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Oil Chiller-An Ultimate Buying Guide by TopChiller.

The industries associated with oil heating face a considerable risk of damage and degeneration to their machinery due to the extra heat produced.

The Oil Chiller works to displace the heat produced, thus saving the equipment and maintaining an optimum temperature.

Having an affordable cost and efficient performance, and Oil Chiller is preferably used for temperature regulation in hydraulic oil, lubrication oil, and other oils that are used in the machinery in industries. Let’s know more about Oil Chiller.

What is an Oil Chiller?

Oil Chiller helps to control the temperature of oils and specially designed and manufactured for oil-related cooling,

Whether it is lubricating oil, hydraulic oil, or any other oil necessary for the machinery, the Oil Chiller performs the best cooling.

The moving parts of an Oil Chiller produce heat due to friction. This heat leads to thermal deformation and therefore, it must be reduced.

The Oil Chiller can save all the machine tools, gears, bearings, and spindles by cooling them down.

This extra heat can also reduce productivity and efficiency; therefore, an Oil Chiller is a necessity in oil-associated cooling.

How Does an Oil Chiller Work?

The Oil Chiller works on the principle of indoor temperature. The temperature can be set so that all the equipment must stay protected, and there should be no thermal deformation.

In the evaporator, freon is used for heat absorption and internal vaporization of the cold machine. The cooled oil is obtained from the cold oil.

The oil is then sent back to the tank, where it gets mixed with the rest of the oil.

In this way, the oil is continuously circulated, and the temperature of the tank is reduced.

The Oil Chiller is automatically controlled by the temperature controller, and the switching on and off is also done through the sensor. However, at the set temperature, the oil temperature is constant.

What are the Important Features of an Oil Chiller?

The important and unique features of an Oil Chiller are as follows;

• It is well equipped with all kinds of safety features to ensure safe function.
• There is a good mechanism for thermal overload protection.
• A discrete alarm is present to indicate safety guard oil flow protection.
• Efficient speed control is offered.
• All the materials used in the Oil Chiller are branded and of premium quality.
• There are numerous waterproof features.
• A highly efficient proper condition control system allows precise maintenance.
• All the right conditions are maintained within precise limits.
• The cooling capacity range of an Oil Chiller is 0.98 kW to 28 kW, and you can choose the capacity according to your application.
• The temperature reliability range of ±0.1℃ to ±2℃ is offered.

What are the Applications of an Oil Chiller?

Here are a few applications of an Oil Chiller;

It is used for broaching machines, milling machines, and grinding machines in industries.

The Oil Chiller is a part of the integrated machining center machine.

Cutting machinery and woodworking engraving machines also need an Oil Chiller for precise temperature control.

A hydraulic oil station or hydraulic machinery needs an Oil Chiller to remove the extra heat given off by the machinery. This heat can lead to the deformation of certain processing equipment.

The temperature of the discharged oil is maintained at a lower point to ensure that there is no damage to the equipment. Therefore an electric discharge machine uses it frequently.

The service life of machinery is increased by using the services of an Oil Chiller.

In the process of grinding, a great amount of heat is released due to changes on the molecular level. This heat is removed by an Oil Chiller. It also reduces the effects of temperature on the stored raw materials in the industry.

CNC is one of the main applications because there is an extreme need for an accurate processing temperature.

What is the Filtration System of an Oil Chiller?

It refers to the purification of the coolant of an Oil Chiller by passing it through a medium. The spaces in the medium allow only a certain size of particles to pass through.

In this way, the dirt particles are trapped above the filter and, under the action of gravity, form a dirt cake.

The firm assembly of a dirt cake further serves as a filter and leads to more filtration of the coolant.

Here are a few advantages of the filter system;

• The smooth finish of all the components.
• Hygienic working conditions.
• Purifies the coolant.
• It makes the coolant less hazardous.
• Avoids the risk of diseases among the laborers.
• Resist bacterial growth.
• It makes the coolant stink-free.
• Increases the life of the coolant.
• Enhances productivity.

What are the Properties of the Evaporator of an Oil Chiller?

The evaporator is the chamber of an Oil Chiller where the coolant is treated with high temperature and low pressure to allow it to evaporate and expand.

The evaporator must be following the size and capacity of the Oil Chiller so that the coolant can be dealt with accordingly.

After passing through the compressor, the oil-liquid mixture enters the evaporator.

The oil is separated by an oil separator, and the rest of the mixture is sent to the condenser.

It has the following properties;

• It is made up of strong and sturdy material.
• The evaporator is proportional to the Oil Chiller.
• It comes with the Oil Chiller, and you don’t have to buy it separately.

What is the Compressor Type for an Oil Chiller?

Many types of compressors can be used by an Oil Chiller, like an air-cooled type, water-cooled type, a screw or scroll type, and even a centrifugal type.

There are many varieties available with a huge range of capacities ranging from 01 tons to 400 tons.

It also allows various refrigerant options that are safe to be used for applications like the industrial environment cooling process.

The refrigerant options are R134A, R404, R407C, and R410A, with medium GWP HFCs.

These compressors are very high quality and increase efficiency.

Each compressor drive is designed and manufactured to deal with all kinds of cooling loads.

There are only two rotating parts, and the operating speed is not too high so that the function is secure.

An Oil Chiller compressor equipped with a smart H microprocessor unit and has a proactive control strategy.

It has inbuilt industrial automation and energy management ability along with easy interface and safety functions.

What Kind of Condenser is used in an Oil Chiller?

The choice of condenser depends upon the type of Oil Chiller. Here are a few properties of the condenser;

• The condenser is the chamber where the coolant is condensed back into a liquid form by applying pressure and lowering the temperature.
• As the working principle is based upon heat exchange because of the changing states of the coolant, the Oil Chiller has an efficient condenser.
• The condenser may be of water-cooled or air-cooled type. The flow rate and the condenser water temperature both play an important role in the maintenance of the efficiency of your Oil Chiller.

What are the Load Controls for your Oil Chiller?

There are several ways of heat transfer from the load. Some of which include variable speed pumps, two-way valves, face, and bypass dampers, and three-way valves.

All these pathways have their mechanisms, perks, and drawbacks. You must choose the best one for your Oil Chiller, which suits your application and increases the efficiency of the unit.

What are the Pumping Arrangements for your Oil Chiller?

The most suitable thing is to place the pump under the cooling tower sump. This way, you will be able to have enough net positive head.

Individual Cooling Tower for Every Unit

Usually, every Oil Chiller has its cooling tower. This happens when you purchase different units one after the other.

Manifold Pumps

The most suitable way to use a pump in your Oil Chiller is to have a manifold pump with one cooling tower sump, condenser water line, and branched piping. Here are some benefits of using this arrangement.

When you separate the cooling tower cells, any of your Oil Chiller will properly function with any cooling tower cell.

You can easily connect the cooling tower with individual chilling units. Make sure that you provide a supply and return pipe for the easy and smooth circulation of fluid in it.

This way, the hydraulics will cause less trouble as compared to when placed on the chilled water site.

What is the Unit Level Controls for your Oil Chiller?

The Oil Chiller properly controls and monitors the temperature of the chilled water. If you know the temperature of the chilled water, you can use it as a sensed variable to know about the capacity of the unit.

This will help determine the overall suitable load on your system. There are two ways to use the supply temperature control strategy, either on the constant flow system or the variable flow system.

This control system allows the user to operate and monitor the electromechanical, digital, and pneumatic controls in the Oil Chiller. The functions of the controls will help in the following.

• Knowing about the data points that are necessary for the normal functioning of the system.
• Finding the safety points such as the electrical points and the bearing temperatures. In case you fail to maintain the normal range of these features, it may be responsible for your motor’s failure.

What is the Importance of Oil Chiller Performance Testing?

Oil Chiller performance testing refers to the series of tests that the unit has to go through before leaving the manufacturing company.

Make sure that the Oil Chiller works perfectly in all the optimum conditions. It is important so that the power consumption and cost can be estimated.

Another reason is that the potential problems that may arise due to the use of an Oil Chiller may be predicted.

The extent of the potential issues can be estimated. That can also give you an idea about the efficiency of your unit and what are the factors that enhance the efficiency. It allows you to figure out ways to obtain maximum productivity with little time.

What are the System Design Requirements for an Oil Chiller?

It is important to talk about the flow rate fluctuations and temperature controls of an Oil Chiller. You can adjust these two variables accordingly for satisfying your Oil Chiller requirements and adjusting its operation cost-effectively.

Flow rate:

The flow rates must be adjusted to lower values to accommodate wider temperature differences in comparison to the standard values.

Temperature:

Some of the standard temperature requirements are:

• Evaporator leaving water temperature should be 44°F [6.7°C]
• Water-cooled condenser, entering water temperature should be 85°F [29.4°C]
• Air-cooled condenser, entering air dry bulb temperature should be 95°F [35.0°C]
• Chilled-water supply temperatures should range from 44°F [6.7°C] to 34°F 31.1°C]

What is Meant by Oil Chiller Sequencing?

The proper sequencing of the coil control valves, pumps, and other components of the Oil Chiller must be maintained for its smooth and efficient operation.

This also helps in the maintenance of the flow rate via each evaporator falling within the suitable range.

If the flow reaches close to the maximum operating limit of the Oil Chiller, then you must look for supporting machinery to help you deal with the flow rate problems.

When there is a decrease in the flow rate and the system load, you must shut down your Oil Chiller to manage bypass water flow needs.

You must allow the operating Oil Chiller to fully load along with monitoring the leaving evaporator temperature before adding in a new Oil Chiller.

You do not need another Oil Chiller until your current target temperature requirement is being fulfilled. When you feel like your already operational Oil Chiller is not giving enough cooling, then you should activate the new one.

What you must keep in mind is that you should only activate the new Oil Chiller before letting the chilled water flow reach its maximum limit.

What are the Control Requirements for an Oil Chiller?

The control requirements of an Oil Chiller include an automatically controlled system that is updated and easy to use.

• The use of the recent technology enables you to have elaborate control on your Oil Chiller.
• A remote-controlled facility is also available.
• You can set the values easily whenever you want to.
• The advanced interface is user-friendly.
• It allows rapid work with little investment of time.
• The control system allows you to be accurate and precise in your performance.
• It also reduces the time of the function.

What are the Maintenance Requirements for an Oil Chiller?

The efficiency and life of an Oil Chiller can greatly be increased by regular maintenance. Following are a few tips for good maintenance;

Cleanliness

• Make sure that you keep it clean all the time.
• There should be no dirt and debris accumulated in it.
• The pipelines shall also be cleaned on. Regular basis so that there is no obstruction in the flow of the refrigerant.
• All the filters must be cleaned thoroughly.
• Cleaning will also help to disinfect the system, thus making it safe to be used.
• Good ventilation helps to avoid mildew and mold growth.

Repair 

• It is necessary to fix an issue as soon as you face it.
• Don’t leave any leak or damage unattended.
• Identify the most common problems and look for a permanent solution.
• You might need to replace a few parts if damaged.
• Maintain the quality of the whole assembly by installing only good quality products.

How to Install your Oil Chiller?

The complete process of installation of an Oil Chiller is written below;

1. Make sure that your Oil Chiller is delivered safely and that all the components and accessories are with it.
2. Carefully inspect it to see if there are any damages.
3. Avoiding investing and skewing of the Oil Chiller is also important.
4. Now prepare the location for the installment.
5. Decide a place and make sure it goes with the size of your Oil Chiller.
6. The area must be well ventilated and spacious enough to accommodate the whole assembly.
7. Also, the installation site shall be completely dry.
8. There must not be any corrosive material or explosive gas around that location.
9. Set up all the pipelines and make sure that all the fitting is following the size and requirement.
10. Try to avoid joints so that there is minimum resistance offered.
11. All the Connections must be made strong and sturdy so that there is no leakage.
12. Now it’s time to install the oil absorption paper according to the size of your Oil Chiller.
13. Setting up an oil tank is also necessary. Make sure that the accessibility is easy and there is sufficient ventilation.
14. The outlet of the oil must be placed at a lower level than the inlet.
15. Establish a steady electrical supply, and you are good to go.

What are the Safety Precautions to use an Oil Chiller?

Here are a few safety precautions that must be taken while using an Oil Chiller;

• All the electrical connections shall be safe and well insulated.
• The oil level is maintained at a certain level.
• There is no shortage of coolant or refrigerant.
• The refrigerant must be safe, and it shall not harm the ozone layer to cause global warming.
• All the pipelines are well secured with properly sited valves.
• It is important to have sufficient experience and knowledge before operating the machinery.
• Never try to fix the electricity and plumbing systems yourself and seek the help of a professional.
• Wear all the safety equipment like a hat, gloves, and rubber boots while dealing with it.

What are the Common Problems Faced While Using an Oil Chiller?

The most common problems faced by using an Oil Chiller are as follows;

• Oil Chiller does not Start 

It might be due to a weak connection or a disturbing connection to the electricity source. It can be corrected with the help of an electrician. You can also take the help of the manual to set up the connections.

Also, check if the power button is switched on.

• Stops Immediately

If your Oil Chiller stops working immediately, there must be an underlying issue making the hindrance.

Call a professional to inspect and then fix the problem.  Try turning it on and off a few times.

• Refrigerant Level 

Make sure that the refrigerant level is sufficient. The quality of the refrigerant shall also be up to mark. Low quality would harm the environment and slow down the Oil Chiller.

• Obstruction in the Pipelines 

All the pipelines shall be thoroughly cleaned.

There should be an annual inspection to check and replace any old pipes.

Use good quality cleaning agents to ensure that there are no contaminants in the pipeline.

How to Increase the Efficiency of your Oil Chiller?

Here are a few tips on how you can increase the efficiency of your Oil Chiller;

• Keep your Oil Chiller clean.
• More the cleanliness, the more the efficiency because there are no hidden contaminants in it.
• If the cleaning is done frequently, there will be no accumulation of contaminants, and this no obstruction.
• Disinfecting the unit prevents the user from any infectious diseases.
• Constant repair and replacement.
• As the defective parts are removed and replaced with new ones, the efficiency of the Oil Chiller remains high.
• Make sure that you only use high-quality parts so that the working is not affected.
• Optimize control mechanisms.
• Make sure that your Oil Chiller meets all the specification requirements for your Application.
• Make sure that the cooling load is proportional to the capacity of your Oil Chiller.

What is the Power Requirement of an Oil Chiller Dependent on?

The power requirement of an Oil Chiller varies with its size, capacity, and efficiency.

What are Quality Certificates Required for an Oil Chiller?

An Oil Chiller must have RoHS, AHRI, CE, and DIN quality certificates.

How Many Types of Oil Chiller are there?

There are two types of Oil Chiller named open loop and closed loop Oil Chiller.

What is the Difference Between an Open Loop and a Closed-Loop Oil Chiller?

In an Open Loop Oil Chiller, the refrigerant flows from a tank that is away from it. Whereas, in an Open Loop Oil Chiller, the refrigerant recirculates from a tank that is located inside the assembly.

What are the Two Types of Heat Exchangers in an Oil Chiller?

The two types of heat exchangers present in an Oil Chiller are multi-pipe and radiator types.

How Does the Radiator Type of Heat Exchanger Help the Oil Chiller?

The heat exchange in a radiator-type heat exchanger uses an air-cooled system to transfer heat in an Oil Chiller.

What are the Two Freezing Types Used in an Oil Chiller?

The two most common freezing types in an Oil Chiller are the dipping system and circulatory system. Refrigeration and cooling occur through these systems.

What are the Cooling Methods Acquired by an Oil Chiller?

The cooling methods that an Oil Chiller adopts include freezing cycle type cooling and heat exchange cooling.

What Does the Lubrication Unit of your Oil Chiller do?

The Lubrication unit of an Oil Chiller makes sure that there is no wear and tear between two parts of your Oil Chiller. It reduces friction.

What shall be the Properties of Materials Used in the Oil Chiller?

All the materials used in the construction of an Oil Chiller must be durable and corrosion-free.

What is the Construction Description of an Oil Chiller?

An Oil Chiller consists of a cylindrical metal container with several pipes. The space between the pipes is occupied by metal. The coolant is allowed to flow through the heat transfer pipes.

What Does the Air Filter in an Oil Chiller do?

The air filter keeps the inside of all the filters of your Oil Chiller clean. This leads to fewer chances of obstruction.

What are the Determining Factors of a Flow Reduction Episode in Condenser Water Treatment of an Oil Chiller?

The flow reduction episode of an Oil Chiller depends upon a cooling bypass, a variable speed condenser water pump, and a cooling tower valve.

What are the Energy Sources for your Oil Chiller?

The energy sources for an Oil Chiller include thermal storage, alternative fuel, and electricity generation.

Does the Oil Chiller Harm the Environment?

No, the Oil Chiller does not harm the environment as the products used are easily degradable and do not damage the ozone layer.

Oil Chiller-The Ultimate FAQ Guide By TopChiller

What is an Oil Chiller?

Oil Chiller is an industrial cooling device specially designed to cool oil directly through the refrigerant-to-oil heat exchanging circuits.

It is used to chill heat exchanging circuits of a machine and regulate its oil temperature to the required optimum level for better performance.

As its name indicates it uses oil as a refrigerant or coolant in its operation.

What are the Outstanding Features of an Oil Chiller?

Some of the outstanding features of Oil Chiller are listed below:

• Highly-Durable and Efficient:

Highly durable metals like stainless steel, copper, and brazing are used to manufacture different parts of an Oil Chiller that ensure its long life.

Oil Chiller is known for its efficiency and effective control systems.

A high-quality compressor ensures accuracy and precision in maintaining the temperature for a sustainable environment of a process.

• Braze Plated Heat Exchangers:

An Oil Chiller has braze plated heat exchangers used as an evaporator.

Braze is one of the highly durable metals to resist corrosion and rust that make it work efficiently and lower maintenance costs.

• Modern Well-Equipped Micro-Computer Control System:

An Oil Chiller has a smart temperature control system that uses computers to monitor and precisely control each parameter.

What are the Main Parts of an Oil Chiller?

An Oil Chiller consists of a condenser, compressor, expansion valves, electric motor, heat exchanger plates, sensors, and condensation coils.

A condenser is used to condense and a compressor is used to compress the fluid in the refrigeration cycle.

Heat exchangers transfer heat between and are the most important part of an Oil Chiller.

The condensation coil helps to control the temperature of oil in the whole process.

What is the Working Principle of an Oil Chiller Work?

An Oil Chiller consists of a pump that extracts the oil from the machine oil tank and passes it through the cooling process in the refrigeration unit.

The oil temperature is reduced to the required level through the heat exchange process and the cooler oil is piped back into the machine using oil discharge lines.

The system maintains its temperature through the continuous circulation of oil in it.

Heat is exchanged between hot oil in a machine with the cool oil to achieve a temperature level of a certain value.

An Oil Chiller has effective temperature sensors that detect the temperature level micro-computer temperature control system that controls the temperature.

What are the Diverse Industrial Applications of an Oil Chiller?

Oil Chiller is highly demanded industrial equipment used in the industrial cooling process. It is used to cool heavy machinery used in the production industry.

It is commonly used in:

• CNC Machining Centers
• CNC Grinding Machines
• Wood Working Machines
• Plastic Injection Molding Machines
• PET Blowing Machine
• Water Bottle Blowing Machines
• Cutting and Molding Machine
• CNC Punching Machines
• Spindles and Other Machine Tools
• CNC Lathe
• Hydraulic Presses
• Hydraulic Stations
• Electrical Discharge Machines
• Lubrication and Cooling Systems of Several Industrial Processes.

Besides these applications, Oil Chiller has much application for modern industrial processes.

Why an Oil Chiller is more Advantageous for your Industrial Application?

Machines always generate heat in any mechanical process.

A large amount of useful energy is dissipated as heat which results in an unsuitable environment for different industrial processes and demands an effective solution.

An Oil Chiller is a viable option to remove excess heat generated from the headstock bearing, spindles, and gearboxes of different machines. It is used to maintain a constant temperature of a machine process.

It helps the machine’s material to withstand heat for a long life by reducing its internal temperature.

It is a more reliable option for not having a chemical as a refrigerant. Oil is neither toxic nor highly reactive chemical.

Therefore, using oil as a coolant makes it the best suitable device for any reactive and sensitive chemical or industrial process.

What are the Several Types of an Oil Chiller?

The heat dissipation system and cooling system of an Oil Chiller categorizes it into two different types.

• Water-Cooled

The water-cooled Oil Chiller has all features similar to a standard Oil Chiller except for an additional cooling tower.

An additional cooling tower dissipates heat using water as a coolant.

• Air-Cooled: An air-cooled Oil Chiller has the same features as a standard Oil Chiller while it uses a fan to dissipate heat and maintain the temperature.

It has two different types based on configuration and their external shape.

• Closed-Loop: A Closed-Loop Oil Chiller as the name indicates is a closed box with a metal seal and sheet on its outer surface.
• Open-Loop: An Open-Loop Oil Chiller doesn’t have any outer casing instead it is a shell-shaped chiller having all the advanced features.

Why do Machine Tools Require Oil Chiller?

Machines need cooling systems such as Oil Chiller to maintain their oil temperature.

Machines tools such as spindles heat up and deviate from their center of columns and heads.

The displacement of the spindle from its original shape results in poor performance and lacks accuracy.

It minimizes the thermal displacement of the spindle due to high temperatures and enhances efficiency.

It prevents the temperature rise of the motor coil and doesn’t let it heat up.

Excess heat in the motor coil can burn it and cause an explosion in any equipment.

How is an Oil Chiller Energy-Efficient?

An Oil Chiller has advanced features to reduce energy consumption and make an industrial process profitable for you.

It has compressors that consume less energy, highly effective motors, and high-quality electrical components to ensure fewer power losses.

How does an Oil Chiller Ensure an Accurate Temperature Control of the Industrial Atmosphere?

Big machines release a large amount of heat in the environment which makes some Industrial processes unfeasible.

To achieve a sound environment for an industrial process you need to control the temperature by removing excess heat from that environment and an Oil Chiller does so.

The oil at normal temperature is circulated along with different parts of the machine where cooling is required.

Then, the oil absorbs that excess heat and dissipates it into the cool oil placed in a separate tank and makes the process feasible.

To ensure accuracy it uses thermistors and several other devices are used to monitor the temperature of different components of a machine and fully programmed and highly accurate temperature sensors are used to detect it.

Is an Oil Chiller Durable Enough for Severe Factory Condition?

Oil Chiller uses thermal oil having high heat capacity and thermal conductivity, as a refrigerant to withstand high temperature.

Oils are excellent heat transfer fluids therefore using oil as a coolant makes it the most suitable substance for any factory condition.

It controls the temperature for different applications and does not usually corrode the copper.

Not all oils are used in an Oil Chiller, some contain additives.

Avoid these oils in machines having components containing copper.

What are the Types of Refrigerant Oil used in an Oil Chiller?

Oil has many categories depending upon its purpose of usage hence it is essential to figure out why you need an oil.

Oils are used to

• Reduce Friction.
• Reduce the noise made by moving parts.
• Reduce the internal refrigerant leaks.
• Compressor cooling
• Carrying the leak detection agent

Several oils are used as a refrigerant in an Oil Chiller.

• Mineral Oils
• Synthetic Oils
• Semi-Synthetic Oils
• Polyester Oils or POE Oils
• PAG Oils

Why it is much Important to Check the Oil for Containments?

The presence of containments can badly affect the efficiency of an Oil Chiller therefore it is crucial to monitor oil for contamination.

If any type of lubrication is dissolved or mixed up in oil it can affect the oil. You must check the oil condition before using it.

Make sure it’s suitable and according to your work requirements.  Replace or change the oil once a month or as recommended by the manufacturers.

Don’t use excessively used oil it can damage your Oil Chiller parts and ultimately affect its efficiency.

How does a Lubrication System Works in an Oil Chiller?

An Oil Chiller has a lubrication system that reduces the friction in its several components to ensure optimum performance and minimal downtime.

Friction causes more energy consumption and heat generation.

The continuous movement of several parts of a machine requires lubricants to maintain its efficiency.

The lubrication system consists of a suitable oil that is forced onto the surface of parts of the Oil Chiller that needs it most.

Lubricating oil protects the machine from damaging itself due to excessive heat it produces in a process.

Lubricating system of an Oil Chiller Work in following steps:

Step 1: An oil pump forces the oil around the different parts and sites within your machine.

It has an electrical sensor to detect and monitor the temperature of the oil within it.

Step 2: An oil pump is used to move oil to its several parts including heat exchangers.

Step 3: The oil is then transported to the compressor.

Use the filter to transport clean oil to other parts.

The filter won’t let the dirt and contaminants enter the moving components as these can damage the machine.

If your Oil chiller suddenly lost electrical power, its components must have some lubricating oil available until they come to rest.

In case of immediate cut-off of an electrical power supply, the oil pump cannot provide lubrication oil until it stops.

The gravity-fed oil supply is provided by it to the lubricating system to overcome this problem.

Step 4: Oil is well distributed to all sections of the machine.

How can you Calculate the Load of your Oil Chiller?

Step 1: Measure the flow rate of oil.

Step 2: Determine the ΔT of the oil

Step 3: Put the answer into a given formula to calculate a result.

Q = M X C X ΔT

Where:

Q = heat load in British Thermal Units per Hour (BTUH)

M = flow in Gallons per Hour (GPM)

C = specific heat of the oil used.

You can also calculate load by another method mentioned below:

• Calculate BTUs per hour: 

Pounds per hour× specific heat× ΔT = British Thermal Units per Hour

• Convert British Thermal Units Per Hour to Tons:

British Thermal Units per Hour divided by 12000 = Tons per hour.

• Calculate and Add a Safety Factor:

Tons per hour x safety factor = Chiller load in tons

How to Calculate Cooling Capacity of an Oil Chiller?

Each Oil Chiller has a specific cooling capacity depending upon its configurations and its internal system.

You can manually calculate its capacity using a simple formula mentioned here:

• Calculate the change in Temperature= Incoming oil Temperature (°F) – Required chill oil Temperature
• Calculate BTU/hr. multiply by BTU/hr. = Gallons per hour x 8.33 x change in temperature.
• Calculate its cooling capacity in Tons = Btu per hour divide it by 12,000
• Oversize the Oil Chiller by 20% Ideal Size in Tons = Tons x 1.2

Now you have the ideal size and capacity for your Oil Chiller.

How can you Calculate the Oil Pressure of your Oil Chiller?

Oil pressure plays a vital role in the optimum operation of an Oil Chiller.

Net oil pressure is the pressure that a pump creates to circulate oil throughout the system.

Knowing suitable pressure ranges for your Oil Chiller is mandatory for its Durability.

You can calculate the total oil pressure of a system by measuring the oil pressure at your discharge port.

Subtract the crankcase pressure from this quantity and you will get total oil pressure.

An accurate and suitable range of pressure as recommended by the manufacturers will help the compressor Work efficiently and uniformly.

If you don’t have the right oil pressure in it then it will run without lubricant and damage itself.

The oil pressure of your Oil Chiller should be neither too high nor too low.

It should be the same as recommended by the manufacturers with variations of 5%.

If your oil pressure is very high then it shows that your system has a blockage.

You should immediately resolve this problem with the help of a technician otherwise it would be damaged.

About the above points maintain suitable pressure thorough out the processes by calculating it and using a specific device like pressure sensors for this purpose.

Why an Oil Chiller is Called an Oil Cooler?

Oil Chiller and Oil Cooler have the same working principles for the removal of excess heat.

It is also called an oil cooler because it is commonly used as a cooling device for

• Hydraulic Oil
• Lubricating Oil
• Oil Cooling for your Machine Tools

Oil coolers are used to control and maintain the temperature of oil in automobiles and other heavy machinery.

Oil Chiller can control and maintain the temperature of

• Industrial Lubrication Oil
• Hydraulic Cutting Oil

Their purpose is to remove excess heat from the process.

Due to similarity in working principles, operations, and applications Oil Chiller has named Oil coolers as well.

How does an Oil Chiller Maintain the Quality of Oil in a Machine?

An Oil Chiller maintains the quality of oil in a Machine by maintaining a certain value of its viscosity as recommended by the manufacturers.

The viscosity of oil varies from machine to machine based on their operation and their applications.

It is necessary for the stable operation of machines.

High temperature can alter the viscosity of oil excess heat can make it less viscous while a machine requires a particular amount of viscosity of oil for proper functions.

Oil Chiller maintains that level of viscosity of oil by regulating its temperature and removing heat from it.  It doesn’t damage the oil quality due to high temperature and maintains it.

It uses a sensor to detect the rise in oil temperature and regulate it to the required level using a temperature controller.

What is the Function of an Automatic Alarm System in an Oil Chiller?

An Oil Chiller has an automatic alarm to detect the rise in oil temperature and alert you about dangers.

One of the biggest advantages of a smart automatic alarm is its immediate and accurate detection of temperature change within a few seconds.

Fast and accurate detection of temperature changes helps you to protect your Oil Chiller from any type of damage.

CNC machines require immediate actions when something unusual and unexpected happens to them otherwise they can cause an explosion.

In this regard, an automatic alarm prevents such hazards and alert you before they occur.

An automatic alarm of an Oil Chiller parameter such as temperature has a fixed value marked as a limit for its alarm.

When this limit exceeds your alarm start to give a warning signal.

The warning signal varies in several manufacturers and suppliers.

Can you set the Oil Temperature According to the Required Temperature of a Machine?

Yes, using an Oil Chiller you can set oil temperature according to the required temperature of your machine.

It allows you to change parameters according to your needs.

You can define and set your own parameters limits such as temperature and pressure limits for different applications.

For this purpose, you have to clearly understand suitable temperature and pressure level requirements for the process.

It is recommended to contact suppliers or manufacturers to set it for you if it’s not comprehensible for you.

What are the Protection Devices in an Oil Chiller?

An Oil Chiller is a completely safe option for different industrial applications.

It has several advanced safety protection options available to counter any mishap.

• Refrigerant Leakage Detection Alarm Function:

Oil Chiller has a refrigerant leak detection alarm to prevent any mechanical damage or any other undesirable situation.

• Upgraded Modular Design to Withstand Vibration:

Oil Chiller has advanced and upgraded modular designs to withstand vibration and ensure ease while transportation.

• Electronic Components with Resistance for Sulfidization:

Sulfidization is one of the most common problems usually observed with Oil chillers.

As Oil Chiller demands high resistance against sulfidation manufacturers have now upgraded the entire design to fulfill this demand to increase its life span.

• A High-Accuracy Advanced Model with the Inverter-Controlled Compressor:

Inverter-controlled scroll compressor ensures the safety and resolves all conventional problems like insufficient flow, overflow.

• Oil Temperature Sensor: To maintain a constant temperature of oil throughout the process.

What is the Installation Process for your Oil Chiller?

To install your Oil Chiller follow the instructions in the installation instruction manual.

Manufacturers and suppliers provide it with Oil Chiller or simply follow our instructions given below:

• Select the proper location, a suitable ground capable to bear its weight.
• After selecting ground or surface area for placement unpack it.
• Using instructions manual or guide assemble all the parts of your Oil Chiller.
• You can get the help of an expert technician.
• Go to the control unit.
• Go to set SETUP.
• Set the parameter of your application including temperature and pressure.
• Start your Oil Chiller.

What are the Preventive Measures for Installation of an Oil Chiller?

Your Oil Chiller may not function properly due to some mistakes in the installation process.

• Inspect motors for proper functions.
• If your motors sound different from normal you must immediately check for their rotation and power supply.
• Inspect compressor oil, check its quality. It should be fine and good in condition.
• You must follow instructions by the manufacturer for checking and replacement of compressor oil.
• Replace it when needed and always choose the right oil for your compressor.
• Inspect valve stems. They should be tight.
• Lose valve stem results in leakage of refrigerants. Make sure you fix it well.
• Electrical connections should be plugged in the right way.
• Wrong connections can cause damage to your Oil Chiller therefore follow instructions engraved on each component for connections.

How to Service and Maintain your Oil Chiller?

Service and maintenance are essential for long-term high-quality performance.

Inspect your Oil for leakage.

Inspect all the components of compressors unit for accurate oil level, oil leaks, unusual vibrations, operating temperature variations of several units.

Electrical connections should be inspected for short circuits, fuses, and breakdowns.

Check the filter dryer and keep it clean. Remove dirt and clean it once a week.

What Causes an Oil Chiller to Trip?

An Oil Chiller trip and don’t function properly due to:

• Low-Pressure Trip: When your Oil Chiller has a low level of refrigerant it will trip.
• Oil Failure Trip: When your Oil Chiller has a shortage of oil or your oil condition is not good
• Power Assembly Broken Capillary: Your Oil Chiller will trip due to a power breakdown of assembly.
• Clogged Filter: Clogged filters cause blockage and also cause it to trip.
• Antifreeze or Mud Coating Tubes: The muddy evaporator tubes cause poor efficiency and your Oil Chiller trip due to insufficient heat transfer.

How can you Reset your Oil Chiller?

You can rest your Oil Chiller from the control unit.

Go to the control panel and open the menu.

From the menu choose the ‘RESET’ option.

Add parameters and changes you want and you are all set.

How can you improve your Oil Chiller Working Efficiency?

You can improve your Oil Chiller efficiency by dividing the performance load.

Oil Chiller works best when loads are divided you can use several plants for cooling large industrial environment.

Its efficiency decrease if the tubes or heat exchanger are contaminated with dirt, algae, and other particles.

It increases thermal resistance in decreases the overall efficiency of your Oil Chiller.

Heat transfer plays a fundamental role in its efficiency.

Larger heat exchangers will result in an efficient cooling system.

Proper treatment of condenser water also increases the efficiency of an Oil Chiller because dirty water clogs dirt in tubes that reduces water flow and affects the efficiency of condensation power.

A decrease in condensation power of condenser decreases the overall efficiency of an Oil Chiller.

You can overcome this problem by using clean water passed through wastewater treatment.

How to Fix Problems due to Discharge Gas and Overheated Compressor of your Oil Chiller?

An overheated compressor can still work well to perform its function for a while but too much heating will affect its efficiency and durability.

Therefore it is mandatory to get rid of excessive heat using suitable methods.

To fix the overhead compressor you must check the condenser fan.

Most commonly it is observed that overheated compressors have failed in their fans.

Then you must inspect it for refrigerant and it should be accurate as recommended by your Oil Chiller manufacturer.

Keep its surrounding environment cool.

As external heat affects condenser working capabilities.

To cool its compressor disconnect the breakers for a while, remove the lid from its air conditioner, run a  garden hose over the compressor for a few minutes to cool it off.

To overcome problems due to discharge gas inspect tubes, keep them clean, and service and maintain them regularly.

What you should do when your Oil Chiller DC Fan stops?

If your Oil Chiller DC motor stops you should immediately check the electrical connection.

Inspect for damage to wires.

Inspect for fuses in the control unit.

Check the breaker for a blown fuse and repair it.

Inspect the DC motor for any damage and check its rotation direction.

What Causes the Rise in Inlet Temperature and Tank Liquid Temperature of your Oil Chiller?

Inlet temperature and tank liquid temperature rises due to overheating of the compressor and inadequate heat transfer due to heat exchangers.

How to Overcome the Insufficient Flow in an Oil Chiller?

An insufficient flow could be the result of defects in your Oil Chiller compressor, expansion valves, motor, or distribution tubes.

Inspect it well for these defects and immediately repair damaged parts.

How to Overcome Power Source Failures in an Oil Chiller?

To overcome power source failure in an Oil Chiller you should check voltage supply requirements for it.

Improper line of voltage and incorrect phase connections can cause power supply failures.

Use a three-phase supply where needed, don’t overload your Oil Chiller.

Check for blown circuit breaker or fuse.

Make sure that your switch is not in the “off” position.

What is the Cost of an Oil Chiller?

The cost of an Oil Chiller varies from manufacturer to manufacturer and supplier.

Generally, an Oil Chiller costs $1000 to 20000.

How to Select the Right Manufacturer of your Oil Chiller?

Before choosing a manufacturer of your Oil Chiller you must ensure that they have

• Inverter-controlled compressor
• Braze or stainless steel plated heat exchangers.
• High-speed rotation electric motor.
• Compatible design for easy transportation.
• Low failure rates and reasonable prices.