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Air Cooled Chiller: The Ultimate FAQ Guide

Probably, you are looking for a high-quality air-cooled chiller.

Or, you’d like to learn more about air-cooled chillers.

Today’s guide explores all the critical aspects you need to know about these chiller systems.

So, if you want to be an expert in an air-cooled chiller, read this guide.

What is Air-Cooled Chiller?

An air-cooled chiller is a device that extracts heat from a load and transfers the heat to the environment.

It uses a fan or a refrigeration system.

These systems are common in most power plants.

Fluids are cooled by the refrigeration system.

This is possible with the help of air handling equipment.

Air cooled chiller designed by TopChiller

What are the Components of Air-Cooled Chiller?

Components of an air-cooled chiller include:

• Compressor: this is the driving force of the air-cooled chiller. The four main categories of compressors are/ include screw, scroll, reciprocating, and centrifugal.
• Condenser: these are the pipes where the air is moved across the condenser to dissipate unwanted heat.
• Condenser fans: the fans are the main components that differentiate between air-cooled and water-cooled chillers.
• Evaporator/Expansion valve: this works with the heat exchanger to change the air from cold to hot and vice versa.

The three types of evaporators are brazed-plate, direct expansion, flooded shell-and-tube

• Filter drier: protects the chiller from contaminants such as dust and should be replaced regularly.

Air cooled chiller filter drier

How does Air Cooled Chiller Work?

An air-cooled chiller works through the following process:

1. Heat absorption: this is achieved through the absorption process where the heat from the water is absorbed by the air-cooled chiller.
2. Handler system: this allows the hot air that has been used up to be ejected out of the air-cooled chiller.
3. Evaporator: This is a unit that blows hot or cold air to the atmospheric air that is infused into the system.
4. Liquid refrigerant: this is where the water from the evaporator is turned to a gaseous form that is low in pressure.
5. Compressor: the air from the evaporator that is in gaseous form and low pressure is compressed to a high-pressure gas.
6. Condensers: this is where the exchange of gases happens, hot air is blown out while the clean air is blown inside through the fans.
7. For efficiency purposes, it is recommended to place the air-cooled outdoors where there are no obstacles and the flow of air is uninterrupted. This will ensure the air-cooled chiller works at optimum.
8. The main and important process of an air-cooled chiller is changing the liquid that is low pressurized to a liquid that is highly pressurized through the refrigerant.
9. The process of changing low pressurized liquid to high pressurized liquid is a vicious cycle that requires the air-cooled chiller to work at optimum.
10. This process is continuous and after the changing of the pressurized liquid, the process repeats according to how the air-cooled chiller has been set.

How does Air Cooled Chiller compare to Water Cooled Chiller?

Comparisons of air-cooled chillers and water-cooled chillers include:

• A condenser is a component in air-cooled chillers that cools the air blown in.

On the other hand, water-cooled chillers comprise of condenser whose temperature is lowered by water connected with a cooling tower.

• Air-cooled chillers are preferred for large installations while water-cooled chillers are preferred for medium and smaller installations.
• Water-cooled chillers are costly to operate and maintain than air-cooled chillers.
• The water-cooled chiller’s specification is measured in kW/ton that ranges from approximately 0.55 and 0.8kW/ton.

That is different from an air-cooled chiller that has a different load.

• Air-cooled chillers are preferably used in areas where water supply is not constant or where water is very expensive.

While water-cooled chillers are preferable in areas where the water supply is sufficient.

• Air-cooled chillers are preferred for all-weather use including freezing conditions, unlike the water-cooled chillers that cannot be used in winter conditions.
• Unlike water-cooled chillers that need to be set up where there is a constant flow of water, air-cooled chillers can be set up at any location as long as there is a source of power.

Water cooled chiller

Do Air Cooled Chillers require Cooling Towers?

Air-cooled chillers work at optimum are located in an open space where there is uninterrupted airflow and safe from hazards such as traffic.

Most of the air-chiller in a huge building and industrial use are located on the rooftop of the building.

How do you Specify Air Cooled Chillers?

• Check for maximum temperature: Air coolers have a maximum ambient temperature of 40 to 45 degrees Celsius.
• The minimum temperature: The temperature of air-cooled chillers ranges between -12 to 15 degrees Celsius.
• Check for voltage: The voltage range of air-cooled chillers is 400 volts.
• Capacity: The design capacity of air-cooled chillers is about 603 KW.
• Check for airflow: The maximum airflow of air-cooled chillers is about 24.8 to 35 L/S.
• Check the hydronic module: Air-cooled chillers have a built-in hydronic module.

What are the Applications of Air-Cooled Chillers?

Air-cooled chillers are purposely used for cooling purposes, they turn hot air into the cold air and vice versa.

Some of the applications of air-cooled chillers include

• They are used in large industries to cool production processes and machinery.
• They are used in huge residential buildings to cool hallways and common areas.
• Are used in large-scale industrial cool rooms to keep products such as meat and vegetables fresh.
• Used in hospitals for air circulation purposes.
• Some are installed in tracks and vans that transport fresh produce or highly perishable products.
• Air-cooled chillers are also popular in the retail environment where large stores use them for cooling purposes.

Air cooled chiller is widely used for commercial buildings

How do you Maintain Air Cooled Chillers?

I. Daily maintenance procedures for air-cooled chillers will entail:

• Turning off or sequencing unnecessary chillers
• A complete inspection of the air-cooled chiller to ensure that all the equipment is operating and there is safety.
• Checking off all the setpoints to ensure proper setting and function.

II. Monthly maintenance procedures for air-cooled chillers will entail:

• Assessing condenser and evaporator coil to ensure it is as required.
• Checking the temperature to ensure that it is as per the manufacturer’s specifications.
• Conduction a leak test to ensure that all compressor fittings, relief valves, and pump joints are not leaking.
• Checking the insulation condition to ascertain that it is appropriate
• Verifying proper control functioning including verification of hot gas bypass and liquid injection.

III. Semiannual maintenance procedures for air-cooled chillers will entail:

• One should thoroughly go through the manuals that come with the air-cooled chillers to ensure that they are as per the manufacturer’s specifications.

IV. Annual maintenance procedures for air-cooled chillers will entail:

• Checking all the alignments on the compressor and assembly to ascertain that they are as per the manufacturer’s specifications.
• Checking all the seals on the compressor and providing lubrication where needed.
• Conducting an analysis of the compressor oil system and changing the necessary oil pumps and seals and having a look at the oil heater, strainers, valve, and thermostat.
• Checking all the electrical connections and the terminals to ensure contact and tightness.
• Recording the amounts of refrigerant level and condition and addressing any leakage issues.

Air cooled chiller maintenance

How do you Increase the Efficiency of Air-Cooled Chillers?

The efficiency of air-cooled chillers can be increased in the following ways:

a) Temperature regulation: implementation of supply air temperature reset control helps to save on energy and ensure the efficiency of the air-cooled chiller system.

b) Consider variable speed retrofits: most companies with an air-chilled cooler benefit from variable speed drives save on the energy used in operation.

Close monitoring of the system is essential when saving energy using variable pumping speed.

c) Optimization: running multiple parallel devices optimizes the savings and efficiency of air-cooled chillers.

They run more efficiently at lower speeds rather than operating at full capacity.

d) It’s recommended to set your air-cooled chillers on automatic to allow them to control the temperature when needed and save on energy.

e) Air-filters: ensure you clean and change the air-cooler filters periodically and as instructed by the manufacture for optimal efficiency.

f) All repairs and maintenance procedures should be undertaken by trained HVAC

They should be certified and also ensure the manufacturer’s maintenance and repair protocols are followed to the latter.

What are the Quality Standards of Air-Cooled Chillers?

Quality standards of air-cooled chillers depending on the country of origin include:

• Australian/ New Zealand Standards: AS/NZS 4776.2-2 00
• California Public Utilities Standards: (CSA) CSA-C743-09
• Canada/ United Kingdom standards; GB 19577-200 4
• Canada standards Association: CNS 12575-200 7
• China standards: EMSD, HKSAR
• Hong Kong Standards: ASHRAE Standard 90.1-2013

Do Air Cooled Chillers Require On-site Assembly?

Air-cooled chillers come partly assembled to make it easy to assemble the various components on-site.

Some require you to assemble components such as fan, filter drier, expansion valve condenser, compressor, and heat exchanger on site.

Some components like filters also come uninstalled.

How much do Air Cooled Chillers Cost?

Air-cooled chillers vary in cost depending on kW/ton, model, and power supply voltage.

Some other factors that also determine the cost of air-cooled chillers include

• Maximum ambient temperature.
• Minimum ambient temperature.
• Maximum R.H.
• Type of cooling system.
• Unit structure for instance integral
• Cooling method.
• Selected voltage
• Noise level

Putting the above factors into consideration, an air-cooled chiller can cost anywhere from as low as $500 to as much as $500000.

What Optimization Procedures do Air Cooled Chillers Require?

The optimization procedures required by air-cooled chillers include:

• The air-cooled chiller should be inspected every quarter.
• You should routinely check for refrigerant leaks.
• Always confirming that the operating pressures of the compressor are within a reasonable range.
• Voltage: carry out an optimization test while including the amps.
• Electrical components: ensure all the wirings, starters, and all electrical components are optimized.
• Unloader operation: this includes the gas exchanges and the process involved.
• Heating and cooling should be optimized by ensuring the air-cooler self regulates and this should be used to reach maximum efficiency.
• Obtaining line readings from discharge lines.

Do Air Cooled Chillers have a Warranty?

Yes, air-cooled chillers have warranties that can run from the normal one year.

The warranties depend on the use of the chillers. Industrial/ large commercial chillers have a longer warranty than those procured for personal use.

How does Air Cooled Modular Chiller compare to Air-Cooled Chiller?

This is an air-cooled chiller that can work independently or can be assembled as a unit with other chillers.

Air-cooled modular chillers are usually small and contain refrigerant circuits.

An air-cooled chiller is a chiller with a single module working independently and more costly than an air-cooled modular chiller.

Air cooled modular chiller

Do you Help with Air Cooled Chiller Installation?

Yes, we help in air-cooled chiller installation.

In the case of large-scale industrial chillers, the manufacture will send a representative to guide on the installation protocols of the air-cooled chillers.

How do you Change Air Filters?

You can follow the following procedure to change air filters from chillers:

a) Before you start, you must read the manufacturer’s manual on how to change the air filters.

This is important because different air-cooled chillers require different shapes and sizes of filters.

b) Turn the air-cooled chiller off and carry out a safety check before beginning, the safety check procedure is provided by the manufacturer.

c) Determine the position/location of your air filters and the mode in which they are secured.

d) Find the filter dimensions and compare them with your filters.

e) Remove the access panels to get to the filter.

f) Remove the old air filter.

g) Insert the new air filters while paying attention to the arrows on the side of the filter to avoid putting them wrongly.

h) Close the access panels and turn the sir-cooled chiller on.

i) Some air filters require washing and it is essential to follow the manufacturer’s procedures to wash the filters.

What is the Best Material for Air-Cooled Chillers?

Air-cooled chillers have many different components made from different materials.

The dominant materials used are copper for the tubes for the refrigerant flow and aluminum fins for airflow.

Some of the other materials used are plastic tubes to reduce weight and cost.

Copper and aluminum are widely used because of their superior thermal properties.

Is there a difference between Industrial and Residential Air Chillers?

Most of the residential air-cooled chillers use heating and cooling split systems, their HVAC system is split between two main units, one for heating and once for cooling.

This type of HVAC is usually found in homes and is small, portable, and easy to install.

Industrial air chillers are usually large and come as one single system.

These are common for large industries and large buildings requiring a complicated HVAC system.

They are usually stored kept on top of buildings where airflow is uninterrupted.

What is the difference between AC and Air-Cooled Chiller?

Air Conditioners (AC) is a type of cooling system that is split and uses a split system in cooling.

It uses heating and cooling split systems where the AC is put inside the house while the condenser is put outside the house.

Their HVAC system is split between two main units, one for heating and once for cooling.

This type of HVAC is usually found in homes and is small, portable, and easy to install.

AC

Which Compressor is good for an Air-Cooled Chiller?

There are many designs of compressors available for air-cooled chillers.

They all serve the same purpose of making it possible to remove heat from indoor spaces or industrial processes.

Some of the most commonly used compressors for air-cooled chillers include:

• Reciprocating compressor: it is also known as a piston compressor and it can be either hermetically sealed or open.

The compressor and the motor driving it are coupled directly and they share a sealed housing or can be in separate housing.

• Centrifugal compressors: these are more efficient than reciprocating and rotary-screw compressors.

They are also available in a wide range of cooling capacities.

• Rotary-screw compressors: it uses two helical screws that are designed to mesh with one another seamlessly while rotating at high speed.

The capacity control of rotary-screw compressors is achieved with a special valve that varies the internal volume ratio.

Air-cooled chiller reciprocating compressor

What are the Advantages of Air-Cooled Chillers?

Advantages of air-cooled chillers include:

• They do not necessarily need cooling towers like water-cooled chillers.
• There are low maintenance costs required in the maintenance of air-cooled chillers.
• Air-cooled chillers are advantageous because they can be customized for their use such as industrial, residential, hospital, or storage.
• Provides better environmental stability as there is no water wastage.
• Air-cooled chillers are easier to operate and control as there are no tower freezing and tower bypass.
• With air-cooled chillers, the chemical costs are avoided.
• Water costs are avoided especially if used in cities.
• In the case of disasters in water, the air-cooled chillers are never affected.
• Air-cooled chillers are cheaper because they require fewer components unlike the water-cooled towers that require additional support components such as water towers to be operational
• Air-cooled filters are easy to install.

Are there Limitations of Air-Cooled Chillers?

Limitations of air-cooled chillers include:

• Air-cooled chillers are generally costly to maintain and expensive to repair in case of breakdowns.
• The lifespan of air-cooled chillers is relatively shorter compared to that of water-cooled chillers.
• Air-cooled chillers need constant replacements of components such as air filters and compressors.
• Air-cooled chillers have more operating noise because of their ducts and vents.
• Air-cooled chillers use more energy compared to water-cooled chillers.
• Air-cooled chillers need to be sored outside for them to work efficiently thus limiting the user on storage options.

Which Safety Features do Air Cooled Chillers have?

Some of the safety features found in air-cooled chillers include:

• Capacity controls: maintain the temperature of the chilled air.
• The refrigerant flows control: these protect the compressor.
• Mechanical controls: these consist of how the system can be set to shut down in case the system fails.
• High pressure cut out.
• Low pressure cut out.
• Low oil pressure cut out.

What Causes Chiller to Trip?

Some of the factors that can cause a chiller to trip include:

• When the pressure is high and can cause structural failure.
• The oil pressure is low and can cause damage to the bearings.
• When the chiller experiences an overcharge.
• When there is high ambient temperature, air, or other incompressible gases.
• When there is an obstruction in the discharge line of the compressor.
• When the air-cooled chiller experiences freezing.
• To protect the air-cooled chiller from the ingress of air into the system.
• To avoid leaked oil going to the evaporator.
• When there is short-circuiting.

At What Temperature do Air Cooled Chiller Operate?

Air-cooled chiller mostly operates at room temperature depending on where there are used.

Some industrial air-cooled chillers operate at a minimum ambient temperature of -12 degrees with a maximum ambient temperature of 57 degrees.

How do you Know Air Cooled Chiller Power Consumption?

The electrical power demand of the air-cooled chiller to produce this is 460kW.

The metric calculation would be: 2,500kW / 460kW = 5.4 so the COP is 5.4.

This means that for every 1kW of electricity you put into the machine, you will produce 5.4kW of cooling.

Absorption chillers are often rated in fuel consumption per ton cooling.

With the information in this guide, you can definitely choose high-performance air-cooled chillers for your applications.

For any questions or inquiries, contact TopChiller technical team now.