TopChiller Water Cooled Scroll Chiller Manufacturer and Supplier

Water Cooled Scroll Chiller-An Ultimate Buying Guide by TopChiller.

Maintenance of a moderate temperature throughout the industrial types of equipment is essential for the normal functioning of these devices.

One solution to cope up with this excess heat is using a Water Cooled Scroll Chiller.

Whether you are present in a plastic or printing industry, the Water Cooled Scroll Chiller is an excellent option to lower down the excess heat production of various involved machines.

Before you get a Water Cooled Scroll Chiller, it is essential to know about how it works, how to maintain it, and also how to elevate the efficiency for obtaining better results.

In this guide, we will present detailed information regarding the construction, working, installation, and many other things related to the Water Cooled Scroll Chiller, so let’s get started.

What is a Water Cooled Scroll Chiller?

A Water Cooled Scroll Chiller is a refrigeration machine that reduces the excess heat production from various industrial machines.

Since water is a better cooling medium than air, a Water Cooled Scroll Chiller is more powerful as compared to the Air Cooled Scroll Chiller.

Water Cooled Scroll Chiller comprises of cooler, several hermetic scroll compressors, and a Shell & Tube water-cooled condenser. The Water Cooled Scroll Chiller requires less energy than the Air Cooled Scroll Chiller because of its higher performance.

The chilling module will provide constant cooled water throughout the year, independent of temperature changes that are occurring to its surroundings.

It also adequately supports cooling processes that require a wide range of temperature regulations.

So, whether you want a heat-coping solution in printing, laser, plastic, or many other industries, you may use the Water Cooled Scroll Chiller.

Water Cooled Scroll Chiller Designed by TopChiller

What is the Construction of a Water Cooled Scroll Chiller?

The following components make up the structure of the Water Cooled Scroll Chiller.

• Evaporator
• Condenser
• Compressor
• Expansion valve

Furthermore, the central chamber of the evaporator is enclosed by several tubes. These tubes hold the liquid that aids in the cooling of the water before being sent to the condenser.

The compressor is then attached to the condenser, which completes the process by connecting to the evaporator to complete the circuit once more.

Water Cooled Scroll Chiller Compressor

What are the Main Features of the Water Cooled Scroll Chiller?

• Ergonomic designing
• Low input KW/TR
• Robust and durable structure
• Heat exchanger constructed as per TElvlA/ASME/SEC VIII, DM, 2001
• New technology
• MCS microprocessor/ electro-mechanical
• CFC free refrigerant
• Liquid injection for the full compressor life
• Energy efficient

Higher Energy Efficiency 

The Water Cooled Scroll Chiller with dual compressors works in a sequential range in temperature from 48 to 111 degrees Fahrenheit.

And if only one compressor is present, this increases operational performance during component load times when the whole condenser region is used for heat rejection.

Capacity Modulation 

In most models of the Water Cooled Scroll Chiller, several compressors are used, each with its refrigerant circuit.

During component load conditions, the microprocessor controller ensures that only the necessary number of compressors run, resulting in saving energy.

Operating Reliability 

The motor is cooled by the suction gas and the compressor is a no-contact scroll style. The compressors with suction gas delivery restrictors are used in high capacity Water Cooled Scroll Chiller allowing for a controlled compressor operation.

Before dispatch, the Water Cooled Scroll Chiller is charged and checked in the plant, ensuring high operational efficiency.

Water Cool Scroll Chiller Microprocessor Controller

How Does a Water Cool Scroll Chiller Work?

The working of the Water Cooled Scroll Chiller comprises of the following four components or steps.

1. Evaporator: 

The cycles begin in the evaporator, where liquid refrigerant passes through a bundle of tubes that surrounds the evaporator.

The liquid refrigerant is a chemical that can absorb heat from the water flowing into the pipe. As soon as the water reaches 100 degrees Celsius, it is considered boiling. The water continues to decompose into vapors.

2. Compressor: 

The compressor is designed to move these vapors through. This is where the scroll compressor comes into play. Pump, squeeze and pressurize the fluid with its unusual spiral shape and two interleaving scrolls.

3. Condenser: 

Through injecting vapors into the condenser, the compressor begins to increase the temperature of the condenser.

The heat is transferred to the cooling water while the vapor condenses in the tubes.

4. Expansion Valve: 

The expansion valve is then used to reduce the pressure and temperature of the high-pressure liquid refrigerant.

Water Cooled Scroll Chiller Working Diagram

What are the Applications of a Water Cooled Scroll Chiller?

• Plastic:

It is frequently used to keep materials and equipment cool in the plastic manufacturing industry.

• Laser:

Water Cooled Scroll Chiller aids laser processes by extracting heat from various procedures and machines where extreme heat could affect the overall laser procedures.

• Printing:

It is also used in the printing industry to eliminate the heat produced by heated printing rollers due to friction.

It also aids in the cooling of the paper as it emerges from the ink drying ovens, as well as the use of ultraviolet lamps for ink curing.

• Machine Cooling:

Injection molding, drill and die-cutting, food and beverage, additives, machine tool, semi-conductors, and other industries all use the Water Cooled Scroll Chiller.

Water Cooled Scroll Chiller is Used for Printing Industry

How to Choose the Best Water Cooled Scroll

Chiller for your Application?

To choose the best Water Cooled Scroll Chiller for your application, always consider the following factors.

• A suitable supply of water from the tower source.
• Excellent quality water.
• More than 35 degrees ambient temperature.
• Heat recovery is an essential factor.

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

• Thanks to the distinct benefit of multiple refrigeration circuits with hermetic scroll compressors,
• The compact size is loved by many users.
• It is easy to operate.
• It is efficient and quick in working.
• The power consumption is low as compared to other chillers.
• The refrigerants used are environment-friendly.
• It is not noisy during operation.
• You don’t need a large open space to place this Water Cooled Scroll Chiller.
• It doesn’t contain any toxic chemicals.
• Sun exposure, rain, and storm-like things provide more durability.

How do you Enhance the Working Efficiency of your Water Cooled Scroll Chiller?

• Control Water Velocity

Since too low a flow rate decreases the performance of the Water Cooled Scroll Chiller and leads to laminar flow, it must be carefully controlled. Usually, the lowest flow velocity is about 3 feet per second.

A high flow rate, on the other hand, causes vibration, noise, and tube erosion. So typically, the maximum recommended flow rate is around 12 feet per second.

• Maintain Refrigerant Charge

The amount of cooling it can produce is determined by the amount of refrigerant it can pass through the compressor in a given amount of time.

So, it is important to keep the right amount of refrigerant in the system.

Air and moisture, as well as leakage, limit the performance and system stability. Low refrigerant fee, which is typically caused by leakage, makes the compressor operate harder and provides less cooling.

• Purge Non-Condensable

Non-condensable such as air and moisture may leak into the low-pressure Water Cooled Scroll Chiller. Chimney performance can be reduced by as much as 4% at 60% load and 7% at 100% load when using non-condensable.

Tubes are shielded by cold, which avoids trade and increases condensing temperatures, making the compressor operate harder. The acid formation is aided by rain, which can damage motor windings and bearings.

Purge units used on low-pressure Water Cooled Scroll Chiller reduce the impact of non-condensable. Both air ingress and refrigerant leakage are minimized with today’s high-efficiency purge devices.

Low-pressure ones will gradually be replaced by high-pressure ones using HFC-134a, HFC-410a, and HCFC-22. Since non-condensable cannot penetrate the newer units, they do not need purge units.

• Analyze Compressor Oil

Send a sample of compressor lube oil to a laboratory once a year for a spectrometric chemical examination, which can show moisture content, metals, acids, and other pollutants that, may impact efficiency.

Oil can never be substituted if necessary. High moisture levels can suggest an issue with the purge unit, which can reduce performance significantly.

Using a timetable based on purge run hours, remove samples from low-pressure Water Cooled Scroll Chiller more regularly.

Replace oil filters when the oil charge is adjusted and when there is a large pressure drop.

• Check Wiring

Check the safety and sensor calibrations on microprocessor controls for effective starter and motor operation. Consult the manufacturer’s instructions.

Then search for hot spots and worn contacts in the electrical ties of the Water Cooled Scroll Chiller, wiring, and switchgear. Check motor windings for resistance to ground and winding-to-winding to reduce insulation faults.

To optimize cooling, inspect the shaft seal on open drive motors for potential refrigerant leakage and clean the engine cooling air vents.

Water Cooled Scroll Chiller Wiring Checking

• Reduce Entering Water Temperature

The performance of the Water Cooled Scroll Chiller can be improved by lowering the temperature of the water entering the condenser.

To solve air handler shortcomings such as dirty coils, operators can lower the chilled water set point on certain building systems. Be wary of this procedure, since this would only disguise the signs and not fix the problem.

For the same net cooling result, it makes your Water Cooled Scroll Chiller work harder.

How to Install your Water Cooled Scroll Chiller?

• Install according to the manufacturer’s instructions, shop plans, and Contract Papers.
• Adjust and level the Water Cooled Scroll Chiller so that it is aligned with the supports.
• Check with the electrical contractor to prepare the installation.
• Controls should be coordinated with the control provider.
• Provide the accessories to ensure that the Water Cooled Scroll Chiller is completely functioning and usable.

What are the Main Steps in Using a Water Cooled Scroll Chiller?

Step 1: 

Assess the situation and check if there is a need to turn on the Water Cooled Scroll Chiller.
Step 2:

Adjust the valves and double-check the pressure gauges and the thermostat.
Step 3:

Start the pump so that the refrigerant is then directed to a compressor, which conducts a variety of tasks.

To continue, it eliminates refrigerant from the evaporator and ensures that the evaporator’s pressure stays low enough to retain heat at the proper pace.

Step 4:

Start the cooling tower, so it increases the pressure in the exiting refrigerant vapor to guarantee that the temperature of the vapor is high enough to release heat as it enters the condenser.

Step 5:

Start the chiller and soon the cool air will start flowing as the pressures increases in the condenser.

What are the Safety Tips you must Follow When Using your Water Cooled Scroll Chiller?

• Accidental Release Measures

Ventilate the environment, especially low or enclosed areas where heavy vapors can accumulate. Open fires should be extinguished.

For massive spills or drops, use a self-contained breathing apparatus (SCBA). Delete all electrical sources from the equation.

• Engineering Controls

Vapors should not be inhaled. Stop getting into contact with your skin or eyes. To hold employee exposure below the recommended exposure level, use proper ventilation.

If significant volumes are released, the local exhaust should be used. In low or confined spaces, mechanical ventilation can be used.

• Skin Contact 

Using lukewarm water, flush the place. Prefer using cold water instead of hot. Dial a doctor if you’ve had frostbite.

• Eye Contact

If you come into contact with this, quickly rinse your eyes with plenty of water for at least 15 minutes. Have an appointment with a doctor.

• Ingestion

Do not force yourself to vomit. Give a lot of water in tiny sips.

• Fire Fighting Instructions

Using a water mist or cloud, cool the cylinder. If cylinders burst and contents are released during a burn, self-contained breathing apparatus (SCBA) is required.

Until being released, water drainage should be contained and neutralized.

• Waste Disposal Methods 

If this substance is removed, it should be brought to an approved facility and disposed of according to local legislation.

Wear Gloves While Operating your Water Cooled Scroll Chiller

How to Maintain your Water Cooled Scroll Chiller?

Unit Status: 

Make sure there are no fault messages shown by clicking the ‘STATUS’ key on the keypad (refer to the MBCS Manual for an explanation of messages and the Trouble Shooting section for courses of action).

Operating Conditions: 

Using the ‘OPER Details’ key, verify the operational pressures and temperatures at the control panel to ensure they are within the MBCS Manual’s operating limits.

Refrigerant Leaks: 

Check for damage and gas leakage in the cooler, condenser, compressors, and pipework.

Compressor Oil Level:

When the compressor is running normally, check the oil level in the compressor. In the oil sight bottle, the oil level should be between ½ and ¾. The oil level will drop to the lower limit of the oil sight glass during the shutdown.

Compressor Oil Quality: 

The compressor oil is a light yellow color. If the oil color darkens or changes, it may be a sign that there are toxins in the refrigerant method.

When this happens, a sample of the oil can be obtained and analyzed. To avoid compressor failure, the machine must be cleaned if pollutants are present.

• Refrigerant Charge:

A flow of bubbles can be seen in the liquid line sight glass as a device starts up, or often during a capacity adjustment.

The bubbles should clear after a few minutes of steady activity, leaving only liquid refrigerant visible in the sight window.

In addition to the above-mentioned scans, the device should be inspected regularly to ensure proper service. Loose machinery, component activity, unexplained sounds, and other problems should be checked and fixed as soon as possible.

Compressor Oil Checking

What are the Control Options for your Water Cooled Scroll Chiller?

Evaporator – Condenser Pumps 

The controller can power one or two evaporator pumps and manages pump switching automatically. It’s also possible to prioritize the pumps and switch off one of the two for a while.

A special condenser water pump can also be controlled by the controller.

Compressors 

The controller can power up to four compressors on one or two separate refrigerant circuits. The programmer will be in charge of all of the compressor’s protective functions.

Expansion Valve 

The controller will monitor an electronic expansion valve for each refrigerant circuit to ensure the best possible output.

What Are Safety Devices and for a Water Cooled Scroll Chiller?

1. General Safety Devices 

This degree of intensity would lock down all circuits and bring the whole device to a halt. When a general safety system malfunctions, manual action on the unit is needed to restore the machine’s normal operation.

In the case of warnings relating to transient irregular circumstances, there are exceptions to this general law.

Emergency Stop

A push-button is mounted on the unit’s electrical panel door. The red color on a yellow background attracts attention to the bell.

By pressing the emergency stop button manually, all loads are stopped from turning, avoiding any further accidents. The Unit Controller also triggers an alert.

The device can be restarted only after the alarm on the controller has been cleared by releasing the emergency stop button.

2. Circuit Safety Devices 

The circuit they secure would be shut down if the standard of safety is this high. The remaining loops will continue to operate.

3. Component Safety Devices

A component would be shut down if it detects an unexpected operating state that could result in irreversible damage.

The below is a description of the safeguarding devices:

• Over Current/Overload Protections

In the event of an overload or short circuit, overcurrent/overload systems secure electrical motors used in compressors and pumps. Overload and overcurrent safety is built into the electronic drives for inverter-driven motors.

Fuse or circuit breakers mounted upstream of each load or group of loads provide additional short circuit protection.

• Over Temperature Protections

Thermistors found in the motor windings prevent compressors from overheating as well. The thermistors can trip and allow the motor to stop if the winding temperature rises over a predetermined level.

• Phase Reversal, Under/Over Voltage, Ground Fault Protection

When one of these alarms is triggered, the device is automatically turned off or even prevented from starting. Once the issue has been settled, the warnings will go away immediately.

This auto simple logic helps the unit to immediately recover if the supply voltage exceeds the upper or lower limits set on the safety system.

To solve the problem in the other two situations, a manual intervention on the device would be needed. Two steps must be reversed in the event of a phase reversal warning.

• Flow Switch

A flow switch is needed to protect the device. When the water flow falls below the minimum allowable flow, the flow switch will shut down the unit.

The flow protection is automatically reset when the water flow is restored. When the flow switch opens with at least one compressor running, the warning must be manually cleared.

• Freezing Protection

Antifreeze safety protects the water in the evaporator from freezing. When the water temperature (entering or leaving) at the evaporator falls below the antifreeze cap, it automatically activates.

If the device is on standby in a frozen state, the evaporator pump would be triggered to keep the evaporator from freezing.

If the frozen state happens when the unit is working, the entire unit will shut down in an alert mode while the pump continues to operate. When the frozen state is no longer there, the alarm will go off immediately.

• Low-Pressure Protection

If the circuit’s suction pressure falls below an adjustable limit for an extended period, the circuit’s safety logic can shut it down and trigger a warning.

To reset the alarm, manual action on the Unit Controller is necessary. Only if the suction pressure falls below the safety level will the reset take place.

• High-Pressure Protection

If the discharge pressure increases too high and reaches a cap connected to the compressor operating envelop, the circuit safety logic will attempt to deter the warning from firing.

Or if corrective steps are unsuccessful, it will shut down the circuit before the Mechanical High-Pressure switch opens. To reset this alarm, manual action on the Unit Controller was necessary.

Water Cooled Scroll Chiller Emergency Stop Button

What Are Some Common Problems and their Solutions for a Water Cooled Scroll Chiller?

When the Discharge Pressure of the Water Cooled Scroll Chiller is increased

1. Test the cooling water tower, water pump, and every water valve if the condenser’s inlet water temperature is too high or the flow rate is inadequate.
2. The device produces air or non-condensable gas, which can be extracted according to the fault monitor.
3. Severe condenser scaling: washing copper tank
4. Surplus refrigerant filling: excess refrigerant must be discharged.
5. The condenser’s inlet valve is not completely open: search and fully open;
6. If the suction pressure is greater than average, see the “too high suction pressure” troubleshooting.

When the Discharge pressure of the Water Cooled Scroll Chiller is decreased

1. The water pressure through the condenser is excessive: the valve should be minimized at this moment.
2. If the condenser’s inlet water temperature is too low, change the cooling water tower’s fan speed or the number of fans.
3. Inadequate refrigerant filling: charge the refrigerant to the specified amount.
4. Lower than average suction pressure: see “low suction pressure” troubleshooting.

FAQ of Water Cooled Scroll Chiller.

What is the difference between a Water Cooled Scroll Chiller and Water Cooled Screw Chiller?

The Water Cooled Scroll Chiller can range from 20 to 200 tons in weight. Moreover, it can comprise of two compressors however the Water Cooled Screw Chiller only has a single compressor, losing which can cause a fault in the whole process.

Water Cooled Screw Chiller

What is the Best Water Cooled Scroll Chiller Efficiency?

A Water Cooled Scroll Chiller functioning at around 70 to 75 percent load and that allows the minimum temperature of the incoming condenser water has probably the maximum efficiency.

What is the Water Cooled Scroll Chiller Set Point?

For acquiring the maximum efficiency of the Water Cooled Scroll Chiller, the set point of the condensing temperature changes with the outdoor temperature in a linear way.

This allows minimum stoppage or fluctuation in the efficiency of the Water Cooled Scroll Chiller.

Which Refrigerant is used in the Water Cooled Scroll Chiller?

If the Water Cooled Scroll Chiller offers medium capacity, R-407 C and R-410A are the refrigerants used.

However, for a highly efficient Water Cooled Scroll Chiller, R-123 and R-134a are the most commonly used refrigerants.

Why is the Water Cooled Scroll Chiller More Efficient Than the Air Cooled Scroll Chiller?

The Water Cooled Scroll Chiller is more efficient than the Air Cooled Scroll Chiller because it uses a cooling tower in the whole process.

Also, it provides condensation according to the ambient temperature bulb temperature which is less than the ambient dry bulb temperature.

What do you mean by the Water Cooled Scroll Chiller Staging?

Staging up and staging down of the Water Cooled Scroll Chiller is essential to cope up with the load and to prevent the faulty working of the Water Cooled Scroll Chiller caused by less flow or any other problem.

Which Water Do you Use in your Water Cooled Scroll Chiller?

The deionized water is used in a Water Cooled Scroll Chiller, for preventing the electric current flow. Water glycol mixture is also used for preventing freezing and bacterial growth.

What is the Most Suitable Temperature of a Water Cooled Scroll Chiller?

The most suitable temperature of the Water Cooled Scroll Chiller ranges from 35 degrees to 50 degrees.

What is the ideal pH of the Cooling Tower Water of the Water Cooled Scroll Chiller?

The ideal pH of the cooling tower water of the Water Cooled Scroll Chiller ranges from 6.5 to 7.5. This pH helps in the reduction and prevention of scale formation.

What is the Average Life of the Water Cooled Scroll Chiller?

According to research, the average life of the Water Cooled Scroll Chiller ranges from 15 to 20 years. However, this life is highly influenced by the way and frequency of using your Water Cooled Scroll Chiller.

What Chemicals are Used in the Cooling Tower of the Water Cooled Scroll Chiller?

The Water Cooled Scroll Chiller uses corrosion inhibitors such as bicarbonates for the protection of metallic compounds and the neutralization of acidity.

For the reduction and prevention of microbes, it also uses algaecides.

Moreover, it also uses scale inhibitors such as phosphoric acid is also used for the reduction of scale formation.

What is the Result of Increased Purge Counts in the Water Cooled Scroll Chiller?

If the Water Cooled Scroll Chiller has increased purge time, this indicates a leak in the system.

However, if you require that the purge time is decreased or normal, you need to properly maintain your Water Cooled Scroll Chiller.

What is the Purpose of Adding Biocides in the cooling tower of the Water Cooled Scroll Chiller?

The purpose of using biocides in the cooling tower of the Water Cooled Scroll Chiller is to control bacterial growth. If you fail at using a suitable cooling water biocide system, you will have to face bacteria and corrosion issues.

100% Quality Tested Water Cooled Scroll Chiller