pipeline is disconnected, the front end of the machine is raised, and the water wrapped in the frost condenser is discharged.
The shell-and-tube evaporator of the ice water chiller is used for a long time.
The outer side of the heat-transfer tube accumulates scale, which affects the heat transfer effect. Celebrate the cleaning of the evaporator regularly to keep the machine in good working condition.
The evaporator is cleaned by washing the cold ice cream condenser. The scale is discharged from the drain.
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