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Air Cooled Water Chiller: The Ultimate FAQ Guide

If you have any questions about the air-cooled water chiller, then your answer is right here.

Whether you want to learn about the working principle, components, classification criteria, or safety features – your answer is right here.

Keep reading to learn more.

What is an Air Cooled Water Chiller?

An air-cooled water chiller is a refrigeration system that cools down or lowers the industrial process water or glycol mixture’s temperature.

This versatile machine effectively absorbs the heat from the industrial water and eliminates it into the surrounding environment.

After that, you can, in turn, use the eliminated heat for other auxiliary purposes such as warming the industrial machines during winter seasons.

Take note; it is the refrigerant present in the chiller that is responsible for cooling the process water or extracts the heat from the industrial process water.

That entire process takes place in the condenser part of the chiller.

Apart from that, the chillers come in an array of modifications, most of them being compact, highly efficient, quick to install and disassemble.

Thus, they are ultimately suitable for supplemental, emergency, and temporary usage.

 Air-cooled water chiller

Which are the Available Types of Air Cooled Water Chillers?

We can widely classify the air-cooled water chillers into three distinct groups of chillers:

• Portable air-cooled water chillers.
• Stationary air-cooled water chillers.
• Central air cooled water chillers

● Portable Air Cooled Water Chillers

In this case, portability refers to the basic configuration of the machine, while having little to do with the mobility aspect.

That’s so because even after installing the device, it would not move unless you disconnect it.

However, it is easier to remove and re-install the machine elsewhere in the cooling chamber.

Most importantly, a portable chiller is a configuration of the machine system that incorporates all the essential components, i.e., refrigeration circuit, pump(s), reservoir,  into a single entity/ footprint.

Above all, the portable configuration is solely suitable for cooling a single unit of process water.

If you have a few machines, you will have to buy for each a separate chiller.

In that case, the chiller uses a single control system from one point.

Still, they come in capacities ranging from 2 tons to a hundred tons.

Portable air cooled water chiller

· Stationary Air Cooled Water Chillers

The stationary type of chillers have separately interconnected pumps and reservoir/tanks in different footprints from the primary chiller.

The parts include a standalone chiller connected to the pump or the reservoir by using a piping system.

Consequently, the chiller system has distinct connections and controls for each of the separate components.

Better still, the chillers and the pumps have a solitary interconnected control system that integrates the entire operation of the chiller.

Lastly, the stationary chiller comes in a variety of capacities ranging from 2 tons onward.

· Central Air Cooled Water Chillers

The central air cooled water chiller is a particular chiller category that effectively cools numerous industrial water processes within the same plant.

In most cases, one central chiller should be capable of serving an entire floor or building.

Therefore, a central chiller is crucial whenever you need to cool process water in several machines at a uniform temperature.

Better still, it’s suitable whenever you care less about the accuracy and specificity of cooling.

Besides the reservoir, the chiller requires sets of pumps to distribute and deliver the water to the processes to guarantee its functionality.

They are as well available in both stationary and portable configurations.

Similar to the portable configuration, the central chiller also has a single-point control center.

Additionally, the machines are available in varying capacities, from a minimum of 2 tons to hundreds of tons.

Central air cooled water chiller

What are the Benefits of Air Cooled Water Chillers?

Low initial costs; the chiller system comprises an easy-to-all install package of a compressor, reservoir, and pump, which equally does not cost much.

Therefore, the machine requires little capital investment for a startup compared to the high costly water-cooled type.

Little maintenance costs; after installing and when operational, the chiller does not attract any more additional charges because they have no parts that need water treatment.

Energy-efficient; the units may incorporate electronically commutated (EC) fans that consume minimal energy.

Still, you can accumulate the expelled heat for use in heating the machine during cold seasons.

Space conscious; the preferential set-up point for the chillers is outdoors, and thus they consume little interior space.

The outdoor type is, therefore, suitable for places with space constraints.

However, you can as well install them indoors.

Easy set-up; lastly, these chillers are quick to install and easy to operate.

What are the Limitations of Air Cooled Water Chillers?

Short lifespan; the air-cooled water chillers generally have shorter durability; even worse, their lifespan can be shortened by external factors, especially when installed outdoors.

High noise level; the chiller fans sometimes generate a certain noise level that may improperly conform to some environment.

Nevertheless, every chiller is unique since they use different types of fans, which produces varying levels of noise.

What are the Parts of Air Cooled Water Chillers?

The machine structure incorporates four essential components:

• Compressor
• Condenser
• Evaporator
• Expansion valve

Other auxiliary parts also include a control system, power panel, and water tank/ reservoir.

Air cooled water chiller thermal expansion valve

How Do Air-cooled Water Chillers Operate?

The chillers utilize a closed-loop refrigeration circuit to cool the process water.

The operation begins from the compressor compressing the refrigerant into the closed-loop, i.e., from the condenser to the expansion valve, through the evaporator, then ultimately back to the compressor.

Meanwhile, amid the flow, the expansion valve regulates the refrigerant’s quantity flowing through the loop.

After that, the evaporator expels the heat from the process water, thereby lowering its molecular temperature while increasing the refrigerant.

With the extra accumulated heat from the system, the condenser comes in handy to expel it.

At a higher temperature resulting from the heat generated by the evaporator fluid and the compressor, the refrigerant enters the condenser.

Subsequently, in the condenser, the refrigerant flows amidst a series of interconnected tubes attached to a collection of densely spaced fins.

Just nearby, a set of fans blow ambient air via the fans and over the exterior segments of the tubes, intermittently cooling the now freely flowing refrigerant inside.

The machine then expels the excess heat generated into the surrounding air.

Alternatively, you can accumulate it for use somewhere else within the facility.

Which Features Should you Consider When Buying Air Cooled Water Chiller?

The following are what you should consider:

Initially, the heat burden you have to evaluate and determine the quantity of heat that your chiller shall eliminate.

The heat burden is thus the amount of heat that the machine expells.

With the right information, you shall be on track to selecting a suitable machine.

The installation surrounding; Determine whether you have proper spacing.

You have to decide between installing it either indoors or outdoors, and lastly, evaluate the exact ambient temperature for where you shall install it.

Better still, find out whether you shall need extra accessories for your chiller.

Coolant parameters; next, you have to verify the machine’s coolant flow and pressure, then weigh them against your application.

Note that if these two specifications are much lower or higher than your expectations, then obviously, you shall underutilize them.

For clarity, you can always find the coolant parameters information embedded on the device.

Coolant temperature range; another fundamental aspect of your decision is the working temperature; you have to evaluate it if it coincides with your temperature expectations.

Again, failure to which you may bump onto a machine that least meets your expectations.

Noise; air-cooled water chillers produce different degrees of noise, some much while others low.

The extent of noise depends on the compressor specifications, so make sure to recheck them.

Type of compressor; generally, you shall find three compressors, i.e., centrifugal, reciprocating, and screw-type compressors.

The reciprocating type delivers little refrigerant but at too high pressure.

Elsewhere, the centrifugal one is a popular type due to its efficiency and delivery of the refrigerant at a high flow rate compared to a reciprocating compressor of equal size.

Lastly, the screw compressor is entirely mechanical in its operations. It comprises two significant screws joined.

Ultimately, depending on your application and needs, you have to choose the best compressor type keenly.

What is the Difference Between Air Cooled Water Chiller and a Water-Cooled Water Chiller?

When evaluating between air cooled water chiller and water-cooled water chiller, you should consider the following:

The difference in the Mode of Operation

The significant difference between the two lies in the manner by which they eliminate the expelled heat.

And that distinction is in the condenser operation.

As earlier indicated, air-cooled water chillers’ condensers rely upon the ambient air to cool the warm refrigerant.

The water-cooled water chillers solely use water to cool down the hot refrigerant in the condenser.

The water-cooled chillers’ condensers are usually in the framework of a tube-tube, plate type, or tube in shell heat exchangers.

They depend upon water from an external source, either a tank or another source, to cool the refrigerant.

In this case, the only difference is that the water and the refrigerant never come in touch; they, however, counter flow in various passageways inside the heat exchanger.

Note: The tubes are always in proximity to make them more efficient for heat transfer.

The cooling process entails; flowing water over the refrigerant passageways as it absorbs the heat, thereby decreasing the refrigerant’s temperature to a sustainable level.

Environmental Installation Differences

Indoor and outdoor installation; even though both the chillers are installable outdoor and indoors, the water-cooled water chillers are predominantly stationed in the rooms.

This is because they never need much space for ventilation.

Contrastingly, the air-cooled type chiller requires lots of fresh air for ventilation and is thus suitable for outdoor installation or a properly ventilated indoor.

Water-cooled chillers are sustainable for use in the hot surrounding environment because it does not rely on ventilation.

And that makes it suitable for help even in crowded rooms.

You should pick a water-cooled chiller for reliance on water usage if you have proximity to a steady supply of water.

However, if you need to conserve water by eliminating water treatment and expulsion, then an air-cooled chiller is a perfect choice.

Water cooled water chiller

The General Costs and Expenditure

Solely relying on the initial purchase price for the two chiller types as a basis for determining the costs and expenditure is quite a bias.

Instead, an analysis of the machine’s lifelong costs is an ideal model.

If you go for indoor installation of air-cooled water chillers, you will undoubtedly incur the costs of ductworks, controls for ventilation, and fans.

Besides, due to their functional design, they may consume high energy costs.

On the flip side, water-cooled chillers have decreased initial upfront costs.

Nevertheless, they will still incur lots of operational costs since they require installing a cooling tower.

The use of a cooling tower generates additional costs for water treatment, pump operation, and fans.

Ultimately, the costs of electricity, water, and efficiency can instantly change the chiller’s lifetime costs.

How does Air-Cooled Chiller Compare to Water-Cooled Chiller?

Both the air-cooled chiller and water-cooled chiller are industrial chillers.

Besides, they cool down the industrial process fluids, mostly water.

However, they are distinct in terms of operation, convenience, costs, and performance, as prior indicated.

Water cooled chiller

What is the Air Cooled Water Chiller Load?

The air-cooled water chiller load refers to the optimum rate at which the machine reduces the water temperature or eliminates the heat present in the process water to a preferred temperature range.

The air-cooled water chiller load unit is the Ton of Refrigeration (TR).

A few critical factors may affect the chiller load.

They include:

• Chiller’s internal equipment
• Surrounding weather conditions
• The capacity of the process water
• The volume of the cooling compartment
• Base temperature of the process water

How much does Air-Cooled Water Chiller Cost?

Generally, the prices of air-cooled water chillers are reasonable, cost-based, and affordable.

However, the prices hinge on quite a few essential parameters, including

• Your specifications
• customized requirements if any
• Price terms such as EXW, FOB, CIF, C&F, Door to Door
• Shipping methods such as sea shipment, air shipping, amongst others.

What Should you Consider when Installing Air Cooled Water Chillers?

Indoor area installation; if you need to install the chiller indoors, you have to ensure the room’s proper ventilation.

The site must have a constant supply of fresh air to enhance a suitable surrounding temperature within the space.

Outdoor area installation; air-cooled water chillers blend well with the outdoor arena since there is plenty of fresh air within the space.

In this case, the expelled heat dissipates into the ambient air.

However, you will have to ensure the proper set-up of electrical connections for outdoor installation depending on the environmental conditions.

The temperature of the surrounding; the chiller requires a proper supply of fresh air, thus you always have to ensure adequate provision for ventilation.

Clearance; the recommended distance around the chiller should be at least three feet to accord you space for routine services and provide space for ventilating the condenser.

For overhead clearance, you can always offer an unlimited range of areas.

Proximity to the process; the chiller should always be closer to the process.

Though certain variables may affect the distance, such as the type of piping and diameter, the highest flow rate, and the kind of fluid.

Better still, you may increase the space depending on your application by modifying the chiller system and distribution.

What are the Specifications of Air Cooled Water Chillers?

The cooling capacity: The chiller can extract heat from the process water, which is the cooling capacity.

The cooling capacity unit is Kilowatts, Tons of Refrigeration (TR).

The fluid discharge; is the required temperature for the release of the liquid discharge.

It indicates the quantity of the absorbed heat by the entire chiller operation process.

Process flow; refers to the flow capacity of the pump.

Process pressure; the accumulated stress of the pump.

Compressor motor horsepower; the units for measuring the horsepower are Kilowatts, horsepower, or megawatts.

Reservoir capacity; the reservoir’s capacity that holds the liquid has the units in a gallon.

The power source; includes the specifications for the voltage, phase, and frequency.

Industrial applications, generally air-cooled water chillers, are applicable in pharmaceutical, laboratory, food, electronics, and power generation.

Installation; you can install the air-cooled water chillers in both indoor and outdoor arenas to maintain the minimum requirements.

For detailed information about the air-cooled water chillers’ specifications, you should always consult your technical manual or product manual as a rule of thumb.

Can you Mount Air Cooled Water Chillers on the Roof?

You can always install air-cooled chillers on well-engineered weight-bearing roofs.

Most importantly, you have to work with a verified company for this venture.

That is, by providing them with details, including chiller dimensions, both empty and full weights, electrical, and lastly, fluid connection points.

Roof mounted air cooled water chiller

How Far Should You Install Air Cooled Water Chiller From the Process?

The chiller should be closer to the process; usually, a distance of approximately fifty feet will do.

How Long Should an Air-Cooled Chiller Operate?

Air-cooled chillers can operate continuously without any hitch; however, you can stop the operation by turning the system off at the end of every shift.

Even so, you should always keep the disconnects on to maintain the re-energization of the compressor heaters.

Above all, switch off the chiller when not in use to cut down energy use and consumption.

Are Air Cooled Water Chillers Automated?

Yes, air-cooled water chillers are automatic.

The machine provides automatic start, stop operation, and protection sequences.

Besides, the device may make use of a microprocessor control prompt.

How do You Test the Quality of an Air-Cooled Chiller?

After the completion of manufacturing, the chiller passes through a mandatory quality certification protocol.

You have to test each chiller for proper operations of the entire functions, controls, and safety accessories.

Only After guaranteeing that all the machine parts are leak-free, operationally, and mechanically stable, that’s when you can send it for delivery and shipping.

Which Controls do Air Cooled Water Chillers Use?

The standard controls include:

Firstly – The General controls; provide an automatic start, stop, operational and protection functions.

Secondly – Microprocessor control, which does more in-depth functions such as monitoring safety points.

This is inclusive of withstanding temperatures and electrical issues which may cause mechanical failure when not functional.

It also monitors all the data points, which might cause operational faults if no prompt corrective measure is in place.

A specific example is too low chilled water or low refrigerant temperature, which may freeze in the evaporator tubes’ interior and exterior sections.

Finally, it monitors the general chiller points to ensure proper performance and viable refrigerant containment.

What are the Applications of the Air Cooled Water Chillers?

You can use air-cooled water chillers across numerous industrial and manufacturing plants, including medical, laboratory, pharmaceutical, food, injection molding, and brewery.

Air cooled water chiller widely used in the injection molding industry

What Determines the Operational Costs of Air-cooled Water Chillers?

The precise location of the chiller has a direct impact on its operational costs.

So ultimately, the choice of installing the machine either indoor or outdoor should reflect on its incurring operational expenses.

Specifically, for indoor installation, you shall incur the expenses of installing fans to regulate and maintain proper air temperature within the room.

Consequently, the fans are high energy consumers and thus may increase your costs on energy.

However, the operational costs will be meager for outdoor installation since there would be a steady supply of fresh air, thus offering little to no fans.

How do You Increase the Efficiency of an Air Cooled Water Chiller?

Below are a few measures you can undertake to increase the chiller efficiency:

Routine maintenance; always conduct scheduled maintenance of your chiller by considering inspecting and cleaning the condenser coils.

Besides, maintaining a refrigerant charge is crucial.

Applying predictive maintenance; by using Artificial Intelligence through the deployment of the Internet of Things, you will save many potential mechanical failures that can be catastrophic to your machine.

With the IoT and AI, you can access an in-depth analysis of your system operation more than the visual inspection.

Optimization; when you do a holistic optimization of your entire chiller system, you will get to access and evaluate your chiller performance against your expectation.

Thanks to the IoT and AI, you will have access to the necessary data to improve the system.

What Determines the Service Lifespan of the Air Cooled Water Chiller?

The service lifespan of the chiller significantly depends on the nature of the surrounding environment.

For an outdoor installation, the chiller would be subject to numerous environmental factors that may shorten its lifespan.

So, therefore, always assess the environment and try to eliminate or prevent potential hazards to the chiller.

Does an Air-Cooled Chiller Require a Cooling Tower?

The air chiller does not necessarily require the services of the cooling tower; instead, they make use of the fans to dissipate the heat into the ambient air.

Cooling tower

What is a Chiller Set Point?

The chiller set point is the ideal temperature at which the machine operates.

Most manufacturers recommend a set point of approximately 48◦ F and above.

How do You Determine Air Cooled Water Chiller Cooling Capacity?

You can determine the chiller’s cooling capacity by arithmetically calculating it out or instead engaging your manufacturer for assistance.

To ease your struggle, you should consider applying the following formula.

Cooling Capacity = Rate of Flow x Fluid density x Fluid specific heat x Constant x ΔT°

What is Vapor Compression Chiller Technology?

Vapor compression chiller technology is a technique whereby a special liquid known as a refrigerant undergoes phase changes to cool down the target liquid/ medium.

Specifically, the technology utilizes a refrigerant that absorbs and expels heat from a medium that needs cooling.

Subsequently, the refrigerant ejects the heat elsewhere.

Initially, the refrigerant is at a saturated vapor phase but ultimately condenses to a watery liquid after undergoing the compressor system’s sets, hence the name vapor compression.

What are the Common Chiller Problems and Solutions?

1. No Cooling/ Refrigeration

I. Cause: Leakage of the refrigerant

Solution: lookout for any potential leaks and rectify the

II. Cause: A broken compressor.

Solution: verify the working current of the compressor; if it is abnormal, then consider replacing the compressor.

III. Cause: Broken motherboard.

Solution: exchange the board with an operational one.

IV. Cause: Overload

Solution: replace the chiller with a larger one that can provide the necessary temperature.

2. Low Voltage Error

I. Cause: leaking of the refrigerant

Solution; confirm if any leaks and rectify them.

II. Cause: broken pressure regulator

Solution: try resetting the pressure controller if not possible, then replace it.

III. Reason: broken computer board

Solution; replace the computer board.

IV. Cause: blocked filter

Solution: replace the filter

3. High Voltage Alarm

Solution: cut off the electricity supply and turn off the machine.

Test the pressure controller and the computer board to see whether there is an issue.

If the problem persists, then try replacing the computer board or the pressure controller.

Chiller refrigerant leak inspection

Which Safety Features Should Air-Cooled Water Chillers Have?

The chiller’s safety features not only enhance the performance of the machine but also promote user safety.

Some of the standard safety features and devices of air-cooled chillers include

• Fuses in power circuits
• Thermal overloads on the compressor, fan’s, and pump’s motors.
• Anti-freeze thermostats
• Low and high-pressure switches on refrigeration compressor
• Flow switches/ valves in chilled water lines
• Low refrigerant alarms
• Fire alarms
• Compressor oil level, sight glasses, and alarms
• Safety valves

Clearly, there are many factors you should consider when buying an air-cooled water chiller.

At TopChiller, we give you the best air-cooled water chillers for the specific needs of your applications.

For any questions or inquiries, contact us now.