TopChiller can design and manufacture all types of air cooled screw chillers for you

Air-Cooled Screw Chillers: The Ultimate FAQ Guide

This guide will answer all questions you have been asking about air-cooled screw chillers.

Whether you want to learn about the working principle, benefits, specifications, or features, you will find all information right here.

Keep reading to learn more.

What is an Air-Cooled Screw Chiller?

An air-cooled screw chiller is a special type of screw chiller that you will use to cool industrial equipment.

The fact that makes the air-cooled screw chillers is that it uses air as the coolant to get rid of heat.

Air-cooled screw chiller

What is the Best Location for Installing the Air-Cooled Screw Chillers?

You can install the air-cooled screw chiller in different locations as long as you adhere to installation specifications.

Implying that you can install the air-cooled screw chillers outside the building or inside a mechanical room.

One of the major requirements for locating the air-cooled screw chiller is proper aeration of the system.

Installing the air-cooled screw chiller outside the building will automatically guarantee a constant supply of air.

In case you have it in a mechanical room, you must provide proper ventilation for air to flow easily.

How Do the Air-Cooled and Water-Cooled Screw Chillers Compare?

In the screw chillers, there are two main types of cooling agents which include water and air.

Just from the name, you will note that the air-cooled screw chillers use air as the main cooling agent.

On the other hand, water-cooled screw chillers use water as the main cooling agent that takes away the heat.

You will also install the air-cooled screw chiller outside the building and the water-cooled screw chiller in mechanical rooms.

Air-cooled screw chillers are often quite noisy in comparison to the water-cooled screw chiller which is quieter.

Despite the above differences, both air-cooled and water-cooled screw chillers have similar components.

The working principles of the air-cooled and water-cooled screw chillers are also the same.

Water-cooled screw chiller

How Much Does the Air-Cooled Screw Chillers Cost?

The cost of air-cooled screw chillers varies between 3000 to 50,000 US Dollars.

There is a price variation since air-cooled chillers are of various sizes and types.

The most efficient and high capacity air-cooled screw chillers often cost more than their low efficient counterparts.

You will also look at other factors such as type and quality of material which will also affect the price.

What are the Advantages of Using the Air-Cooled Screw Chillers?

There are many benefits that you will enjoy by using the air-cooled screw chillers.

Some of the benefits that you will realize with the air-cooled screw chillers include:

· High-Efficiency Rates

Screw chillers have very high efficiency working rates thanks to the high-efficiency load evaporators and condensers.

The condensers have a very wide louver fin that increases the efficiency of working with the air-cooled screw chillers.

· Reduced Size and Weight

Air-cooled chillers have very few components in comparison to water-cooled chillers thus making them smaller and lighter.

The lightweight and small sizes increase the ease with which you can move and install air-cooled chillers at different locations.

· Noise Reduction

Noise is often one of the greatest concerns when t comes to air-cooled screw chillers.

Modern types of air-cooled screw chillers often reduce the noise that the machine produces hence quieter operations.

· Proper Control Systems

You will also have proper controls of the machine due to the presence of the centralized control system.

It has features that will allow you to control the air-cooled screw chillers even from a remote location.

Are There Disadvantages of Using Air-Cooled Screw Chillers?

Yes, some limitations may discourage you from using the air-cooled screw chillers.

Here are some of the limitations that you should look out for.

· High Initial Cost

You will spend quite a lot of money when it comes to purchasing and installing the air-cooled screw chillers.

The cost of the equipment is high and you will have to hire professionals to help in the installation process.

· Maintenance Difficulties

In addition to that, you will find it difficult to maintain the hermetic air-cooled screw chillers.

Disassembly of the main parts of the air-cooled screw chillers is very difficult thus making the maintenance process very difficult.

· Noisy Type of Screw Chiller

Air-cooled screw chillers are often quite noisy in comparison to water-cooled screw chillers.

It is the reason why you have to install it outside the building to reduce the effects of too loud noise.

· Low Durability Levels

Generally, air-cooled screw chillers are often less durable in comparison to water-cooled screw chillers.

This is because of the exposure to the weather elements which affect the shelf life of the construction materials.

What are the Main Components of the Air-Cooled Screw Chillers?

Air-cooled screw chillers have various components that help in achieving the cooling effect of the air-cooled screw chillers.

Here are the main components that you need to consider when looking at the different types of air-cooled screw chillers.

· Control Panel

This is the unit with all the control systems for controlling and monitoring the operations of the air-cooled screw chillers.

It has a touch screen with an HMI that allows you to control the machine even from a remote location.

· Compressors

This type of air-cooled chiller has a screw-type of compressor that helps in the compression of the refrigerant.

There are two different types of screw compressors that help in the compression of the refrigerant to increase pressure.

· Electric or Power Unit

This is the part of the air-cooled chiller that will provide the machine with the power that it needs to produce a chilling effect.

You can control the amount of energy flowing through the air-cooled screw chiller just by setting the power unit.

· Evaporators

This is the part of the chiller that will eliminate the heat from the pipes containing hot water.

It is the section that will feed the refrigerant with the heat thus leading to a change in state to gas.

· Condensers

You will also use the condensers in the process of eliminating the heat from the refrigerants.

It also helps in condensing the gas refrigerant and changing its form from a gas back to liquid after removing heat.

· Expansion Valve

The expansion valve will help in controlling the flow of refrigerant from the condenser back to the compressor.

It will reduce the pressure of the flowing refrigerant from the condensers and supply it in various quantities.

How Does the Air-Cooled Screw Chiller Work?

One of the most important factors that you have to supply constantly is air.

Air will flow from the outside environment and into the air-cooled screw chiller through the inlet.

The inlets have filters that block any form of debris or dirt that might be in the air.

As that happens, the impeller on the air-cooled screw chillers rotates and helps in pushing the refrigerant.

As soon as you power on the machine, you will activate the release of the refrigerant from the refrigerant storage cylinder.

The refrigerant will flow to the compressor unit which will compress it between two rotating scrolls,

The compression process will increase the speed and pressure of the refrigerant and propel it to the evaporator.

At the evaporator, refrigerants will collect heat that comes from the flowing water and change its state to gas.

The heat within the evaporator will evaporate the fluid changing it from a liquid into gas.

The gas refrigerant with the heat inside will flow straight to the condenser at the same pressure and velocity.

While in the condenser, the cool air from outside will flow over the refrigerant and carry with it the heat.

This will create a condensation effect on the refrigerants thus changing them back to the liquid state.

The air will blow away the heat into the environment and leave the liquid refrigerant flowing straight to the expansion valve.

This is the final spot that will control the flow of refrigerant by reducing the overall pressure and speed of movement.

It will feed the compressors with the necessary amount of refrigerant thus allowing the process to continue.

What are the Main Applications of the Air-Cooled Screw Chillers?

Air-cooled screw chillers come in handy in different applications to help in controlling temperatures.

You will use the air-cooled screw chillers in different applications such as.

· Pharmaceutical Industry

In the pharmaceutical industry, you will use air-cooled screw chillers in cooling different types of pharma products.

It will help in cooling the equipment that holds highly sensitive pharma medication thus maintaining their shelf life.

· Food Industry

You will use the air-cooled screw chillers in the process of cooling the food-making equipment in the food-making industry.

In addition to that, the air-cooled screw chillers also cool off the food products in the food industry before packaging.

· Construction Industry

You will use the air-cooled chillers to cool off different equipment that may gain a lot of heat due to the continuous working process.

It will also help in cooling the water that you will use in the process of mixing different materials such as concrete.

· Chemical Processing Industry

You will need air-cooled chillers to control the temperature environment within the chemical processing plants.

It will also cool the equipment as well as provide the chemicals with the right ambient temperature for proper mixing.

Air cooled screw chiller regulates the temp of the chemical processing industry

Which Features Do You Look at When Choosing an Air-Cooled Screw Chiller?

You need to look at specific features of the air-cooled screw chillers before you settle on one type of chiller.

Here are the main features of the air-cooled screw chillers that you ought to know about.

· Semi-hermetic Screw Compressor Systems

First of all, you need to look at the presence of the compressors in the air-cooled screw chillers.

It should have compressors that have four steps of cooling capacity including 100%, 75%, 50%, and 25%.

· PCL Control System

It also comes complete with a PCL control system that helps in the programming and monitoring of the whole process.

The PCL control system has a touch screen that is user-friendly with a human-machine user interface.

· Safety Features

It also has different types of safety features that help in keeping the machine and the operators of the machine safe.

Some of the safety features include over-current protection, consumer inner protection, pressure protection, and temperature protection system among others.

What is the Process of Receiving and Handling the Air-Cooled Screw Chiller before Installation?

There are particular procedures that you have to conduct on the air-cooled screw chillers as soon as you receive them.

First, you will have to pass it through a series of inspection procedures where you will look out for possible damages.

You will also confirm that all the items on the bill of lading were on the shipment to your destination.

In case of any damages to the air-cooled screw chillers, you must report the damages to the carrier and manufacturer.

Ensure that you check the unit serial plate and confirm that it conforms to the power specifications in your locality.

You must never accept the air-cooled chillers in case it has damaged as that will transfer the responsibility to you.

Which Safety Precautions Should You Take Before You Install an Air-Cooled Screw Chiller?

You should also be very careful when you are installing the air-cooled screw chillers in your production facility.

First, you must use the most convenient tools to help in moving the load to the installation site.

Once on the ground, you will proceed with the installation process by clamping the machine to the ground.

You must only allow professionals and authorized personnel within the installation site to avoid unnecessary injuries.

You must also switch the power supply units before you begin operations on the electric systems.

Apart from that, you must also have an insulating platform where you will perform the electrical installations.

When it comes to the maintenance of the machine, you must contact professionals to help in the maintenance process.

Ensure that you avoid contact with the sharp edges on the machine as they are a great safety hazard.

You must also keep the installation environment clean to prevent any form of contamination on the systems.

This includes fitting mechanical filters at the inlets of the air-cooled screw chillers to block the entry of contaminants.

Wear PPE before air-cooled screw chiller installation

Which Specifications Should You Look at Before Choosing an Air-Cooled Screw Chiller?

There are many specifications that you will have to look at when you are choosing the air-cooled screw chillers.

Here are the main specifications that you must pay close attention to during the selection process.

· Location of Installation

In this case, you will look at the place where you will install the air-cooled screw chillers.

When choosing the location, you should avoid shorter airflow recirculation and obstacles blocking air paths.

Ensure that the floor is stiff to reduce vibration of the machine and also avoid dusty environments to keep clean equipment.

· Space Requirement

It is important to know the space that you have for the installation of the air-cooled screw chillers.

With this information, you will be able to choose the right size of air-cooled screw chillers to fit the space.

· Operation Heat Capacity

In this case, you will look at the capacity of heat that you will be cooling using the air-cooled screw chillers.

You will, therefore, choose the air-cooled screw chillers that are capable of maintaining the total heat capacity requirements.

· Type of Materials

In addition to that, you must also look at the types of materials that will conduct enough heat and increase efficiency.

In addition to that, it must also be strong enough to support the rigorous operations, temperature, and pressure systems.

How Many Power Connections of the Air-Cooled Screw Chillers Do You Have?

There are two main types of power connections of the air-cooled screw chillers power connections.

Here are the two main types of air-cooled screw chiller power connections.

· Single Point Power Connection

This is the type of connection where you will connect the machine to one main source of power.

· Multi Point Power Connection

In this case, you will connect the air-cooled screw chiller to multiple sources of power within the entire system.

Air cooled screw chiller power connection establishment

How Do You Troubleshoot an Air-Cooled Screw Chiller?

Air-cooled screw chillers often experience a few problems that may occur mid-operations.

Here are some of the problems that you can easily identify by troubleshooting the machine.

· Power Connection Issues

There are situations when the machine will definitely stop working or fail to start due to the interference of power connections.

In such a case, you will have to check the power lines and cable and also confirm if the switch is on.

In case of a problem, you should contact an electrician to help in fixing or replacing the broken electric systems.

· Pressure Drop

You may also experience failure of the fluid flow due to issues with the pressure system.

The pressure supply system may have leaks or insufficient fluid within the reservoirs.

It might also be a problem with improper control of the systems which you can adjust from the control panel.

You should contact a technician to fix and replace the leaking valves or broken pipes.

In addition to that, you will refill the fluid reservoirs to the right capacity.

How do you Clean and Maintain an Air-Cooled Screw Chiller?

Cleaning and maintaining the air-cooled screw chillers are very important steps in the chilling of different equipment.

It involves carefully removing or disassembling the parts of the air-cooled screw chillers after switching the power off.

After that, you will proceed with the cleaning of the parts of the chillers by scrubbing o get rid of stains.

You can also blow it off with a blower which will get rid of the dust from the system in a simpler model.

In addition to that, you can have an automatic clean-in-place system that will automatically clean the chillers.

After cleaning the chillers, you will replace the broken part with new ones before you proceed with the assembly process.

Remember to lubricate the moving parts of the machine to reduce damages that occur as a result of friction.

Air-cooled screw chiller inspection

How Do You Increase the Efficiency of the Air-Cooled Screw Chiller?

There are very simple processes that you can follow to increase the efficiency of the air-cooled screw chillers.

One of the factors that you will pay close attention to is proper record keeping daily.

You will use your records to identify the parts that require improvement to increase efficiency.

It is also important to have a schedule for inspecting, cleaning, and maintaining the machine regularly.

Inspecting the air-cooled screw chillers will help you identify any issues with the system for scheduled maintenance.

Cleaning the machine will eliminate obstacles and contaminants that tend to reduce the efficiency of the machine.

Maintenance involves replacing the broken parts, refilling the reservoirs, and lubricating the moving parts.

Finally, you must treat the fluid to get rid of the contaminants that may cause problems on the air-cooled screw chillers.

Remember that you should seek the services of professionals to help you in running the machines.

Which Types of Refrigerants Work Best for the Air-Cooled Screw Chillers?

There are quite a several refrigerants that you can use in the air-cooled screw chillers.

Here are some of the best types of refrigerants that work well in air-cooled screw chillers.

• Glycol
• Water
• Glycol and water mixtures
• Chlorofluorocarbons (CFCs) such as R12
• Hydrochlorofluorocarbons (HCFCs) such as R22
• Hydrofluorocarbons (HFCs) such as R4410A and R134

You will choose the type of refrigerant for your application requirements according to the application specifications.

Refrigerant best for the air-cooled screw chiller

How Does the Air-Cooled Screw Chiller Compare to Air-Cooled Scroll Chiller?

Well, the main difference between the air-cooled screw chillers and scroll chillers is the type of compressors.

Air-cooled screw chillers have screw compressors while air-cooled scroll chillers have scroll compressors.

Despite that difference, you will note that most of the features are similar to one another.

Both air-cooled screw chillers and air-cooled scroll chillers have similar components except for the compressors.

In addition to that, the working principle will differ only on the compression of the refrigerants in the chillers.

Implying that all the other parts of the air-cooled scroll and screw chillers will work following the same working principles.

Depending on your unique requirements and specifications, TopChiller offers a range of air-cooled screw chillers.

Whether you need water-cooled chillers or air-cooled chillers, TopChiller offers a perfect solution for you.

Contact us today for all your air-cooled screw chiller needs.

Air cooled scroll chiller