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Water Cooled Screw Chiller-An Ultimate Buying Guide by TopChiller.

A Water Cooled Screw Chiller is an advanced machine that reduces the temperature in industrial and commercial areas.

It is important to keep all the features, maintenance, and cleaning tips in mind so that the life of your machines can be increased. So let’s begin.

What is a Water Cooled Screw Chiller?

A Water Cooled Screw Chiller is a machine that gets rid of unwanted heat from a location and industrial environment.

Based on the recent and advanced technology, the HVAC function and efficient cooling allow a Water Cooled Screw Chiller to regulate the temperature of Industrial machines and products.

Water cooled screw chiller

What are the Features of a Water Cooled Screw Chiller?

• A Water Cooled Screw Chiller can be customized according to your needs and demands.
• Water Cooled Screw Chiller has a twin motor, hermetic screw compressor, which adds to its efficiency.
• The evaporator is made up of premium quality material to allow maximum productivity.
• A Water Cooled Screw Chiller comes with PID technology and a very user-friendly interface for the users.
• You can print the problem data or the operation with any values.
• The cooling tower is equipped with a fan controlling system for maximum cooling.
• The time display is available so that you can see keep a check on the cooling function in real-time.
• The temperature of the water outlet can also be monitored.

What is the Working Principle of the Refrigeration Cycle in a Water Cooled Screw Chiller?

• The working principle of a Water Cooled Screw Chiller starts with a low-pressure liquid or gas mix.
• A low-temperature refrigerant is sent to the compressor from the evaporator. An electric motor is used for this purpose.
• The refrigerant is mixed with the oil, which is drawn from the oil dispenser. This oil and refrigerant mixture is then transported to an oil separator.
• It efficiently separates the oil and the refrigerant by using the centrifugal mechanism.
• The separated oil is recycled, and the clean refrigerant goes to the compressor.
• The next step is condensation, which allows the cooling to occur.
• More heat is lost when the refrigerant passes through the sub-cooling section. The more the heat loss, the higher the efficiency of the Water Cooled Screw Chiller.
• The dissipated heat is transferred to the water flowing in the tubes.
• A part of the refrigerant loses its pressure and becomes vaporized due to passing through the expansion valve, and the expansion process begins.
• The final product is low pressure and a low-temperature mixture of gas and liquid, which enters the evaporator.
• The refrigerant undergoes superheating in the evaporator as it reaches the vapor state. In this way, all the external heat is taken by the Water Cooled Screw Chiller, and the external temperature is lowered.

Working principle of the refrigeration cycle in a water cooled screw chiller

What are the Applications of a Water Cooled Screw Chiller?

The Water Cooled Screw Chiller is mostly used in industry for the following functions;

• HVAC

HVAC refers to the heating, ventilation, and air conditioning of the external environment. The air is dehumidified to create a comfortable environment when the natural conditions are extreme.

• Die Casting

The molten metals need to be poured into molds to give them the desired shape under high pressure.

The five steps of metal casting, i.e. clamping, injection, cooling, ejection, and trimming, need a constant supply of cold water, which solidifies the metal.

• Milk Cooling

A Water Cooled Screw Chiller is necessary for keeping the milk cold so that it does not spoil. In this way, the storage life of the milk can be increased, and it can be easily transported to long distances.

Applications of a water cooled screw chiller

What are the Electrical Considerations for your Water Cooled Screw Chiller?

• All the electrical connections shall be made according to the rules.
• Only copper shall be used as an electrical conductor as it is safe.
• Use the disconnect switch for extra safety while you are servicing your Water Cooled Screw Chiller.
• More than 150 mA leakage can normally occur towards the ground.
• If VFD and phase-cut are used, the leakage can be as much as 2 Ampere.
• The area of installation of electrical connections shall be only accessible to authorized persons.

What are the Standard Codes that Need to be Followed for a Water Cooled Screw Chiller?

A Water Cooled Screw Chiller needs to follow the following certification codes;

• For boilers and pressure vessels, ASME Section VIII is useful.
• The vapor compression cycle for chilling water packages has to follow AHRI 550/590.
• GB/T 18430.1 is only for Chinese products. It is concerned with chilling water packages, whether they are industrial or commercial.
• ANSI/ASHRAE 34 deals with safety and designation numbers.
• These codes make the use of Water Cooled Screw Chiller much well managed and safe for the industries and commercial buildings.

What are the Main Parts of Water Cooled Screw Chiller?

• Compressor

The most important component of a Luxury Portable Bathroom is a semi-hermetic twin compressor which is specially designed for optimum refrigeration and air conditioning.

Each compressor unit comprises almost six patented screw rotor profiles, which makes it efficient and operational.

There is dedicated equipment for the compressor such as discharge temperature thermistors, oil level switch, economizer, axial bearings, and oil differential switch.

The compressor chamber has a slide valve for capacity control.

• Evaporator

The evaporator is equipped with an oil separator demister, a capillary, a solenoid valve, falling film, capillary, lubricant, and gas out. It is of falling film type which contains a shell and a tube. There is cold water in the tubes and lubricant in the shell.

A falling film type of evaporator requires very little refrigerant recharge and greater heat transfer.

The shell is constructed with copper heat exchanging tubes and steel tubes. The cleaning of the refrigerant circuit is done by removing the side steel boxes.

The flow of the refrigerant is made smooth with the help of a distributor located on top of the shell. It flows downwards like a continuous film.

• Refrigeration Circuits

There are separate refrigeration circuits for each compressor. Also, it has valves for drainage. All the refrigeration circuits are well insulated and well equipped with all the safety features.

• Expansion Valve

The vent of the expansion valve allows a steady flow of the refrigerant. The loss of pressure of the refrigerant is also less as compared to the condenser.

In this way, most of the refrigerant reaches the evaporator. Also, the refrigerant level is proportionate to the load on the whole assembly.

The flow rate is controlled when the refrigerant flow through the butterfly-shaped valve is reduced, and the gas amount becomes greater at the vent.

Water cooled screw chiller screw compressor inside view

What are the Features of Control Panel Layout of a Water Cooled Screw Chiller?

The control panel layout of a Water Cooled Screw Chiller has the following features;

• Remote operation through a stop and remote function.
• A clear and wide LCD with a 7 inches screen
• Scheduling features allows you to schedule the function according to your need. It is very useful for holidays.
• The loading is easy and convenient, thus making load startup easy to handle.
• Many safety features for avoiding surge, extreme pressures of the condenser and compressor.
• The most recent technology for advanced controls functions.
• Each function is improved and updated to provide more efficient cooling.
• All the sensors are set automatically and work on the recent technology to provide optimum productivity.
• All the functions can be obtained with a preset option available
• An automatic repeat key allows saving time by using preset values.
• The remote function uses Modbus protocol communication to enable efficient control.

What are the Accessories that Come with a Water Cooled Screw Chiller?

The Water Cooled Screw Chiller coke with the following accessories;

• Compressor Acoustic Enclosure

This accessory enables the Water Cooled Screw Chiller to work silently. It is composed of different panels that have sound-absorbing properties.

It has insulation with foam which allows maximum reduction of sound. You have the option to include it in your unit from the factory.

• Evaporator Options

The evaporator can also be insulated with the help of a thick foam ranging from 19 mm to 38 mm.

• Flow Switch

It helps to keep a check on the water flow. It has a built-in single pole double throw function that gives an optimum output. The working pressure is 1.6 MPa, and the temperature is -10 degrees to 120 °C. Each unit must have a flow switch installed so that the flow can be monitored.

• Power Factor Correction

No matter what the conditions are, a power factor of 95% is required. This accessory enables power factor correction capacitors so that a decent displacement is maintained.

• Non-Fused Breaker

Also called the power disconnect switch, it is useful when the unit is being serviced or repaired. A door interlock is also available. The whole accessory is factory installed, but you can get it separately too.

• Suction Isolation Valve

This accessory comes in a standard Water Cooled Screw Chiller for every refrigerant circuit.

What Kind of Compressor is used in a Water Cooled Screw Chiller?

A Semi-hermetic type of screw compressor with a twin motor system is a major part of the Water Cooled Screw Chiller.

Here are the properties of a semi-hermetic compressor;

• The low speed and direct drive of the compressor increase its efficiency.
• It has only three parts. Therefore, it is simple and requires little maintenance.
• It can be serviced on the field and is very reliable.
• The rotor tip clearance is also precise and accurate.
• The screw tooth is made by using advanced technology, and therefore, it has a silent and smooth operation.
• The screw compressor is also equipped with a refrigerant dispersing device that is responsible for cooling. It uses return refrigerant cooling.

What are the Water Treatment Requirements for your Water Cooled Screw Chiller?

• For maximum productivity, the water in a Water-Cooled Screw Chiller must be clean.
• It must be run through a few tests each time to make sure it is pure from any contaminant.
• The water for the system is first filtered and sieved through so that impurities like wrappers and small stones can be avoided.
• The filtrate now only contains small particles which can be removed mechanically.
• Chlorine can also be added to the water to make it safe to be used.
• The water thus supplied to the Water Cooled Screw Chiller must be very cold and clean.

What is the Importance of Unit Performance Test of a Water Cooled Screw Chiller?

By running a unit performance test, it can be made sure that the Water Cooled Screw Chiller has the following qualities;

• It has all the functions properly running.
• There is no need for replacement or repairing of any part or equipment of the Water Cooled Screw Chiller.
• Several problems can be prevented by running a unit test before dispatching the unit for delivery.
• The speed and efficiency can be monitored.
• The maintenance and running costs can be estimated.
• It is made sure that the function is updated and convenient so that the unit can be easily started.
• A laboratory-grade investigation is also important to assess the performance of the unit.
• The factory test enables you to predict any damages or risks that might be involved with the use of the Water Cooled Screw Chiller.
• It reduces the chances of complaints or returns from the customer.
• Unit performance tests need specific conditions that must be created to obtain maximum output.

How to Install your Water Cooled Screw Chiller?

Here are a few points that you should keep in mind while installing your Water Cooled Screw Chiller;

• Remove the packaging and make sure that all the components and parts are present.
• Carefully observe all the components and see if there are any damaged or unusable parts. Inform the supplier if there are any.
• Read the manual carefully because all the installation should be according to the instructions.
• Also, keep the contract documents and project drawings because they are helpful when you own a Water Cooled Screw Chiller.
• Decide a place where you want to install your unit.
• Create a support structure and then place your Water Cooled Screw Chiller on it with the help of a lifter.
• Make sure that the place is easily accessible so that you can easily operate and maintain your unit.
• Establish a stable electricity connection to make your unit fully operational.
• All the control requirements must be fulfilled.
• In the end, look for any damages or abraded paint areas. This is so that you can fix these problems immediately.

Water cooled screw chiller installation

How to Operate your Water Cooled Screw Chiller?

Here is a list of the things you should do while operating a Water Cooled Screw Chiller;

• Make sure all the electrical and water connections are well coordinated.
• Maintain a steady water flow.
• Now switch on the system and do as it is stated in the manual.
• Never forget to read the manual as it saves time and energy.
• Set the values by using your advanced technology on the PID system.

How to Charge the Refrigerant in your Water Cooled Screw Chiller?

• First of all, open the service valve on the suction pipe. This is done through the Schrader valve on the evaporator and adding the refrigerant.
• The load condition can lie between 25-100 %.
• Make sure that the suction superheating temperature is in a range of 4-6 °C.
• Now add the refrigerant in such a way that there are no more bubbles, and you can view it from the liquid sight glass.
• Also, keep a check on the liquid temperature and pressure to calculate the sub-cooling value.
• The sub-cooling value needs to be in a range of 3-5 °C. It will be higher when the load is 50%.
• Make sure you don’t overcharge the system because it leads to increased pressure in the compressor.

Water cooled screw chiller refrigerant charging

What are the Maintenance Tips for your Water Cooled Screw Chiller?

The following tips must be kept in mind while maintaining your Water Cooled Screw Chiller;

• Carry out the regular cleaning routine along with a monthly and annual cleaning routine.
• Remove any obstructions in the pipelines, filter, and storage areas.
• There should be no biological colonization of bacteria etc.
• All the debris, dirt, and other contaminants must be taken out of the system.
• Keep repairing any damage as soon as it appears.
• Keep a strict check on the water and refrigerant levels.
• All the external and internal cleaning shall be done regularly.
• All the pipelines and ducts shall be thoroughly cleaned now and then.
• Keep a look at the filters and get them changed as soon as possible.

What are the Safety Precautions you Must Follow While Using a Water Cooled Screw Chiller?

Here are a few safety precautions you must take while using your Water Cooled Screw Chiller;

• Make sure that all the electrical connections are secure.
• Keep a check on the water and refrigerant level because it can affect the function and reliability.
• Only a trained individual should operate the machine.
• Prevent the freezing and bursting by the use of a run/stop signal and contact between the cooling pump and the chilled water.
• The automatic valve is connected to the integrated panel and can be remotely controlled.

Here are a few safety measures for a Water Cooled Screw Chiller which make its use convenient and safe;

• Avoid high pressure in the condenser.
• Go for compressor overheat protection.
• Opt for a wire-wound three-phase temperature monitoring
• The low temperature in the evaporator is not desirable.
• Chilled water flow shall include below.
• A reverse phase protection relay is important.
• Enable overcurrent protection.
• Differential oil pressure must be considered.

Only a trained individual should operate water cooled screw chiller

What are the Major Problems you can Face While Using a Water Cooled Screw Chiller?

The major problems that arise from a Water Cooled Screw Chiller are as follows;

• There is a possibility that the electronic valve might be obstructed and is blocking the flow.
• The water pipes cannot be drained because of the position and accessibility issues.
• Refrigerant and oil leaks are very common.
• The refrigerant oil mixture is not uniform, and either the oil or the refrigerant is greater in quantity.
• The exhaust temperature is very low, which hinders the productivity of your Water Cooled Screw Chiller.

How to Troubleshoot the Problems of your Water Cooled Screw Chiller?

One can troubleshoot problems with the following tips;

• Look for the root cause of the damage or the decrease in inefficiency.
• Make sure all the electrical connections are intact.
• All the water connections shall be well managed.
• A steady water supply must be maintained to ensure an optimum water level.
• Keep measuring the refrigerant and oil level to avoid any inconvenience.
• Never use a low-quality refrigerant so that all refrigerant-related problems can be avoided.
• You can also refer to a professional who is capable of dealing with a broken-down Water Cooled Screw Chiller.

Water cooled screw chiller compressor troubleshooting

How to Increase the Efficiency of your Water Cooled Screw Chiller?

The efficiency of a Water Cooled Screw Chiller can be enhanced by taking care of the following points;

• Only a high-quality refrigerant shall be used.
• All the vents and pipes must not have any obstruction.
• There should be no accumulation of any contaminants like sand and debris.
• More parallel compressors can also be added to increase the efficiency of a Water Cooled Screw Chiller.
• A steady supply of electricity is also helpful for increased efficiency.
• The layout shall be easy to understand for all the users.

What are the Routine Check Requirements for your Water Cooled Screw Chiller?

The routine check requirements are that the check shall be carried out by an authorized agency and the Water Cooled Screw Chiller be inspected regularly.

What is the Classification of a Water Cooled Screw Chiller?

A Water Cooled Screw Chiller falls in the fourth category according to the European Directive PED 97/23/EC.

What are the Refrigerant Requirements for your Water Cooled Screw Chiller?

The refrigerant used for a Water Cooled Screw Chiller must be eco-friendly. It shall not damage the ozone layer and must not add to global warming.

What Should be the Evaporator Flow Rate for your Water Cooled Screw Chiller?

The evaporator rate of your Water Cooled screw Chiller should be in the range of 80 to 120 degrees. Neither higher nor lower than this.

Where is the Evaporator Rate Sensor of a Water Cooled Screw Chiller Located?

The evaporator rate sensor of a Water Cooled Screw Chiller is located on the water connection and is operated through a microprocessor. It can deal with the thermal load.

What is the Additional Advantage of an Evaporator Flow Rate Sensor?

An evaporator flow rate sensor also participates in preventing the freezing of the evaporator and its contents in a Water Cooled Screw Chiller.

What is an Inlet Water Sensor of a Water Cooled Screw Chiller?

The inlet water sensor is present on the water connection of a Water Cooled Screw Chiller, and it detects the return water temperature.

What is a Compressor Discharge Pressure Transducer in a Water Cooled Screw Chiller?

It is responsible for controlling the fans and keeping a check on the discharge pressure of your Water Cooled Screw Chiller.

What is the Appropriate Value of Screw Compressor Discharge Pressure of a Water Cooled Screw Chiller?

The normal value should be 1.40~1.60MPa, and the protection value for a Water Cooled Screw Chiller should be set to 2.00MPa.

What Should be the Distance Between Two Pieces of Equipment in a Water Cooled Screw Chiller?

There should be a distance of 1.5 – 2 meters between all the equipment if a Water Cooled Screw Chiller.

Why Is the Distance Between Two Pieces of  Equipment in a Water Cooled Screw Chiller Important?

The Distance between two pieces of equipment of a Water Cooled Screw Chiller is important for additional safety.

How to Avoid the Noise from your Water Cooled Screw Chiller?

The noise from a Water Cooled Screw Chiller can be avoided by using insulation. The insulation can be foam or vacuum.

Water cooled screw chiller noise controlling pads

What is the Most Suitable Refrigerant for a Water Cooled Screw Chiller?

The most suitable refrigerant for your Water Cooled Screw Chiller is R134a.

Why Copper is Used as a Conductor in a Water Cooled Screw Chiller?

Copper is used in a Water Cooled Screw Chiller because it is reliable and corrosion-free.

What is the Maximum Voltage for your Water Cooled Screw Chiller?

The maximum voltage for your Water Cooled Screw Chiller is 150 vac.

What is the Maximum Current for your Water Cooled Screw Chiller?

The maximum current for your Water Cooled Screw Chiller is 2 amperes resistive-2 amperes inductive.

What Should be the Distance Between the Water Cooled Screw Chiller and the Condenser?

The distance between a Water Cooled Screw Chiller and the condenser should be less than 60m.

Is there an Emergency Stop Option in your Water Cooled Screw Chiller?

Yes, there is an option for an emergency stop in a Water Cooled Screw Chiller.

Water cooled screw chiller emergency stop

Does the Compressor of a Water Cooled Screw Chiller need Lubrication?

No the compressor of a Water Cooled Screw Chiller does not need lubrication.

How to Dispose of a Water Cooled Screw Chiller?

A Water Cooled Screw Chiller is made of metal and plastic parts. All these parts must be disposed of following the rules and regulations.