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Laser Chiller-The Ultimate FAQ Guide By TopChiller

What is a Laser Chiller?

In the laser business, a Laser Chiller is a type of process chiller that is specifically developed and constructed for chilling laser devices or laser processing.

To maintain an ideal wavelength in laser processes, laser equipment requires precise and consistent cooling.

In laser procedures, electrical energy is converted into light of identical wavelength and phase with the help of gases (mix of carbon monoxide, nitrogen, and helium).

This approach generates a lot of heat, which is harmful to the manufacturing procedures when laser beams are employed.

If the temperature conditions are not correctly managed, heat-sensitive industrial processes will produce changed or poor-quality goods.

The use of a Laser Chiller to cool the laser processes is an excellent option for limiting the heat created by laser usage.

The precision, accuracy, and working of the Laser Chiller are completely reliant on the performance of high-power exciter, CO2, or ions.

Laser chiller manufactured by TopChiller

What are the General Features of a Laser Chiller?

• Temperature flow & level remote signals
• Anti-corrosion wetted surfaces
• Low & high-temperature alarms
• Heat exchanger made of stainless steel
• Refrigerant receiver
• Seal fittings

Laser chiller heat exchanger

What are the Features of a Single Zone Laser Chiller?

Some outstanding features of a single zone Laser Chiller are:

• Temperature control precision for a single cooling loop is present.
• Cooling capacities range up to 140 kW.
• The temperature range of operation is 20°f to 80°f.
• Composed of the construction of a nonferrous water circuit.
• Has r407c and r410a “ozone-friendly” refrigerant designs which are energy efficient
• Dependable scroll compressor designs.
• Made customizable to match your application needs.

What are the Features of a Dual Zone Laser Chiller?

The dual-zone Laser Chiller comes with the following features:

• Low watt density heater for the optical circuit.
• Fail-safe flow switch.
• Check valves to avoid backflow during the shutdown.
• Loop air purge for optics is present (it can be both automatic or manual).
• Laser connections with remote alarm signals.
• The conductivity sensor gets activated when the conductivity hits 60 micro siemens.

How does a Laser Chiller work?

A Laser Chiller contains a refrigerant unit that works for the channeling of the coolant.

The coolant is then moved to the process laser tube which is the site for heat exchange.

After the heat exchange process is finished the laser is cooled to its optimal temperature.

The cooling fluid absorbs heat in cooling the laser and returns back to the refrigeration unit where the absorbed heat is eliminated.

Laser chiller working

What are the Different Types of a Laser Chiller?

• YAG
• Disc
• Fiber
• Dye
• Semiconductor
• Excimer
• Gas
• Solid-state

What is the Importance of Heat Regulation in Laser Cutting Process of Laser Chiller Application?

You cannot overstate the importance of maintaining temperature stability inside a laser system.

These are the key advantages of efficient heat dispersion generated by a laser cutter:

• On silicon or metal sheets, you can create cleaner cuts.
• Heat-sensitive laser parts are protected.

Laser cutting process

What is the Cooling Capacity Range of Standard Laser Chiller?

In a Laser Chiller, the term cooling capacity is used to refer to the amount of heat that it can eliminate.

You can calculate the cooling capacity of a Laser Chiller by subtracting its input power from its output power.

The cooling capacity of a conventional Laser Chiller ranges from 1.5KW to 198KW.

What are some Important Temperature Levels Related to a Laser Chiller?

Every Laser Chiller has its own set of performance curves.

The nominal chiller capacity is normally specified at a temperature of 20°C for the coolant output and 20°C for the ambient air temperature.

For example, a Laser Chiller working at 425

W having a coolant temperature of 10°C of the output might run at 600 W with a coolant output temperature of 20°C.

The cooling capacity of a Laser Chiller is decreased when the ambient temperature recorded states 20°C or even higher.

What are the Coolants Used in a Laser Chiller?

The kind of coolant required by the laser process is a significant aspect. Distilled or tap water is the most widely used Laser Chiller coolant.

Other coolants include algaecide, ethylene glycol, and deionized water.

Algaecide is used to prevent algae growth, and ethylene glycol is used to prevent corrosion and lower the fluid’s freezing point.

Sometimes a Laser Chiller needs deionized (DI) water, which itself is corrosive to a wide range of materials.

In this case, the Laser Chiller must only come into contact with DI-compatible materials and for maintaining the correct resistivity level, must have a deionization cartridge fitting.

Ethylene glycol for laser chiller

What is the Function of a Compressor in a Laser Chiller?

The main component of your Laser Chiller is the compressor, which provides a pressure differential in the system to transport the refrigerant around.

Refrigerant compressors are of different types, the most popular of which are centrifugal, screw, scroll, and reciprocating compressors.

Each kind has its own set of advantages and disadvantages. A compressor is always in the mid of the system, between the evaporator and the condenser.

It’s normally somewhat insulated, and the driving power is normally an electrical motor, which can be positioned either internally or outside.

Hearing protection should be used in the surrounding of a Laser Chiller since compressors may be quite noisy, emitting a persistent deep droning sound with an overlaying high pitch.

How does the Cooling Tower Function in a Laser Chiller?

The cooling tower, which is normally positioned on the roof, is the last destination for the building’s unwanted heat.

The cooling tower is equipped with a big fan that circulates air throughout the device.

The water from the condenser is pushed to the tower and sprayed into the air stream.

In an open cooling tower, the cold ambient air will enter and come into direct contact with the condenser water spray, allowing the heat of the condenser water to transfer into the air, which will then be blasted out into the environment.

The condenser water gathers and returns to the condenser, ready to absorb further heat.

Cooling tower function in a laser chiller

What is the Function of Expansion Valve in a Laser Chiller?

Between the evaporator and the condenser lies the expansion valve.

Its goal is to expand the refrigerant, lowering its pressure and increasing its volume, allowing it to absorb heat from the evaporator.

The thermal expansion valve, the pilot-driven thermal expansion valve, the electronic expansion valve, and the fixed orifice expansion valve are the most frequent types of expansion valves.

What is the Working Principle of the Evaporator in a Laser Chiller?

The evaporator, which is placed with the expansion valve and the compressor, gathers undesirable heat from the building and transfers it to the refrigerant, which is then delivered to the cooling tower and discarded.

The water starts to cool as the refrigerant extracts the heat; this “chilled water” is then circulated throughout the building to provide air conditioning; and then returns to the evaporator, carrying any undesired heat with it.

How does the Condenser Works in Laser Chiller?

After the compressor, but before the expansion valve, comes the condenser.

The condenser plays the job of taking out the refrigerant heat that was collected in the evaporator.

Air-cooled and Water-cooled condensers are the two basic types of condensers.

The hot refrigerant that enters the condenser from the compressor will transfer its heat into this water, which is delivered up to the cooling tower and rejected from the building.

Water-cooled condensers will cycle “Condenser water” between the condenser and the cooling tower regularly.

The refrigerant and the water will not combine because they are separated by a pipe wall, which allows the water to flow inside and the refrigerant to flow outside.

Condensers on an air-cooled chiller function a little differently; instead of using a cooling tower, they blast air over the exposed condenser pipes, with the refrigerant running on the inside.

How is a Laser Chiller Beneficial for your Applications?

• Maintain a Constant Temperature: Water circulation helps cool the laser generator and provides optimum working temperature for efficient performance.

In case of longer use, the laser generator will keep on providing high temperatures, which impact its normal function, initiating water cycle cooling and temperature regulation by the Laser Chiller.

• Reduces Several Processes: It reduces downtime, reduces the amount of noise and heat, reduces the number of interruptions, and discrepancies are also minimized.

• Combine Operations: Several operations of the Laser Chiller are also combined for saving time and providing maximum efficiency.

• Preventing Cartridge Failure: It prevents cartridge failure for proper working.

Laser chiller is widely used for laser industry

What are the Optional Controls of a Laser Chiller?

The Laser Chiller, for example, can be connected to a computer with the help of its great communications features.

Remote turn on and off of the Laser Chiller is possible via RS-232 interfaces.

Alarms and shutoffs for high and low temperatures assist in avoiding harm from coolant which is too warm or too cold.

The problem is indicated by a visible display, an audio warning, or a computer (if an RS-232 interface is employed).

It is protected from damage by the frozen coolant by low-flow warnings and shutoffs.

Coolant filters keep hazardous particles out of the Laser Chiller.

Dust and filth are prevented from building on the condenser by using air filters (which reduce the cooling capacity).

The hot-gas filter protects the compressor from excessive wear.

The flow of heated refrigerant is directed to escape the condenser and run straight to the evaporator.

What are the Applications of Laser Chiller?

• Laser engraving equipment
• Laser marking equipment
• Laser welding equipment
• Laser cutting equipment
• Laser processing equipment

Applications of laser chiller

What are the Primary Considerations of Buying a Laser Chiller?

The primary considerations for buying a Laser Chiller include:

• Laser Chiller size vs. Power
• Purchase and installation cost
• Special cooling features
• Additional customization options

What are the Secondary Considerations of Buying a Laser Chiller?

The selection of a Laser Chiller is influenced by several secondary factors, such as the convenience of use.

The noise level of the Laser Chiller might be an issue.

A quiet Laser Chiller will be appreciated by those who live near it. If it has to be moved frequently, choose one with casters to make it easy to move.

When the Laser Chiller is in use, locking casters will keep it steady.

Guarantee and technical assistance should be available for a better user experience.

Why Consider Power Rating VS Sizing of your Laser Chiller?

According to standard practice, the greater the power rating of a Laser Chiller, the greater is its capacity.

To effectively cool the laser process with high chilling demand, a larger Laser Chiller is more preferable.

How is the Cost of Installation and Purchasing of your Laser Chiller is an Important Consideration for your Applications?

This is not a major deciding factor for a high-powered Laser Chiller because it only accounts for a small amount of the total cost of the entire laser process.

This purchase and installation factor is an important consideration in the case of low-powered Laser Chiller applications where air cooling may be a more cost-effective alternative.

Why is Cooling Capacity Important to Consider When Buying a Laser Chiller?

Choosing a Laser Chiller for laser applications, there are several considerations to take. The most crucial factor is cooling capacity.

Cooling-water requirements are often provided by the manufacturers. A good Laser Chiller offers maximum cooling capacity under low-power settings.

Because the Laser Chiller will be used only a fraction of the time (low duty cycle), its average output power will be substantially lower than its maximum design output.

Control issues might arise if the duty cycle goes below 50% of the cooling capacity.

To alleviate control issues, it must have capacity control over the whole chilling range.

Why do you need to Consider the Thermal Efficiency and Volume of a Laser Chiller?

The water volume and thermal efficiency of the Laser Chiller, refer to the compressor’s operating control mode and water tank size respectively.

A bigger tank is more preferable, although the various compressor control systems used in its design will be complicated and diverse.

The compressor cooling capacity and water volume mean the same.

The PID feedback mechanism in the operation control mode will considerably increase the cooling capacity of your Laser Chiller.

What is the Temperature Control Accuracy of a Laser Chiller?

This scale is entirely based on the laser application needs.

The temperature control precision for a Laser Chiller must be 0.1°C to help the compressor predict the temperature change and adapt to load change.

Moreover, the temperature requirement for CO2 lasers is 2°C to 5°C, which most dedicated models on the market can meet.

Why Choose a Laser Chiller with Unique Cooling Requirements?

The heat load of a Laser Chiller is the capacity of how much heat it generates while it’s operating properly.

Industrial operators must choose a Laser Chiller unit that can effectively drain the heat created by their specialized laser processes.

What are the Pump Requirements of a Laser Chiller?

The correct Laser Chiller pump is determined by the needed coolant flow rate and pressure for providing enough cooling to the laser process.

Flow rates per minute and the delivery pressure per square inch are commonly specified by the suppliers.

Most manufacturers provide a choice of pump varieties. Regardless of the system pressure drop, the same flow rate is produced by a positive displacement pump.

A centrifugal pump is pressure-dependent, thus at lower pressures, it will provide a higher flow rate.

A turbine pump can be compared to a centrifugal pump and is more productive for applications having a high-pressure drop.

If the supplied pumps’ pressure or flow rate isn’t low enough, the Laser Chiller provider should provide a flow bypass loop as an alternative.

The bypass loop, which is connected to the Laser Chiller in parallel, permits unnecessary flow to escape the Laser Chiller.

Laser chiller water pump

What are the Water Quality, Filtration, and Circulation Requirements of a Laser Chiller?

The water quality, filtration, and circulation requirements are sometimes overlooked, but are extremely useful and have a direct impact on the Laser Chiller life.

The lens installed at both ends of the CO2 glass tube Laser Chiller has a connection with the water flow dead angle, and impurities in the water are easily retained, which ends up in inefficient heat dissipation.

The lens’s micro-deformation has a direct impact on the spot pattern and output beam quality.

The formation of copper rust and scale on the heat sink of the Laser Chiller causes the cavity temperature to rise too high, causing the temperature sensor to warn and stop the Laser Chiller from emitting light.

The spot pattern and optical power of a Laser Chiller are directly affected by the pump lamp surface cleanliness and crystal, and gold-plated cavity.

The majority of refrigerant tubes are of copper. The evaporation trays are directly inserted into the cooling water, resulting in a high amount of copper rust that damages the Laser Chiller directly.

The tap water’s direct insertion into the Laser Chiller or long-term use of unchanged pure water is two examples of inappropriate Laser Chiller operations.

They will cause germs and contaminants to develop on the Laser Chiller shortening its life and limiting its usage.

What are Some Safety Options Related to your Laser Chiller?

When using your Laser Chiller you should consider these important safety options:

• Capacity controls
• Refrigerant flow controls
• Protection valve
• Low and high voltage protection
• Antifreeze switch
• Temperature control switch
• Electronic time protection

Laser chiller safety switches

What are the Installation Instructions for your Laser Chiller?

The Laser Chiller is easy to set up. The following is how its initial step can be carried out:

Step: 1 Check that your Laser Chiller is in excellent working order and that all of the accessories are included.

Step: 2 Remove the water injection port and fill it with cooling water. During the addition of water, keep an eye on the gauge’s water level and carefully pour in the water.

Make sure the water doesn’t overflow! An adequate amount of anti-corrosion chemicals should be applied to the cooling of carbon steel equipment. In colder parts of the country, noncorrosive antifreeze should be used.

Step: 3 Depending on the Laser Chiller, connect the output and intake pipe.

Step: 4 Turn on the power switch and plug in the power wire. Check the water level in your water tank.

The air is drained from the water pipe, and once you turn on the Laser Chiller the water level also drops.

Water can be added again to maintain the water level within the green region.

Step: 5 Take note of the present water level. Then wait for some time until the Laser Chiller has been running for a while before checking the water level indicator again.

Check for a leak in the water pipe if the water level decreases drastically.

Step: 6 Modify the Laser Chiller temperature controller’s settings and your Laser Chiller is ready to use.

Which Necessary Steps you Should Take after Turning on the Power Switch of your Laser Chiller?

• The Laser Chiller circulatory pump starts functioning as soon as the power switch is switched on.
• Following the initial start-up of your Laser Chiller, you must immediately inspect the water pipe for leakage.
• According to the established control settings, the thermostat manages the operational state of the fan, compressor, solenoid valve, and other components automatically.
• Because the compressor and other devices have a long start-up time, which can range from seconds to minutes depending on the operating circumstances, maintain the Laser Chiller regularly.

Laser chiller explosion proof power switch

How to Optimize your Laser Chiller?

• Avoid using antifreeze that is automotive grade.
• Use compatible and suitable coolants only.
• Install variable frequency drives.
• Provide an efficient temperature supply.
• Carry out regular maintenance and on-time repairing.

What are the Maintenance Tips for Using a Laser Chiller?

The normal frequency of the laser welding system is relatively high, and the Laser Chiller as a significant element of the laser welding system is directly connected to the proper functioning state of the laser welding system.

As a result, in normal times, you should pay greater attention to the Laser Chiller maintenance.

Manage your Laser Chiller and learn how to repair it if it breaks down.

• Check its Compressor on a Routine Basis: The compressor is the major part of your Laser Chiller. Its quality has a direct impact on the reliability of the Laser Chiller.
• Clean the Condenser and Evaporator regularly: The condenser and evaporator are the foremost components of your Laser Chiller.

It is recommended that you clean them every six months.

• Regular Cooling Water Changing: The cooling water’s quality is critical to the Laser Chiller output efficiency.

The internal flowing water’s conductivity should undergo inspection once a week to ensure its maintenance at 30.5 MWcm, and it should be replenished once per month.

The recently injected clean water must have a conductivity of 32 MWcm to circulate deionized water.

• Frequently Clean and Rinse the Laser Chiller Dirt Grid: Constantly keep an eye on the changing color in the ion exchange column.

The dustproof grid gathers some dirt when the Laser Chiller has been operated for a while.

The replacement of the circulating cooling water is an important part of your Laser Chiller maintenance.

Because the circulating cooling water is being used, some contaminants such as dirt and metal pieces will be removed as part of the revolving operation.

What Are Some Common Problems of Using a Laser Chiller?

Some common problems which you can face while using your Laser Chiller are:

• Improper power supply
• Clogging up of pipes
• Inefficient results
• Pipe leakage

Laser chiller piping leakage

How to Solve the Most Common Problems of your Laser Chiller?

You can solve the common problems of your Laser Chiller using these solutions:

• Check if the power source is working and the wires are not cracked or broken
• Clean the pipes regularly and take care of their maintenance.
• Use variable frequency drives or other efficiency-enhancing devices.
• Replace the pipe.

Laser chiller water pipes replacement