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

Water Cooled Water Chiller: The Ultimate FAQ Guide

If you have any questions about water cooled water chiller, your answers are right here.

This guide covers everything about water-cooled water chillers such as components, working principles, specifications, safety features, and benefits, just to mention a few.

Keep reading to learn more.

What is Water Cooled Water Chiller?

A water-cooled water chiller is a device that facilitates the transfer of heat using water in its system from an internal environment such as a building to an external environment.

A water-cooled water chiller always depends on the state of the circulation of the refrigerant through the system.

Water-cooled water chiller

What are the Benefits of Water Cooled Chillers?

• Longer lifespan: water-cooled water chillers do not require frequent replacement of the parts because they do not encounter outdoor factors that may damage them.
• Quiet operation: the flow of water through water-cooled water chillers does not produce any noise and is thus very efficient for silent environments such as schools and hospitals.
• No open space needed: water-cooled water chillers do not need an open space for operation as they are kept inside buildings. Therefore, water-cooled water chillers are appropriate for companies that lack enough space on the outside of the building.
• Energy efficiency: water-cooled water chillers transfer energy more efficiently enabling businesses to save on energy costs.
• Safety: water-cooled water chillers use water as a refrigerant rather than chemicals which makes them safer for people operating the system.

Are there Limitations of Water Cooled Chiller Systems?

• Higher cost: water-cooled water chillers are relatively expensive because they need additional parts like towers for cooling and water pumps for the condenser.
• Maintenance: water-cooled water chillers have required more maintenance as they contain a lot of additional parts which need frequent monitoring and servicing to ensure efficient functioning of the system.
• Complicated installation: water-cooled water chillers are difficult to install because they have a lot of parts that result in increased labor installation costs.
• Requires mechanical room: water-cooled water chillers require a mechanical room therefore businesses have to incur an additional cost for this.

How do Water-Cooled Water Chillers Compare to Air Cooled Chillers?

Water-cooled water chillers and air-cooled chillers have the following comparisons:

• Water-cooled water chillers are preferred for large installations while air-cooled chillers are preferred for medium and smaller installations.
• A condenser is a component in air-cooled chillers that cools the air blown in while water-cooled water chillers comprise of condenser whose temperature is lowered by water connected with a cooling tower.
• Water-cooled water chillers are costly to operate and maintain as compared to air-cooled chillers.
• Water-cooled water chillers specification is measured in kW/ton that ranges from approximately 0.55 and 0.8kW/ton that is different from an air-cooled chiller that has a different load.
• Water-cooled water chillers are preferable in areas where water supply is sufficient while air-cooled chillers are preferably used in areas where water supply is not constant or where water is very expensive.
• Air-cooled chillers are preferred for all-weather use including freezing conditions, unlike the water-cooled water chillers that cannot be used in winter conditions.
• Water-cooled water chillers need to be set up where there is a constant flow of water while air-cooled chillers can be set up at any location as long as there is a source of power.

Air cooled chiller

What are the Components of Water-Cooled Water Chillers?

Components of a water-cooled water chiller include:

• Compressor: this is the driving force of the water-cooled water chiller. The four main categories of compressors are/ include screw, scroll, reciprocating, and centrifugal.
• Condenser: these are the pipes where the air is moved across the condenser to dissipate unwanted heat.
• Condenser fans: the fans are the main components that differentiate between air-cooled and water-cooled chillers.
• Evaporator/Expansion valve: this works with the heat exchanger to change the air from cold to hot and vice versa. The three types of evaporators are brazed-plate, direct expansion, flooded shell-and-tube
• Filter drier: protects the chiller from contaminants such as dust and should be replaced regularly.
• Auxiliary safety and control parts: this includes water pump, flow switch, safety valves, expansion valves, and temperature sensors.
• Electric control board and LCD thermostat.

Water cooled water chiller shell and tube condenser

How does Water Cooled Water Chiller Work?

A water-cooled water chiller works in the following way:

• Compression and absorption: a water-cooled water chiller works by compression of vapor and absorption of vapor.
• Coolant: water-cooled water chillers ensure the flow of the coolant at a temperature of about 50 degrees Celsius to the cold side of the system.

Pumping of the coolant through the system eliminates heat out via one area of the system and flows back via another side.

• Vapor compression: the water-cooled water chiller uses a mechanical refrigeration system for vapor compression.

It connects the process water system using an evaporator.

• The refrigerant then circulates via the parts of a water-cooled water chiller.
• Evaporator: evaporator works by helping in the heat exchange process by making sure that the cooling purpose of the water-cooled water chiller is achieved.
• Heat transfer: this process causes the evaporation of the refrigerant into a vapor with low pressure while ensuring the temperatures of the coolant are reduced.
• Compressor: once the refrigerant gets into the compressor, it carries out the following functions:

a) Removal of refrigerant: the compressor removes the refrigerant out of the evaporator while at the same time ensuring that the pressure in the evaporator is at the right temperature for the absorption of heat.

b) Raising pressure: the compressor increases the pressure of the refrigerant leaving the system to ensure maintains the right temperature and reaches the condenser with the right heat.

• A cooling medium (water) then carries to the environment the heat that is produced when the refrigerant changes to a liquid.

How do you Calculate the Cooling Capacity of a Water-Cooled Water Chiller?

To calculate the cooling capacity of a water-cooled chiller, the following should be put to mind:

• Volume rate: this is the water in the evaporator.
• Temperature: this is the water temperature both in the inlet and outlet.
• The density of water: determine it at the average temperature.
• Heat capacity: determined at the average temperature.

After determining the above factors then you can calculate the capacity of the water-cooled chiller.

When should use Water Cooled Water Chiller?

Water-cooled water chillers are purposely used for cooling purposes; they turn hot air into the cold air and vice versa by the use of water in their system.

Some of the applications of air-cooled chillers include

• They are used in large industries to cool production processes and machinery.
• They are used in huge residential buildings to cool hallways and common areas.
• Are used in large-scale industrial cool rooms to keep products such as meat and vegetables fresh.
• Used in hospitals for air circulation purposes.
• Water-cooled water chillers are also popular in the retail environment where large stores use them for cooling purposes.

How do you Determine the Working Temperature of the Water-Cooled Water Chiller?

Some of the determinants of the working temperature of a water-cooled water chiller system include:

• Exhaust temperature, when it’s high the temperature also goes up.
• Compressor housing temperature, when it’s high the temperature of the water-cooled chiller goes high.
• Condensation temperature, when it’s hot the temperature drops and vice versa.
• Condenser shell temperature: should be hot in the upper half and warm in the lower half.
• Reservoir temperature
• Filter and liquid tube temperature.
• Suction tube temperature.

How do you Increase the Efficiency of a Water-Cooled Water Chiller?

The efficiency of water-cooled water chillers can be increased by:

• Inspection and cleaning condenser coils: heat has a large impact on water-cooled water chillers and therefore frequent inspection of condenser coils for clogging and cleaning them is important.
• Maintaining refrigerant charge: water-cooled chiller cooling ability depends on the refrigerant level.

Therefore, maintaining a refrigerant charge will impact energy efficiency and reduce cooling costs.

• Maintaining condenser water: condenser water must maintain proper flow.

It is to ensure the efficiency of the water-cooled water chiller.

Thus the frequent observation of debris such as sand, contamination materials, and erosive solids was looked at.

Inspection and cleaning water cooled water chiller condenser coils

What is the difference between Water Cooled Water Chiller and Air-Cooled Water Chiller?

Water-cooled water chillers and air-cooled water chillers have the following differences:

Capacity: water-cooled water chillers have a capacity of 10 to 4000 tons (35 to 14,000 KW) while air-cooled water chillers have a capacity of 7.5 to 500 tons (25 to 1580 KW).

Maintenance: water-cooled water chillers require cooling towers while air-cooled water chillers do not require cooling towers.

Location: water-cooled water chillers are located in buildings inside a room known as a mechanical room while air-cooled water chillers are mostly placed outside buildings.

Energy efficiency: water-cooled water chillers save more on energy thus reducing operating costs and compared to air-cooled water chillers which use high amounts of energy.

Delivery and installation: air-cooled water chillers have packed systems.

All parts are configured together as one.

This simplifies installation while water-cooled water chillers have additional parts such as condenser water piping, pumps, cooling towers, and controls thus complexity in installation.

Longevity: water-cooled water chillers have a longer life span of 20 to 30 years while air-cooled water chillers last 15 to 20 years.

Air cooled water chiller

What Causes Water-Cooled Water Chiller to Fail?

The following features can cause a water-cooled water chiller to fail:

1. High-pressure discharge: this is mainly caused by the use of bad water treatment regimes. Before installation, you should make sure the building has strict water treatment regimes in place.
2. Low-pressure discharge: this comes about if the suction valve is partially closed and therefore to avoid this, frequently check the water-cooled water chiller to ensure the suction valve is always open.
3. Low suction pressure: this result is due to a low refrigerant charge. You should always check around the water-cooled water chiller system for signs top-ups needed and in case of any leaks.
4. High suction pressure: this is caused by:

• Excessive load: this comes about when the load in the system is too much for it to handle. You should reduce the load or spread it among water-cooled water chillers so that the system can work efficiently.
• Overfeeding: the expansion valve might be overfeeding refrigerant so you should check if it requires changing the expansion valve or adjusting the superheat set point.
• Overcharging: another cause of high suction pressure could be the chiller overcharged with refrigerant.

This can be avoided by checking set points, temperatures, and pressures around the system to make sure they are okay and then removing any excess refrigerant.

5. Electrical faults: water-cooled water chillers can experience electrical faults due to an unbalanced voltage supply.

To avoid this, you should measure your voltages frequently to make sure they are always balanced.

6. Controls: this occurs when the flow sensor breaks more so do the paddle sensors.

It can be avoided by checking the water-cooled water chiller system before turning it on.

It is to ensure that there is sufficient flow of water through the evaporator and the condenser preventing it from freezing.

How do you Maintain Water-Cooled Water Chiller?

I. Daily maintenance procedures for water-cooled water chillers will entail:

• Turning off or sequencing unnecessary chillers
• A complete inspection of the system of water-cooled water chiller to ensure that all the equipment is operating and there is safety.
• Checking off all the setpoints to ensure proper setting and function.

II. Monthly maintenance procedures for water-cooled water chillers will entail:

• Assessing condenser and evaporator coil to ensure it is as required.
• Checking the temperature to ensure that it is as per the manufacturer’s specifications.
• Conduction a leak test to ensure that all compressor fittings, relief valves, and pump joints are not leaking.
• Checking the insulation condition to ascertain that it is appropriate
• Verifying proper control functioning including verification of hot gas bypass and liquid injection.

III. Semiannual maintenance procedures for water-cooled water chillers will entail:

• One should thoroughly go through the manuals that come with the water-cooled water chillers to ensure that they are as per the manufacturer’s specifications.

IV. Annual maintenance procedures for water-cooled water chillers will entail:

• Checking all the alignments on the compressor and assembly to ascertain that they are as per the manufacturer’s specifications.
• Checking all the seals on the compressor and providing lubrication where needed.
• Conducting an analysis of the compressor oil system and changing the necessary oil pumps and seals and having a look at the oil heater, strainers, valve, and thermostat.
• Checking all the electrical connections and the terminals to ensure contact and tightness.
• Recording the amounts of refrigerant level and condition and addressing any leakage issues.

Water cooled water chiller fault checking

How do you Specify Water-Cooled Water Chiller?

• Check for maximum temperature: water-cooled water chillers have a maximum ambient temperature of 40 to 45 degrees Celsius.
• The minimum temperature: The temperature of water-cooled water chillers ranges between -12 to 15 degrees Celsius.
• Check for voltage: The voltage range of water-cooled water chillers is 400 volts.
• Capacity: The design capacity of water-cooled water chillers is about 603 KW.
• Check for airflow: The maximum airflow of water-cooled water chillers is about 24.8 to 35 L/S.
• Check the hydronic module: water-cooled water chillers have a built-in hydronic module.

What are the Types of Water-Cooled Water Chiller Condensers?

The types of water-cooled chiller condensers include:

• Shell and coil condensers: these area type of water-cooled water chiller condenser are made of steel and has copper tubes inserted in the shell.

It works by water circulating through the tubing and condensing hot gases to form a liquid.

• Shell and tube condensers: the capacity of shell and tube condensers range between 7 KW to 3500 KW of refrigeration.

They have diameters of between 100 mm to 2 meters.

The ends of the shell and tube condensers are removable to allow mechanical cleaning of the water tubes.

• Double tube condensers: this is the most popular water condenser because it can be manipulated to fit the size of the unit to be cooled.

In double tube condensers, one tube is put within another.

It is in such a way that the refrigerant in the outside tube is cooled by water passing through the inside tube.

How Long does it take to Manufacture Water Cooled Water Chiller?

The time taken to manufacture a water-cooled water chiller varies depending on the specifications required, the design, the size, and the time of the year.

The typical time taken to manufacture a water-cooled water chiller is 4 to 6 weeks.

Water cooled water chiller finished manufacturing

How do you Choose Water Cooled Water Chiller Installation Area?

Some of the factors to consider when installing a water-cooled water chiller include:

• Install the water-cooled chiller away from fire.
• Store the water-cooled chiller in a clean environment free from dust.
• Ensure that the installation site has an adequate light to allow for easy maintenance and inspection.
• Ensure that the installation site has sufficient space for tubing.
• Ensure that the installation room/space is high and wide enough for installation purposes and to allow air circulation.
• Ensure the installation site is drained well and water flow is uninterrupted.

How much do Water-Cooled Water Chillers Cost?

Water-cooled water chillers vary in cost depending on kW/ton, model, and power supply voltage.

Some other factors that also determine the cost of water-cooled water chillers include:

• The maximum ambient temperature.
• Minimum ambient temperature.
• Maximum R.H.
• The type of cooling system.
• Unit structure for instance integral
• Cooling method.
• Selected voltage
• Noise level

Putting the above factors into consideration, a water-cooled water chiller can cost anywhere from as low as $400 to as much as $500000.

Our Water Cooled Water Chillers Assembled on Site or Factory?

Water-cooled water chillers come partly assembled to make it easy to assemble the various components on-site.

Some require you to assemble components such as water pump, flow switch, safety valves, expansion valves, and temperature sensors, filter drier, expansion valve condenser, and compressor on site.

Some components like filters also come uninstalled.

How much Power do Water-Cooled Water Chillers use?

Water-cooled water chillers consume about 10,737 MWh that is 51 percent of the total consumption energy of electric energy for different percentages of loading in the system.

The use of efficient water-cooled water chillers helps to cut down annual power consumption by about 8368 MWh.

Do Water-Cooled Water Chillers Require Cooling Towers?

Yes, water-cooled chillers require cooling towers to use water to cool the refrigerant in the condenser.

The cooling water and refrigerant do not come into direct contact as they flow in separate tubes within the heat exchanger for efficient heat transfer.

Water cooled water chiller cooling tower

What are the Safety Features of Water-Cooled Water Chillers?

Some of the safety features of water-cooled water chillers include:

• Power circuits come with fuses
• Compressors have thermal overloads.
• All pump motors have thermal overloads.
• All fan motors have thermal overloads.
• Chillers are equipped with anti-freeze thermostats.
• Motors are equipped with over-temperature cut-outs.
• Timers prevent the water-cooled chiller from a not short cycle.
• Compressors have low-pressure switches.
• Compressors are also equipped with high-pressure switches.
• Compressors are equipped with oil pressure protection.
• Condenser and chilled water lines are equipped with flow switches.
• Receivers are equipped with fusible plugs and pressure relief devices.
• Alarms and temperature devices are installed in the plant room.

Water-cooled water chiller emergency stop button

What Material are Water-Cooled Water Chillers made of?

Water-cooled water chillers have many different components made from different materials.

The dominant materials used are copper for the tubes for the refrigerant flow.

Some of the other materials used are plastic tubes to reduce weight and cost.

Copper and aluminum are widely used because of their superior thermal properties.

What are the New Technological Developments in Water Cooled Water Chiller Technology?

Some of the new technological developments in water-cooled water chiller technology include:

• Energy efficiency
• Reduced carbon emissions.
• Quiet operation and low maintenance
• Smaller and more efficient chillers.
• Easing the transition to lower-GWP refrigerants.
• Advances in oil-free chiller technology

What are the Quality Standards for Water Cooled Water Chiller?

Quality standards of water-cooled water chillers depending on the country of origin include:

• Australian/ New Zealand Standards: AS/NZS 4776.2-2 00
• California Public Utilities Standards: (CSA) CSA-C743-09
• Canada/ United Kingdom standards; GB 19577-200 4
• Canada standards Association: CNS 12575-200 7
• China standards: EMSD, HKSAR
• Hong Kong Standards: ASHRAE Standard 90.1-2013
• Cooling Technology Institute
• BSCIC ISO 9001

At TopChiller, we have a range of custom water-cooled water chillers for the specific needs of your process.

Talk to our team now for free consultations or inquiries about water-cooled water chillers.

100% quality tested water cooled water chiller