Water Cooled Chiller

TopChiller: Your Leading Water Cooled Chiller Supplier and Manufacturer in China

TopChiller is a professional water-cooled chiller manufacturing company since year of 1999.

Mostly, Water cooled chillers are more refrigeration efficient than air cooled chillers.

It is because water cooled chiller uses a water-cooled shell and tube type condenser, alongside an external water cooling tower and circulation water pump to make sure the chiller cooling is efficient.

Water Cooled Chiller can be installed both indoors and outdoors. Those installed outdoors must have a waterproof electrical control box.

Each Water Cooled Chiller designed by TopChiller with mobile brake casters can move easily from one place to another.

With 20 years’ experience in Water-Cooled Chiller, TopChiller supplies first-class qualified water-cooled chillers to clients all over the world.

Please contact the TopChiller team to customize your Water Cooled Chiller solution for your industrial process.

Water Cooled Chiller for Outdoor Installation

Water Cooled Chiller: The Complete Buying Guide

Chapter 1: What is a Water-Cooled Chiller?

Water Cooled Chiller is a device used to remove heat and transfer it to the environment.

Water-cooled chillers are mostly used in air-conditioning, industry, or any other specific places that require temperature control.

Water Cooled Chiller has advantages over air-cooled chiller in terms of capacity, efficiency, life, and environmental impact. In the cycle of cooling, Water Cooled Chiller uses water instead of air for refrigerating.

Water Cooled Chiller is a machine or machine unit that absorbs heat from process water and transfers it to a water tower or any other water source that serves the same function.

The main components of the water-cooled chiller are evaporator, condenser, compressor and expansion valve.

In the cycle of refrigerating, the compressor draws the vapor from the evaporator and compresses it into high-pressure air and transfers it to the condenser.

Inside the condenser, the heat of the high-pressure air is removed to the ambient air or condenser water and the high-pressure air is transformed into a high-pressure liquid.

The liquid then goes through the expansion valve and enters the evaporator as vapor, where the chilling process is taking place in this link. And the vapor then again is drawn to the compressor repeats the cycle.

Water Cooled Chiller Designed by TopChiller

Water cooled chiller is one kind of industrial chillers, so that water cooled chillers can be used in various applications, like injection molding, extruding, thermal forming, foaming, food and beverage processing, die-cutting, tooling, etc.

When we coming into the topic of water-cooled chiller, we can’t avoid the water-cooled chiller partner–water cooling tower.

A water-cooled chiller must work together with the proper cooling tower and circulation water pumps.

Water Cooling Tower Working Principle

Chapter 2: How does a Water-Cooled Chiller work?

As suggested by its name, Water Cooled Chillers use circulating water to take away the heat produced by industrial equipment or process, in contrast to air-cooled chillers that disperse heat by air.

Please take a look at below video for how water-cooled chiller works to get more details:

How a Water Cooled Chiller Works?

As we know from above, the work cycle of Water Cooled Chiller is like this: the refrigerant vapor after chilling the process water in the evaporator is drawn into the compressor, where both of its pressure and temperature are elevated.

The refrigerant in the form of a high-pressure high-temperature form then is discharged into the condenser. There its heat is removed by the cooling water, which runs through another cycle connected to the outdoors water tower.

The refrigerant then is condensed into liquid and falls at the bottom of the condenser.

Through orifice (expansion valve, caterpillar tubing), the low-pressure refrigerant enters the evaporator in the form of vapor to perform its work-chilling the process water and then repeats the cycle.

 Water Cooled Chiller Working Principle

So here we can break down the water-cooled chiller into the following main parts: Compressor, Condenser, Expansion Valve, Evaporator, and also in the cooling tower cycle, the cooling tower and its auxiliary devices.

Compressor:

Various types of compressors are used in Water Cooled Chillers for different cases due to preferences. centrifugal, screw, scroll or reciprocating types are most commonly used.

Each one has its pros and cons over others.

The compressor provides the refrigeration power of the chiller. By creating a pressure difference, it moves the refrigerant around the system.

The compressor is usually installed between the evaporator and the condenser. It is connected to the internal or external motor as a driving force.

Danfoss and Copeland Scroll Compressor

Condenser:

For water-cooled chiller, it using water-cooled shell and tube type condenser.

The shell and tube condenser links between the compressor and the expansion valve.

Its function is to remove the heat the refrigerant takes from the process water in the evaporator.

Water Cooled Shell and Tube Condenser

After the compressor compresses the refrigerant and sends it to the condenser, the condenser use air or water to condense the refrigerator.

In the case of Water Cooled Chillers, the condenser connects with the water tower outdoors and transfers the heat to from the refrigerant to the water tower.

In the condense water cycle, water runs inside the pipe repetitively between the condenser and the water tower. The water and the refrigerant are separated by the pipe wall.

The water runs inside the pipe while the refrigerant on the pipes. After the refrigerant is chilled, it falls into the trough of the condenser and is collected.

Water Cooled Shell and Tube Condenser

Thermal Expansion Valve:

The expansion valve is a very important refrigeration spare parts for a water-cooled chiller.

It locates between the condenser and evaporator. It functions as a device to reduce the pressure and increase the volume of the refrigerant, which is condensed into liquid in the previous link-condenser.

How Thermal Expansion Valve Works

Through the expansion valve, the refrigerant can enter the evaporator as vapor and pick up heat from the process water.

Different types of expansion valves are available, such as thermal expansion valve, electronic valve, pilot operated expansion valve and orifice expansion valve, caterpillar tubing, etc.

The Most Popular Thermal Expansion Valve Brands are Danfoss and Emerson.

Danfoss Expansion Valve

Evaporator:

The evaporator is the link where the heat of the process water is extracted by the refrigerant and the chilled process water is pumped to where it is needed.

The process water comes in and out of the evaporator in a cycle for chilling. In the evaporator, the refrigerant runs in the pipe while the water in the shell.

There are 3 types of evaporators for the water-cooled chiller, Stainless steel water tank with a coil, close-loop shell, and tube heat exchanger and stainless steel plate heat exchanger.

This depends on the client requirements and project site condition to select which type condenser is suitable for your water-cooled chiller.

Stainless steel water tank with a coil

Built-In Stainless Steel Water Tank With Coils

Close-loop shell and tube heat exchanger

Shell and Tube Type Evaporator

Stainless steel plate heat exchanger

Stainless Steel Plate Type Heat Exchanger

Now let’s take a look at how stainless steel plate heat exchanger working? then you will have a general idea about this type of water cooled chiller evaporator.

Stainless Steel Plate Heat Exchanger Working Principle

In terms of system, water-cooled chiller having the refrigerant circulating system, water circulating system, and electric automatic control system.

The refrigerant circulating system is the cycle we explained above.

The water cycle pumps chilled process the water from the water tank to the equipment that requires chilling and absorbs the heat and then returns to the water tank.

The electric automatic control system includes a power unit and automatic control devices. switches, starter, circuit breakers, speed controller and power monitoring devices control the flow of electrical power of the chiller.

The automatic control system includes temperature controller, pressure control, delayers, relay, overload protector, etc. to monitor various aspects of the chiller’s performance and to make adjustments accordingly.

Schneider Contractor

Chapter 3: What is the difference between a Water-Cooled Chiller and an Air-Cooled Chiller?

For industrial applications, people weigh the pros and cons of the two options, Water Cooled Chillers or Air Cooled Chillers.

Before we starting this topic, please take a look at this video to get a rough idea of the difference between the air-cooled chiller and water-cooled chiller:

Difference Between Air Cooled Chiller And Water Cooled Chiller

Both air chillers and water chillers have their advantages and disadvantages.

Now we shall discuss from a few aspects the difference between the two chiller types and come to a conclusion which type is preferred under the circumstances.

Air Cooled Chiller and Water Cooled Chiller

3.1 Cost

Both air cooled chiller and water cooled condensing the refrigerant in the condenser.

The air-cooled condenser uses propeller fans to draw ambient air over a finned coil to condense the refrigerant, while water-cooled condenser uses re-circulating water from a water tower to condense the refrigerant.

Water Cooled Chiller VS Air Cooled Chiller

3.1.1 Installation Cost and Maintenance Cost:

As we know the water-cooled chiller requires a cooling tower (water tower) which usually is installed outdoors, thus it has higher installation and maintenance costs than the air-cooled chiller.

Besides the water tower, a water pump and chemical treatment for the water circulating loop add to the initial investment cost and the regular maintenance cost.

In this case, a water-cooled chiller is costly than an air-cooled chiller.

Water Cooled Chiller Installation

As we know, the major difference between the air-cooled chiller and water-cooled chiller is the condenser types or condensing ways. For water-cooled chiller must connect with an external water cooling tower, but for air-cooled chiller, it’s not necessary.

How Water Cooled Chiller and a Cooling Tower Work Together?

3.1.2 Operation Cost:

In the case of Air Cooled Chillers, the condensing temperature depends on the ambient dry-bulb temperature, but for Water Cooled Chillers, the refrigerant condensing temperature depends on the condensing water temperature and flow rate, which equals to the wet-bulb temperature.

As usual, the web-bulb temperature is lower than dry-bulb temperature, it is not difficult to see that refrigerant condensing temperature in a water-cooled chiller is considerably lower than the air cooling chiller, so the water cooling system is more efficient than the air-cooled chiller and thus more saving in terms of electricity consumption.

So water cooled chiller is more suitable for the area which has plenty of water sources.

3.1.3. Cooling efficiency

Like a coin has its two sides, Considering the cost, we must pay attention to the cooling efficiency.

As we all know air-cooled chiller drops the boring heat by exhaust cooling fans. But water-cooled chiller exchanging heat by using a water cooling tower or water source.

The two different cooling methods will give quite a different cooling efficiency. It is obvious that water-cooled chiller is more effective in cooling performance than an air-cooled chiller.

As testing data from TopChiller engineering, the same chiller models, the water-cooled chiller is more 20% cooling efficiency than an air-cooled chiller.

The Advantage of Air-Cooled Chiller and Water-Cooled Chiller

Of course, you should consider your specific circumstances.

For example, if you are in the area where water cost is extremely high or the water quality is very poor and requires a high cost in water treatment, then air-cooled chiller might be more economical overall speaking.

If you have questions in selecting a water-cooled chiller or an air-cooled chiller for your application, just feel free to contact our technicians or salespersons.

We shall be glad to look into your situation and offering our professional advice.

Please, you can also send us your Water Cooled Chiller inquiry.

3.2 Cooling Capacity

As regards as chiller cooling capacity, Air Cooled Chillers are usually available in sizes up to about 500tons.

But in contrast, Water Cooled Chiller capacity is available up to 1000tons, and tailor-made designs can be up to even higher.

So if you have a higher capacity requirement, Water Cooled Chiller might be preferred.

3.3 Service Life

In terms of service life, Water Cooled Chiller is more lasting than Air Cooled Chiller.

This is mainly because Water Cooled Chillers are installed indoors (except for the cooling tower/water tower), while most of the Air Cooled Chiller stays outdoors.

The other reason is large scale Water Cooled Chillers are built with heavy-duty and industrial-grade components.

3.4 Installation Space and Environment Requirements

Solely from the size of the chiller machine, an Air-Cooled Chiller is bigger than a Water Cooled Chiller. But a Water-Cooled Chiller requires connecting to the water tower.

We must consider the chiller installation space problem.

So in case a water tower installation is not a problem or there is a water tower in place, a Water Cooled Chiller might be preferred.

However, in case the indoor space is very limited and ventilation, temperature, environmental humidity conditions are favorable, Air Cooled Chillers might be preferred.

From the above comparison, the users should look into their specific circumstances and needs to evaluate both options. The simple and arbitrary conclusion should not be made on which type is more favorable.

If you need help in selecting the right products for machines or work processes, please contact us.

As a famous water-cooled chiller manufacturer, all technicians from TopChiller with 20 years experience in cooling systems would like to offer you advice and share with your our expertise.

Chapter 4: Water Cooled Chiller Applications

Water Cooled Chiller Applications

Water Cooled Chiller can be used in air-conditioning or industry. Here we focus on the application in the sector of the industry.

In various manufacturing processes, it requires chilled water/process water or liquid to cool down the products or equipment, for the purpose of protecting equipment, improving product quality, etc.

Water-cooled chillers are most commonly used in plastic industries, like injection molding, thermal forming, blow molding, extruding.

Water-cooled chillers are also used in die-casting, machine tooling, metalworking cutting oil and welding equipment, in pharmaceutical production, chemical processing, food, and drink processing, storing, and transporting, they are widely used.

And in agriculture, medical facilities, constructions, chillers have wide applications.

Water Cooled Chiller with its large capacity, can be centralized in the application.

In that case, a chiller can serve more than one cooling need, such as chilling process water for more than one injection molding machine.

Or when a chilling need is high, chillers can be decentralized too, in which case one application or one machine uses one water-cooled chiller.

In designing the manufacturing processes, both applications can be considered. You can combine both centralized and decentralized water-cooled chillers in the solution, as some applications have the same cooling requirements and some applications are not.

Below we choose applications in some important sectors and discuss them in detail.

4.1 Plastic Industry

A water-cooled chiller is widely used in the plastic industry.

Appropriate cooling is essential in plastic product manufacturing. It could affect the product surface’s smoothness, brightness, and product forming.

Effective cooling can reduce scrap rate and hence reduce cost, improving efficiency, so the water-cooled chiller will do its job.

4.1.1 Injection molding

Water-cooled chillers can remove heat not only from plastic molds but also from mold temperature controllers, hydraulic heat exchangers, feed throats of injection molding machines.

Water Cooled Chiller for Injection Molding Machine

Time-saving: In a cycle of one injection molding shot, cooling cover about an average of 95% of the cycle time.

Both heating and cooling are important in the process, but cooling can be regarded as critical. Even, identical-rate cooling results in high-quality products and efficient production.

With the right water-cooled chiller to cool quickly, you will save time and thus save a lot of costs, especially in high volume production.

Defect reducing: The reliable water-cooled chiller also ensures the coolant access to every location evenly and reduces the thermal stress defects, like warping, sink marks, weld lines, etc., which could cause you tremendous loss of profit.

Quality improving: In the first stage of shooting, thermoplastic resin pellets are heated to the degree that they are molted and then they are shot into the mold.

However, the thermoplastic resin can’t be molten for a too long time, otherwise, the chemical make-up might degrade and the plastic quality might be compromised. An accurate cooling solution is vital in this regard.

Product accuracy improving: For some high-precision products, dimensions tolerance is very strict. The cooling rate plays a significant effect on part dimensions. To make sure you reach the dimension target, you have to control the cooling cycles identical.

4.1.2 Blow Molding

The water-cooled chiller can also be found in blow molding machines.

Blow molding is a plastic manufacturing process by which hollow plastic parts are formed.

In the blow molding process, a plastic resin is melted down and formed into a parison or perform.

A parison is a plastic tube-shaped piece with a hole in one end, through which air can be compressed.

Water Cooled Chiller for Blow Molding Machine

Dehumidifying air: In the blow molding process, clean and dry compressed air is needed. The water-cooled chiller can be used to dehumidify the air effectively.

Cooling mold: In the blow molding process, if the cooling and forming are not effective, the product will not be in the right shape; the wall thickness will not be even; the color and brightness will not be sufficient. In the worst case, the products can’t even be formed.

Water Cooled Chiller for Cooling Mold

4.1.3 Extruding, Stamping, etc.

Extruding, plastic extruder extrusion line also needs to use a water-cooled chiller

Plastic extruders, extruding or stamping machines also need a steady cooling water source.

The extruded profile has to be cooled to the temperature that it can maintain the desired shape and dimensions.

Water Cooled Chiller is essential in removing heat effectively. Barrel cooling is also important in the extrusion process.

During the extrusion process, maintaining temperature control over the melt is very important. Chilling the barrel is one of the methods to control any over-heating of the plastic.

There are various kinds of manufacturing processes that require cooling that Water Cooled Chiller can perform the duties.

Please contact our technical team or salesperson if you have any needs or questions in your production processes.

The most important one we need to pay attention to is there is an external water tank together with an extruder machine, so if we give a water chiller solution or design, We must go for a closed-loop system water chiller without a built-in water tank. This is an important factor.

Water Cooled Chiller for Plastic Extruder

4.2Food and Beverage Industry

Water-cooled chiller is always used in the cooling food and beverage process.

In processing food and beverage, like mixing, cooking, or pasteurizing the products, water-cooled chillers are widely used to removes the heat during their production process.

Beverage, dairy, and drinking need a steady certain temperature controlled when their fermentation process. So the water-cooled chiller is a must machine.

Water Cooled Chiller for Fermentation

4.3 Medical Equipment and Medicines

Water-cooled chiller often used for cooling medical equipment like MRI machines and CT scanning machines.

MRI (Magnetic Resonance Imaging) is a medical examining method of creating images of human organization.

Water chillers have to be used to transfer heat from the MRI scanner to the air (in case of the air-cooled chiller) or cooling tower (in case of Water Cooled Chiller).

Low temperature storing of plasma, vaccines, and other medicines that require a low-temperature environment also uses chillers.

Water Cooled Chiller For Medical Process

4.4 Anodizing

In anodizing processes, especially hard coating processes, a lot of heat is generated and cooling is a critical requirement.

A water-cooled chiller is a necessary partner machine for the anodizing industry.

4.5 Other industries

There are too many circumstances in the industry that chilling is a must and is critical in equipment protection and product quality guarantee.

If you have any special cases that need to have a cold water solution, please come to us and TopChiller will provide you professional advice and custom-made solution to your application.

Whatever there is boring heat need transfer, there must need a water-cooled chiller.

Chapter 5: Maintenance of Water Cooled Chillers

Buying a good quality water-cooled chiller is the first important thing but how to maintain the water-cooled chiller is the coming key point.

As we know Water Cooled Chillers have wide applications in various industries, Water Cooled Chillers are performing heavy duties in the production of the factories.

It is maintained and safe operation is essential to the industrial processors.

Keep a daily log, a checklist, and closely monitoring the chillers will help to keep the water-cooled chillers in peak performance and save cost and energy in production.

Maintenance of Water Cooled Chillers

Below are the tips for water-cooled chiller maintenance.

5.1 Keeping daily logs or checklist

Keeping daily logs or checklists can help you build a history of the machine’s operation conditions, like temperatures, pressures, fluid levels, flow rates, etc.

With records of a certain period, you could quickly detect abnormal operations and predict errors before causing bigger problems.

And the data will allow you to see the trend of change and identify the maintenance needs before they become an issue and thus cause a big loss.

Maintenance of Water Cooled Chillers

5.2 Keeping tubes clean to ensure efficient heat transfer

As heat transfer efficiency greatly affects the chiller performance, maintaining clean tubes is extremely important.

Contamination such as minerals, scale, mud, algae, and other impure substance will add to the thermal resistance and reduce the overall performance of the water-cooled chiller.

A good indicator of heat transfer efficiency is the condenser approach temperature. Higher approach temperatures indicate decreasing heat transfer is happening.

Water-cooled chiller’s condenser tubes should be cleaned regularly, preferably once a year.

You should also look into the specific situation of your case to decide the cleaning schedule.

Maintenance of Water Cooled Chillers

5.3 Treating condenser water so as to prevent scale and corrosion

As the condenser water cycle circulates through open water sources-the water from a cooling tower, water treatment is required so as to prevent scale, corrosion, or biological growth.

These factors will lead to fouling in the condenser and impede heat transfer, decrease tube and piping effectiveness.

Annual inspection of the chilled water cycle is necessary. Water cooling tower maintenance will be discussed alone below.

Maintenance of Water Cooled Chillers

5.4 Entering water temperature control

Try to maintain the entering water temperature low can save a lot of work for the water-cooled chiller and increase the efficiency of its performance.

Look into the specific environment and conditions of your case and try to improve this condition.

5.5 Maintaining sufficient refrigerant

The cooling amount depends on the number of refrigerant moves through the compressor. Thus it is important to maintain an adequate level of refrigerant so as to have desired machine performance.

In the case of refrigerant leaking, air or moisture entering into the system, performance efficiency will decrease and the liability of the system will be compromised.

Refrigerant charge lower than the required level will force the compressor to work harder but result in an unsatisfactory cooling effect.

Maintenance of Water Cooled Chillers

5.6 Preventing non-condensable matters

Non-condensable matters such as air or moisture get into the cycle can cause lower pressure in the chiller, as the evaporator works in a vacuum environment.

Air or moisture reduces the performance efficiency of the water-cooled chiller up to 4% at 60% load and 7% at 100% load. The air purge unit is employed to minimize the non-condensable matters in the cycle.

5.7 Compressor oil checking

Compressor oil, a lubricant used to prevent wear and minimize corrosion, is better to be checked by the laboratory once a year. The oil should be changed if the analysis shows that it is necessary.

5.8 Maintaining the chilled water flow rate in the proper range

The too low or too high water flow rate will affect the chiller’s performance.

If the flow rate is too low, the water-cooled chiller efficiency will be lowered and lead to laminar flow in the end.

However, a flow rate too high will lead to vibration, noise, and tube erosion.

The typical flow rate is in the range of 3ft-12ft (FPS).

5.9 Regular checking of starters and motors operation

To ensure the starter and motors operate efficiently, check the safety and sensor calibrations on microprocessor controls.

Electrical connections, wiring, switchgear also have been checked and hot spots or worn contacts have to be identified.

Detect any insulation faults by testing electrical motor windings for insulation resistance to the ground.

Maintenance of Water Cooled Chillers

If you have more questions about the regular maintenance of Water Cooled Chillers, please feel free to contact our technicians and we would be glad to answer your questions.

Chapter 6: Why TopChiller can be your reliable Water Cooled Chiller supplier?

Since its founding in 1999, TopChiller devoted itself to producing high-quality dependable chillers to clients around the world.

Over the years, TopChiller has accumulated knowledge and experience in engineering, designing and manufacturing Water Cooled Chillers for various applications of its clients.

We understand our customs need in their specific cases and we provide the custom-made solution that is most suitable for their application. We will keep moving forward and providing our customer’s cutting-edge chillers.

For the following reasons, Topchiller is your most reliable Water Cooled Chiller supplier.

Extensive water-cooled chiller category:

Besides the wide range of water-cooled chillers options, we provide a full water-cooled chiller list of customized cooling solutions to meet any client’s special needs and circumstances.

We listen, study, look into the details and work out the optimal refrigeration solution that is efficient, energy-saving, durable, and environment-friendly.

Efficiency:
With the knowledge and experience, we obtained over the years, we keep improving water-cooled chiller performance efficiency.

Our skilled sales team also will work with you closely to find out the most suitable solution for your specific case so that the water chiller system selected will be most energy-saving and cost-effective while fulfilling the duties they are expected to carry.

Reliability:

Never compromising the quality under any circumstances, Topchiller insists on using the top quality and famous branded spare parts.

Our rigorous standards on every little part of the water-cooled chiller make our finished products rugged, dependable, durable under any adverse conditions.

Pre-sales and After-sales Service:

Our sales team and technical team will work closely with you to find out the best water-cooled chiller solution for your application.

We answer your water-cooled chiller inquiry and questions within 5 hours. We provide 24/7 online support to your business.

An 18-month warranty is provided and you can be assured that our water-cooled chiller will work properly in your plant.

We provide 8 hours of troubleshooting service. For the whole life of the water-cooled chiller, you can contact us for any problems or questions you have.

Chapter 7: FAQ of Water Cooled Chiller

1. How to get my water-cooled chiller design and quotation fromTopChiller?

Firstly we promise you will get a professional solution for your water-cooled chiller  free of charge, but please provide below important points:

• What’s your electrical power supply?-V-Hz-Phase?
• Do you an idea of the cooling capacity of a water-cooled chiller?
• What’s the required chiller inlet and outlet water temperature? and the water flow rate?
• Which industry this water-cooled chiller to be used in?
• Your country name and destination seaport.

2. What are your payment terms?

TopChiller insists T/T payment – 30% deposit before production once quotation confirmed, and 70% balance before delivery, also can accept 100% irrevocable letter of credit.

3. What’s the warranty time of the TopChiller products?

TopChiller providing 12 months to 24 months warranty time covered all products as clients’ requirements.

4. Can TopChiller provide OEM and ODM service?

Yes, As a professional water-cooled chiller supplier, we do OEM and ODM services for clients.

But first please let us know all your chiller requirements and drawings prior, also indicate the order QTY and volume.

5. Does TopChiller provide any on-site installation and commission service?

Yes, We have a professional engineering team with a rich experience that can do your water-cooled chiller on-site installation and commission. Please contact TopChiller sales for more information.

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TopChiller: Your Leading Water Cooled Chiller Supplier

Mostly, Water Cooled Chillers are more refrigeration efficient than air-cooled chillers.

It is because Water Cooled Chiller uses a water-cooled shell and tube type condenser, alongside an external water cooling tower and circulation water pump to make sure the chiller cooling is efficient.

Water Cooled Chiller can be installed both indoors and outdoors. Those installed outdoors must have a waterproof electrical control box.

Each Water Cooled Chiller designed by TopChiller with mobile brake casters can move easily from one place to another.

With 20 years of experience in Water-Cooled Chiller, TopChiller supplies first-class qualified Water Chillers to clients all over the world.

Please contact the TopChiller team to customize your Water Cooled Chiller for your industrial process.

Water Cooled Chiller-The Ultimate FAQ Guide by TopChiller

If you are looking for a durable, accurately temperature-controlled, and reliable device for cooling your building, shop, or factory then Water Cooled Chiller must be your priority.

Every industry uses different heat-generating systems and every commercial area releases a lot of heat.

If you are planning to plant an industry whether it is that of cotton, alcohol, or a power plant, then Water Cooled Chiller is a must-have device for the sustainable functioning of your systems.

An industry or a building comprises different systems, parts, or portions and Water Cooled Chiller can cause cooling of the whole industrial unit.

All the necessary information is put together in this guide regarding the Water Cooled Chiller.

I hope that you will seek all the help from this guide.

What is a Water-Cooled Chiller?

A budget-friendly, high-in-demand device, sprinkling humid air-stream on you is known as Water Cooled Chiller.

If you are worried about the excess heat in your room or office, or you are facing issues of systematic failures in your factory or mill, then Water Cooler Chiller is your need.

This fits like a glove for your industrial, commercial, or residential needs and provides the desired cooling while eliminating excess heat.

This very useful device is not only cost-effective but also that customization to large extent is possible in it, unlike any standard chiller.

Being a subtype of Modular Chiller, a Water Cooled Chiller is bi-modular in which two modules are linked with each other through a microprocessor controller.

These dual modules of the device are the reason for a Water-Cooled Chiller having a high value of cooling capacity.

A Water Cooled Chiller, a well-made, unique, and technologically superior device have an extensive area of its use. It ranges from houses to offices and commercial to residential sites.

Their usage in summer is common because of high temperatures in the room, offices, and other systems.

Water Cooled Chiller

What are the Features of Water Cooled Chiller?

• Efficiency is the one factor that makes the Water Cooled Chiller a feature-full device. Its condensation rate is low that makes it very efficient in functioning.
• The cooling tower is another feature of the Water Cooled Chiller which further adds efficiency to this unique cooling application.
• The connection of the cooling tower with that of a condenser is the feature of the Water Cooled Chiller that helps in cooling the warmed water.
• It also has a fan that, in case of higher temperature in the condenser, helps in lowering the temperature of the water.
• Its motor run compressor is an awesome feature that gives the Water Cooled Chiller an excessive cooling facility and helps in the optimization of pressure ratio for refrigeration application.
• The compressor quickly maintains the high temperature and low pressure of the refrigerant just after absorption of heat from the system and cooling down of hot water.
• The heat-absorbing refrigerant adds great efficiency to the functioning of the device.
• Water Cooled Chiller can operate constantly for commercial and industrial medium and large installations. The reason is that it is free from ambient temperature variation.
• The other features include the reliability of the Water Cooled Chiller. A Water Cooled Chiller could survive in an environment where others will simply shut down.
• Water Cooled Chiller is a budget-friendly device against the value it added to the customer. This economical device added great sustainability to the processes.

Budget Friendly Water Cooled Chiller

What are the Main Components of Water Cooled Chiller?

Water Cooled Chiller is composed of different components that work together to perform the cooling function.

Every component of Water Cooled Chiller has its importance. It includes; an evaporator, a compressor, an expansion valve, a condenser, a cooling tower, a power supply, and controls.

The detailed functioning of these components is as below,

1. Evaporator

The water chills by the exposure of refrigerant in the evaporator that absorbs all the heat of the water and lowers the temperature of the water.

Within the compressor is a pump that helps it circulating the chilled water (low-temperature water) to the system i.e. load, where it is installed.

Upon its circulation throughout the building, engine, or house, through pipes, the heat exchange takes place according to the second law of thermodynamics.

This law states that energy flows from higher temperatures (building etc.) to lower temperatures (pipes connected with the evaporator).

Consequently, the temperature of chilled water increases and it returns to the evaporator, where, the refrigerator is already waiting for it to come and cool it down again for the next trip of the building or a system.

1. Compressor

In Water Cooled Chiller, the position of the compressor is on top of the device.

After absorbing a sufficient amount of heat, the refrigerant then moves to the compressor.

The compressor of the Water Cooled Chiller, where the refrigerant reaches that is high in temperature and low in pressure after absorbing heat, increases its pressure and temperature.

For that purpose, a compressor has two moving parts i.e. screw rotators in it. These screw rotators are surge-free.

The refrigerant enters the space between the screws.

It compresses the refrigerant by the rotation of the two screws and discharges from the compressor after gaining high pressure and temperature.

1. Expansion Valve

As the name indicates, it uses for the expansion of the refrigerant.

After getting compression, the refrigerant moved towards the expansion valve for expansion.

The expansion valve does the expansion by reducing the pressure of the refrigerant.

Therefore, along with the reduction in temperature, the increase in the volume of the refrigerant takes in the expansion valve as by the law of Boyle.

This expansion in the volume helps the refrigerant in cooling down the high-temperature water running in the evaporator.

The expansion valve positions between the condenser and evaporator because it keeps the check of the quantity of the refrigerant moving from evaporator to condenser.

1. Condenser

The function of the condenser, as depicted in its name, is to work as a mediator between the compressor and cooling tower.

The condenser receives the heat of the water in the evaporator through a pipe.

The refrigerant moves outside the pipes and passes its unnecessary heat to the water that moves towards the cooling tower to disseminate that heat.

In this way, first, the temperature of the running water increases due to the heat exchange of refrigerant and then decreases gradually upon reaching the cooling tower.

In that process, the refrigerant condenses.

The condenser has a connection with the cooling tower through a loop. Therefore, that condenser acts as a medium between the compressor and cooling tower.

After heat exchange in the condenser, the hot water in the condenser moves towards the cooling tower.

1. Cooling Tower

A cooling tower is used for the disposition of the unwanted heat and absorbs it from the system whether it is a building, a hospital, or a factory.

Cooling Tower is the main spot where the actual function of a Water-Cooled Chiller is accomplished.

When condenser water enters a cooling tower, it welcomes air in the cooling tower. The air is produced by a large fan.

This fan helps water getting cool when that water comes from the top of the cooling tower.

Exchange of heat takes place from condenser water to cooling tower air. Cooling Tower of Water Cooled Chiller varies in size and structure.

The functioning of the cooling tower depends upon different factors including the position of the cooling tower, environmental factors, and its structure.

There are different structural variations in the cooling tower depending upon the proposed functions.

1. Controls 

This is the self-explanatory component of the Water Cooled Chiller that helps in controlling the functionality of the device.

Different types of settings are given on this component of Water Cooled Chiller to control the device like on-off and gauges to increase or decrease the values of temperature and pressure.

In addition to this, the controls help in dealing with the emergency and damages to the different parts of the Water Cooled Chiller.

One of the mechanisms is the alarming system fitted in the control component of the Water Cooled Chiller. This system uses alarms in damaging situations.

Like if there is any malfunctioning in any of the components of the Water Cooled Chiller, then the alarming system will start beeping alarms.

Another way adapted by controls is by a trip the running Water Cooled Chiller getting in case of any damage or malfunctioning.

1. Power Supplies

This component of a Water-Cooled Chiller helps in controlling the electrical power by which the device works. All the electrical equipment is part of the power supplies.

It includes power buttons, circuit breakers, speed controllers, a starter, etc.

Water Cooled Chiller Cooling Tower

What is the Working Principle of Water Cooled Chiller?

The work of a Water-Cooled Chiller is the transformation of heat from one place to another.

It fits with systems where there is a need for control of temperature i-e, provision of constant temperature, or low temperature.

The working principle of the Water Cooled Chiller is based upon the law of thermodynamics of

heat transfer which states that heat transfers from higher temperature towards lower temperature.

Water Cooled Chiller is installed in higher temperature region. The lower temperature is achieved in the cooling tower of the Water Cooled Chiller.

The role of refrigerants is also inevitable in this regard.

Therefore, there is the transfer of heat from the building or any heat-emitting system towards the Water Cooled Chiller.

Evaporation Process

The procedure is very simple and speedy. It starts from entering the water into the evaporator.

This entering water has a high temperature that it gains from the heat of the building or a system.

In the evaporator is the refrigerant that is a liquid, which, evaporates at a high temperature.

The refrigerant can absorb heat. It absorbs the heat by phase transition i-e, it turns into a gas at high temperature.

In this way, the temperature of the water in the evaporator reduces which is then sent back to a tank through which it recirculates in the building or a system.

A pump pumps the water back to the system.

The water then receives the heat of the system i-e. the ambient air temperature and its temperature raises once again.

It is necessary to understand that water never interacts or mixes with refrigerant directly. The refrigerant flows outside the pipes to absorb the heat while water moves inside the pipes.

The temperature of the refrigerant increases and its pressure decreases.

Compressor Phase

Meanwhile, the expanded refrigerant pushes towards the compressor.

After passing through the speedily moving screws of the compressor, the refrigerant gains high temperature and pressure.

The refrigerant then gets the entry in the condenser that has the intricate pipes in which low-temperature water runs.

Condensation phase

The heat transfer takes place once again from the refrigerant to the condenser water.

The condenser water after absorbing sufficient heat moves to the cooling tower. In the cooling tower, the fan cools down again when it falls from the chambers of the tower.

After getting cool, the condenser water again moves toward the condenser to absorb more heat from the refrigerant.

Ultimately, the refrigerant gets the condensation and passes through an expansion valve. There, its pressure as well as temperature decreases.

Back to evaporator

Finally, the refrigerant returns to the evaporator where heat-containing water waits for it. The same process keeps on repeating.

Water Cooled Chiller Working

How to Increase the Working Efficiency of your Water Cooled Chiller?

The working efficiency of the Water Cooled Chiller is its ability to cool the building or the system with which it connects, in a speedy way without any harm to the system or the device.

The Coefficient of Performance (COP) indicates the working efficiency of the Water Cooled Chiller.

It is also known as Energy Efficiency Ratio (EER) and it indicates the cooling capacity of the Water Cooled Chiller when it is given a full load of electrical input.

Following are some operational practices that could help to increase the efficiency of the Water Cooled Chiller.

1. The choice of the compressor should be that of the speed type variable.
2. The temperature of the condensation of refrigerant is low
3. The temperature of chilled water is rising
4. Reduction in the consumption of energy to be made possible
5. Changing the set temperature of the chiller to upward when there is less need for cooling.
6. By changing the flow rates of water when there is less need for cooling in the system
7. Having a series connection of chilled water with condenser is another option that experts may utilize to gain efficiency of the Water Cooled Chiller

Following are some optional practices of maintenance that could be a factor for increasing the efficiency of the Water Cooled Chiller,

1. To gain greater efficiency, proper maintenance of the Water Cooled Chiller is the main factor.
2. Proper insulation of the components like the compressor must be there.
3. Keep every component of the Water Cooled Chiller neat and clean so that dust may not enter the system.
4. Calibration of the motors, controls, gauges, etc. is necessary for gaining more or restoring the existing efficiency of the Water Cooled Chiller.
5. Monitor the accumulation of unnecessary particles or dust i.e. fouling especially when open cooling towers are used.

Water Cooled Chiller Efficiency Checking

Why Water Cooled Chiller is More Efficient than an Air-Cooled Chiller?

There are substantial reasons for the Water Cooled Chiller to be more efficient than the Air Cooled Chiller.

• Wet-bulb temperature:

The very first reason for it is that Water Cooled Chiller has a wet-bulb temperature, unlike Air Cooled Chiller that has a dry-bulb temperature.

The degree of wet-lab temperature is lower than dry-bulb temperature.

• Operates at lower condensing temperature:

The condensing temperature of the refrigerant can operate lower due to the low temperature that is different from Air Cooled Chiller. Thus, proven to be more efficient than other chillers.

• Quieter application:

Water Cooled Chiller does not produce noise while Air Cooled Chiller produces a lot of noise due to speedily moving air.

• Longer life span:

Similarly, the operating life of the Water Cooled Chiller is more than Air Cooled Chiller. The energy efficiency of the Water Cooled Chiller is also more than Air Cooled Chiller.

Air Cooled Chiller

What are the Applications of Water Cooled Chiller?

Water Cooled Chiller has extensive use in every field of life. It has the application of cooling down the systems, industrial applications, or any heat-producing processes.

The application of a Water-Cooled Chiller may include cooling the system of a factory, industry, or any place where the thermodynamic process is taking place.

Water Cooled Chiller, though its name is self-explanatory, consumes water for its working.

• Applications in cutting and molding industries.
• For cooling of food and beverages companies.
• Acceptable in laser industries.
• Cooling of chemical industries.

Water Cooled Chiller is used for the cooling of all these above-mentioned industrial processes.

What are the Advantages of Water Cooled Chiller?

Water Cooled Chiller has plenty of advantages over other types of chiller. Here is the list of advantages of Water Cooled Chiller,

• Efficient cooling:

Cools the house, hotels, airports, buildings, factories, and other commercial and residential buildings.

• Customization according to demand:

Can be customized during installation (according to the requirement)

• Uses surge-free compressor:

Unlike standard chiller, the Water Cooled Chiller has a surge-free compressor where there are two screw rotators in it.

The refrigerant is effectively and efficiently compressed and discharged through these screw rotators.

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

There is a variety of Water Cooled Chiller based on the cooling capacity and material quality. The variation occurs in size and structure as well.

Therefore, it becomes critical for the user to click the right option while on the shop of the Water Cooled Chiller.

To get the right Water Cool Chiller, do consider the following things,

• Satisfying your requirements:

What is the requirement of my system rather it is a building, a factory, a hotel, or a firm?

• Your budget:

What is the lifecycle cost of the Water Cooled Chiller?

• Suitable to the operating environment:

What is the climate region your business or building resides?

• Timing of operation:

What will be the operating hours of the Water Cooled Chiller for my system or a building?

• Cooling Capacity:

Check the cooling capacity of the Water Cooled Chiller and match it with the estimated requirement of your system?

• Others:

1. Do I have sufficient space for it?
2. Is it energy efficient to install the Water Cooled Chiller?
3. Seek a detailed description of the different types of Water Cooled Chiller. See the specifications of every Water Cooled Chiller.

How to Install a Water-Cooled Chiller?

The installation process of Water Cooled Chiller starts from the process of preparing a mechanical structure to:

Step 1: Prepare the base

Before even buying the Water Cooled Chiller, a base is prepared. In the mechanical field, the civil team prepares the base according to the size of the Water Cooled Chiller.

Step 2: Mechanical Structure

By using the angles, a structure develops by the mechanical staff. This structure is constructed in a way that the Water Cooled Chiller sets fit on it.

Step 3: Placing the Water Cooled Chiller on the Structure

In this step, a Water Cooled Chiller is placed on the structure. This becomes possible by using a crane because it is not possible to uplift a heavy Water Cooled Chiller by other manual methods.

Step 4: Fitting of Water Cooled Chiller on the Structure

The mechanical structure has a space of nuts and bullets to fix the Water Cooled Chiller to its place.

In this way, the live Water Cooled Chiller cannot misplace from its original position. It seats right on those bullets and the bullets tights by the officials or by the user.

How to Maintain your Water Cooled Chiller?

An abrupt failure of your water-cooled chiller can result in a huge loss for your industry.

The maintenance of the Water Cooled Chiller is as important as the installation of it.

Maintenance of the Water Cooled Chiller is important to gain high efficiency and long-term sustainability.

Following are a few important things to keep check of to ensure the maintenance of the Water Cooled Chiller.

1. Daily housekeeping of the whole area where the Water Cooled Chiller is installed.
2. Daily clean all the components of the Water Cooled Chiller including power buttons, cooling tower, etc.
3. Greasing the parts of the components where it is necessary.
4. Greasing the nut and bullets with which the Water Cooled Chiller is fixed.
5. Properly keep and check the components of the device.
6. See if there is any noise-producing from any of the components.
7. Install the Water Cooled Chiller indoors.
8. Protect the Water Cooled Chiller from the elements of the environment like dust, heat, fire, etc.

Water Cooled Chiller Maintenance

How to Troubleshoot Your Water Cooled Chiller?

Your Water Cooled Chiller can be a significant purchase, so it is essential to see how to keep up and troubleshoot it in order to get good results and save your investment.

Like troubleshooting any device, the Water Cooled Chiller can troubleshoot against any fault or failure of running.

Your Water Cooled Chiller will work more effectively through appropriate and continuous care and troubleshooting.

To troubleshoot the Water Cooled Chiller, do these following things,

1. See if there is any noise-producing from any component of the Water Cooled Chiller.
2. See if any part of the Water Cooled Chiller is warmer more than normal.

Note: Check the temperature by using a mechanical thermometer instead of the direct method of touching with a hand.

1. See if any component of the Water Cooled Chiller is vibrating more than normal while it is running.
2. See if there is any smell of burning a circuit.
3. See if changing the power socket works or not.

Water Cooled Chiller Troubleshooting

FAQ of Water Cooled Chiller.

1.  What Kind of Facilities, a Water Cooled Chiller Can be Used? 

A Water Cooled Chiller can be used in all kinds of industries because of the flexibility in features that it incorporates.

Ranging from smaller units to larger ones including manufacturing, drug-making, and many more.

1. Where is Water Cooled Chiller with Large Cooling Towers used?

Water Cooled Chiller with large Cooling Towers uses in mega projects like that of a power plant, fertilizer companies, refineries, recycling factories, etc.

1. What Kind of Refrigerant is Commonly Used in Water Cooled Chiller?

The coolant gas that is used in Water Cooled Chiller is known as a refrigerant. The refrigerant commonly used are R13a, R407a, or R410a.

1. How you can calculate the Cooling Capacity for your Water Cooled Chiller?

First of all, you need to analyze the flow rate. Secondly, check about inlet and outlet temperature then you can calculate the cooling capacity.

CC (kw) = FR (m3/h)*Temp Change (T1-T2)/0.86

1. What is the Correct Temperature for a Water-Cooled Chiller?

Keep your appliances at the proper temperatures. Normally, the usual temperature of a Water-Cooled Temperature of the Water Cooled Chiller is 4°C.

However, it can increase and decrease according to the requirement of the system.

1. What is the Difference between Air Cooled Chiller and Water Cooled Chiller with Concern to its Position on the Compressor?

In Water Cooled Chiller, the compressor is positioned at the top of the chiller while in Air Cooled Chiller, the compressor is placed under the chiller.

1. What type of Pipe is usually used for Water Cooled Chiller?

Water Cooled Chiller usually uses copper tubes instead of pipes where there is a need of stopping the emission of heat.

However, where there is a need for heat dissemination, stainless steel pipes are used.

8. What is the warranty of a Water-Cooled Chiller?

The standard warranty for Water Cooled Chiller offered by most companies is twelve months.

Within this duration, any problem including breakage of components would be dealt with by the associated company itself.

100% Quality Tested Water-Cooled Chiller