Choosing a Chiller — Factors to Consider - Smart Cooling Products

What Do Chillers Do?

A chiller is a refrigeration system that cools equipment to maintain proper temperatures. It prevents heat damage and ensures systems operate smoothly and efficiently.

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An industrial or commercial chiller system uses refrigerant to absorb heat. Water-cooled chillers use water towers to cool equipment, while air-cooled chillers rely on ambient airflow.

Types of Chillers

The main chiller types include air and water chillers. They are distinguished by their different vapor systems:

• Vapor compression: Low-pressure refrigerant vapor is drawn into a compressor and compressed into a high-temperature and high-pressure gas. The gas then travels to the condenser, where it releases heat to a cooling medium.
• Vapor absorption: The refrigerant vapor is absorbed by a solution like lithium bromide, and this process releases heat. The resulting solution travels to a generator, where a heat source turns the refrigerant back into vapor so it can be condensed into a liquid.

We’ve summarized air and water chillers below to help you better understand them. While both have the same parts, including a compressor, evaporator, expansion valve and condenser, their methods of extracting excess heat differ. This difference is indicated in their titles since air chillers extract heat using air, while water chillers use water to extract heat from the system.

Air Chillers

Fans blow cool air into air chillers to regulate the condenser and prevent it from overheating. These chillers are installed on a building’s exterior, saving internal space.

Water Chillers

In water-cooled chillers, water is pumped through a sealed condenser and sprayed through the cooling tower, extracting heat as the water evaporates. This highly effective method saves more energy and money spent on energy bills.

Some common applications for air and water chillers include:

• Commercial buildings: Support HVAC systems to cool shopping malls, office buildings and other large commercial infrastructure
• Data centers: Maintain IT equipment’s and servers’ ideal operating temperatures, as their heat sensitivity affects their ability to operate optimally
• Cooling systems: Required for food and beverage storage and transportation to maintain their integrity
• Medical and research facilities: Controls temperatures to ensure equipment and biological samples are stored correctly
• Pharmaceuticals: Ensures optimal temperatures for drug production and storage
• The automotive industry: Cools paint booths to maintain the correct temperatures for spray painting and helps control temperatures for vehicle component testing facilities

Considerations When Buying a Commercial Chiller

Before purchasing an industrial chiller, determine the right type for your specifications and choose the best product. Here are some aspects that may influence your decision.

Application

Equipment use is one of the first variables to consider when buying a chiller. Various applications require different chillers, and understanding which kind you need is an excellent start to the buying process.

Size

For many unit applications, size and efficiency go hand in hand. An oversized chiller can consume more energy than necessary, cutting your profit margins. Meanwhile, an undersized chiller may struggle to meet your facility’s needs. A compact chiller that removes the heat from your equipment allows you to cool it effectively while saving energy and money. To determine the correct chiller size for your facility, you must determine the heat load, temperature, flow rate, and coolant type required for your equipment.

While many industrial chiller manufacturers offer mass-produced cooling products, it’s best to partner with one that offers customization. An experienced chiller manufacturer can provide cooling options that meet your industry specifications. When you order a custom-sized chiller, you can rely on it to support your needs.

Location

The ideal chiller relies on your equipment location. Outdoor applications are prone to fluctuating ambient temperatures, while the air surrounding indoor applications may reach excessively high temperatures. Because of these natural temperature differences, indoor or outdoor equipment may require particular sizing or specific accessories such as sump heaters, heat tracing, insulated components, or special controls for components.

Safety

Installing a safe chiller is crucial for your equipment, employees and facility. If you operate in hazardous conditions or process flammable chemicals, an explosion-proof chiller is essential to preventing potential explosions. Only consult with an experienced manufacturer that designs and builds systems to meet National Fire Protection Association standards.

Temperature Control Needs

Choosing a high-quality chiller is vital for work requiring precise temperature control. Reliable, custom-designed chiller systems offer this feature to prevent damage and ensure your equipment operates efficiently.

If your leaving temperature must remain below 35 degrees Fahrenheit, you may require a low-temperature chiller. Choosing the correct chiller ensures your business operations continue smoothly without failure. Reputable manufacturers have the knowledge and technology to design and build quality low-temperature chiller systems, providing you with the necessary temperature control.

Cooling Fluid

Cooling fluid can affect your chiller system, so don’t neglect this factor. Common cooling fluids are propylene glycol mix, Dynalene heat transfer, and water and specialized fluids. Your municipal water supply can contain contaminants that corrode chiller components.

While using a glycol-water mix is always best, your cooling system may require additional filtration if you pull from a city water source. Consult with your manufacturer to determine if your operating temperatures can affect fluid viscosity.

Voltage

Some chillers may have voltages requiring specific electrical work. To decide which type of chiller you purchase, determine what voltage your facility can support and how much electrical work your budget allows. You should also consult the chiller manufacturer about which voltage options support more efficient operation.

Industrial Chiller Cost

Cost is also a critical factor. Before purchasing a chiller, consider its upfront cost, operating costs, potential maintenance costs, and expected life span. Air-cooled systems typically have a higher upfront cost and more installation work than water-cooled systems. They also consume a significant amount of energy to power fans, but they can reduce operating costs because they lack the cooling tower that a water-cooled system requires.

Consider your daily usage. While a central chiller typically costs less than a portable chiller, a portable system may better suit your needs if you need cooling for various purposes at different times.

A chiller’s return on investment depends on its life span. While one model may have a higher initial cost, getting a system with longevity is worthwhile. Comparing different models and designs can help you choose the system with the best financial benefits.

How to Size a Chiller

Sizing a chiller depends on several variables. A critical factor in determining the cooling load requirements is all the heat the chiller must remove and where it originates. For example, several heat sources can exist in a building, including the processes that run machinery and equipment and the heat generated from them. People occupying the space also contribute to the total heat load.

Then, consider heat from external sources such as the temperature outside and heat that infiltrates, especially in warmer climates.

The correct formula helps determine the required chiller size. This process is represented in four steps:

1. Calculate the temperature differential: Calculate this variable with the formula of incoming water temperature (for example, 65 degrees Fahrenheit) minus the required chilled water temperature (55 degrees Fahrenheit). The temperature differential is 10 degrees Fahrenheit.
2. Calculate BTU/hr: British Thermal Units per hour indicate how much heat is removed from a space in an hour. For example, 4 gallons per minute x 60 minutes (4 GPM x 60) x 8.33 x 10 degrees Fahrenheit = 19,992 BTU/hr.
3. Calculate the tons of cooling capacity: Divide the BTU/hr by 12,000 to get the required tonnage.
4. Round up after oversizing the chiller by 20%: Determine the chiller size by multiplying the ideal ton size by 1.2 and rounding it up. For example, if the ideal ton size is 1.666 multiplied by 1.2 to get 1., you’ll need a 2-ton chiller.

To explain this further, if you need to cool 6 gallons per minute (GPM) from 65 degrees Fahrenheit — the incoming water temperature — to 55 degrees Fahrenheit, which is the required chilled water temperature, the flow rate is 6 GPM.

Other factors in chiller sizing include choosing the appropriate chiller type for your application and knowing the required flow rate, inlet and outlet temperatures, and the cooling and buffer capacity.

Why Work With Smart Family of Cooling Products?

Choosing a high-quality chiller is essential — now you know how many factors influence your purchasing decision. Consulting with a reputable chiller manufacturer can help you navigate your options.

Smart Family of Cooling Products manufactures high-quality chillers and offers professional consultation to guide you through purchasing, installation and beyond. Our unique expertise informs clients about their options and determines which systems best meet their needs. When you work with Smart Family, you can discuss your specifications with a knowledgeable engineer who will help you make an informed decision.

Our experts focus on technical details such as application, sizing, location, cooling fluid, temperature control needs, voltage and safety features, equipping us with the information necessary to design and build effective systems.

As a leader in the cooling industry and one of the top chiller manufacturers in the USA, we have experience manufacturing chillers according to custom specifications. We are also one of the few manufacturers able to build explosion-proof and low-temperature systems according to strict codes and standards.

Find the Right Chiller With Smart Family of Cooling Products

Purchasing the chiller that meets your specifications lets you cool your equipment while saving energy and money. Before committing to a product, consider essential details and consult a reputable manufacturer about your application.

Smart Family of Cooling Products can guide you through purchasing by focusing on your needs. We offer reliable, efficient chiller systems to provide your company’s equipment with the necessary cooling you can count on.

Contact us to learn more about our wide range of commercial and industrial chillers, or complete our form for an instant chiller quote!

Portable Water Chiller-An Ultimate FAQ Guide by TopChiller.

What is a Portable Water Chiller?

A Portable Water Chiller is a self-contained configuration system that includes all the essential chiller components to remove extra heat.

It features a unique design configuration and has a small footprint. Different components installed in this single unit include a compressor, process pump, refrigeration circuit, reservoir, electrics, and controls.

It is also mobile making the relocation process easier for you. This is why it is known as the portable. It is always installed close to the process being cooled.

Portable Water Chiller has a diverse cooling capacity range of 1-40 tons. What makes it different from other portable chillers is the particular type of condenser installed in it.

A water-cooled condenser is installed in this unit to eliminate the process heat. It is used to manage small process loads.

It can also be used in applications requiring exceptional flows, temperatures, fluids, or pressures. It is always ideal for temporary use as well as test applications.

Energy Saving Portable Water Chiller Designed by TopChiller

What are the Outstanding Features of a Portable Water Chiller?

A Portable Water Chiller offers many benefits, making your cooling applications easier, efficient, and more convenient. Some of these features are:

• Highly efficient copper brazed plate or stainless steel water-cooled condenser
• PLC control featuring self-diagnostics
• Heavy gauge powder-coated steel cabinet
• Brass service valves with external installation
• Efficient centrifugal pumps with stainless steel construction
• Copper braze plate or stainless steel evaporator
• LAN/WIFI/LTE connectivity to help in predictive maintenance
• Big magnetic contactors

Portable Water Chiller Magnetic Contactors

How Does a Portable Water Chiller Work?

Several steps take place to complete the cooling cycle of a Portable Water Chiller. These steps are broken down for your easy understanding in this section.

• The hot process fluid via the process valve reaches the pump reservoir.
• The pump pulls water from the storage and sends it to the evaporator. This takes place by passing it through a flow switch and a filter.
• The evaporator cools the fluid and returns it to the process via the tube and the process valve.
• The refrigerant is vaporized and turned into a gaseous state by the evaporator. This is accompanied by heat removal from the process fluid.
• The compressor compresses the low-pressure vaporized refrigerant. As a result, it is changed into high-temperature and high-pressure vapors sent to the receiver.
• Municipal water or water tower removes heat from the vapor. As a result, the high-pressure vapor is converted into a high-pressure liquid.
• The expansion valve (TXV) returns high-pressure liquid to the evaporator and converts it to low-temperature low-pressure liquid.

What are the Components of a Portable Water Chiller?

Different parts join together to form a well-functional Portable Water Chiller. Some of the main components are mentioned below, along with their purpose.

Compressor

It comes with highly efficient solid-state interior motor protection. This is rubber-mounted, which helps in the reduction of vibration and noise.

Condenser

During the condensation process, the vapors can cool to a liquid state. This takes place without difference in pressure, latent heat, or temperature.

Expansion Valve

It is necessary to lower the valve opening if the temperature at the evaporator’s outlet is extremely low.

It is necessary to increase its opening if the temperature is higher. This helps in controlling and maintaining the required evaporation temperature.

Filter Dryer

The refrigerant is filtered via molecular sieves desiccant to eliminate traces of moisture and impurities.

Using this filter means you won’t have to worry about it wearing out. This is because it comes with easy operation and indefinite life.

Liquid Line Solenoid Valve

A solenoid valve is installed at the filter dryer outlet. This valve prevents the liquid refrigerant from approaching the compressor when the system is shut down.

Evaporator

The fluid is cooled using a heat exchanger, either a tube in tube type or plate type. The evaporator generates turbulence to improve heat transfer. It is engineered to have a smaller pressure drop than other systems.

Pump

Stainless-steel impeller housing pump features high volume and high and low-pressure maintenance.

A mechanical seal is guaranteed to last for a long time and not leak. Overload is prevented by a safety feature provided by the pump motor.

Tank

When there is reduced heat transfer from a closed tank, FRP or stainless steel well-insulated tank conserves the energy.

Frame

All internal components are approachable for free maintenance. The weather-resistant paint coating is added to withstand tough environmental conditions.

Portable Water Chiller Danfoss Compressor

What are the Benefits of a Portable Water Chiller for your Business?

There are a lot of benefits of using a Portable Water Chiller. Some of the most notable benefits you can get are written below:

• Easy to maintain and repair
• High flow efficiency and performance
• Comes with compact efficiency
• Convenient wash down due to rugged protection
• Highly economical, reliable, and durable

What are the Process Flow Adjustments for your Portable Water Chiller?

A trouble-free and effective operation requires determining and setting the optimum water flow rate.

In the process loop, the pressure losses tell the water flow rate. More significant flow rates generally lead to more turbulent flow, resulting in low maintenance and better temperature control.

The evaporators are usually flow-sensitive; hence, operation efficiency depends on the liquid flow.

In order to achieve maximum Portable Water Chiller efficiency, the flow rate per ton of rated capacity should be around 2.4 GPM.

When the liquid flow is low, the efficiency is reduced. The evaporator might also be damaged in certain situations due to ice building.

The motor overload safety circuit will be tripped with an excessive liquid flow.

For adjusting process flow, follow these steps:

• To start the process pump, turn it on.
• Allow a few seconds for the system to be cleared of any air.
• Look for a consistent reading on the digital coolant pressure gauge.
• Perform flow tests on the unit to see if it is functioning correctly.
• All process valves must be open if a low flow condition exists.

Portable Water Chiller Water Flow Switch

If the flow is low and all process valves are open, the following information should be considered:

• The low refrigerant pressure limit switch might trigger due to low flow.
• A flow bypass must be installed in the processing circuit to run at low flow. There is a chance that a portion of the flow will be redirected back to the Portable Water Chiller.
• As a result, the overall flow remains higher than the limit.
• A bypass may have been pre-installed on some models.

How to Adjust the Low Flow Bypass of your Portable Water Chiller?

Adjusting bypass valves is a critical step for the normal functioning of your Portable Water Chiller. It also helps maintain the flow and prevents the system unit.

1. For Manual Low Flow Bypass Valves

In case of adjusting the low flow bypass valve manually, follow this guide:

• Begin with the bypass valve, which is closed, and slowly open it.
• Stop when the digital display shows that the low refrigerant pressure is in the desired operating range.

1. For Automatic Low Flow Bypass Valves

In case of adjusting the low flow bypass valve automatically, follow this guide:

• The top of the valve has an adjusting stem or a “T” handle.
• When the stem or the “T” handle is turned clockwise, there is a reduction in bypass flow. It is because more pressure is applied to the valve’s spring.
• The spring is relieved, and the counterclockwise bypass flow turns the adjusting stem and “T” handle.
• Keep going until the digital low-pressure display reading for your Portable Water Chiller refrigerant is within the usual operating range. Now stop moving the adjustable stem or the “T” handle.
• Lower the spring pressure to increase bypass if the digital lower pressure display reading is lower than average.

What are the Control Components of a Portable Water Chiller?

Various control components work together in providing smooth and easy control of your Portable Water Chiller. These components are:

• Setpoint lockout jumper
• Illuminated on/off switch
• Probe calibration
• Up and down arrow keys

Portable Water Chiller Controller

What are the Indications Displayed on a Portable Water Chiller?

There are various indications displayed on your Portable Water Chiller. Some of these are:

• Output
• Suction
• Discharge
• To Process
• Display
• Main Menu
• Alarm Codes
• Status Lights
• Water Level
• Percent Loading

Portable Water Chiller LCD

What Does the Water System of your Portable Water Chiller Include?

The automated water makeup system constantly monitors the storage tank, which tops it off as needed. The structure of the water system involves the following steps:

• Fluid pipes or appropriate hoses should be used for building the connection.
• Build a link between the plant’s water supply and the water makeup.
• Makeup water supply pressure should be no less than 20 psi at all times.
• In the makeup water supply line, install a shutoff valve. Outside the unit, attach this valve.
• For the sake of protecting your water from contamination, use a reverse-flowing prevention device. Use one that complies with the local codes.
• When using glycol at temperatures below 48°F, do not use an automated water makeup mechanism.

Portable Water Chiller Water Pump

How to Check the Refrigerant Charge of your Portable Water Chiller?

To the evaporator, the metering devices used are known as thermostatic expansion valves. This remains standard in all Portable Water Chiller models.

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There also is a moisture detector in the sight glass installed in all models. Refrigerant charge should be checked when the system is running normally by taking the following steps:

• Sight glass is covered by a plastic cap that must be removed.
• Let system temperature and pressure settle by turning the system on.
• No foam or bubbles should be seen in the sight glass when running the machine at 100% capacity. It should not be operated in the capacity control mode.
• An experienced refrigeration technician should be called if any foam or bubbles are seen in it. It is because these bubbles are an indication of refrigerant loss.
• The moisture indicator is represented by the “dot” in the center of the sight glass. At all times, it should be green.
• Compressor life is shortened if the color is yellow or white, indicating that moisture has entered the system.
• Replacement of the filter-drier should be done by a refrigeration professional.

What are the Optional Accessories for your Portable Water Chiller?

Different optional accessories available for your Portable Water Chiller are:

Low Flow Bypass Valve

If the process requires flow rates less than those specified in the design, you will need a low flow bypass valve.

Overhead Piping Kit

Installing an overhead piping kit can help keep the storage tank from overflowing when overhead piping is turned off.

In the “from process” line, a full line-size solenoid valve is interlocked with the pump. There is a check valve in the “to process” line (a valve that only moves in one direction).

Process Line Shut Off Valves

To and from process lines are connected via full-size ball valves at the unit exit. The flow rate of the process may be adjusted using these valves.

The flow rate can also be cut off to isolate the Portable Water Chiller.

E-Stop Button

The E-stop button is a mushroom-shaped button that, when pressed, stops all of the activities.

Fused or Non-Fused Disconnect Switch

An on-board disconnection button makes it easy to turn off the unit’s power supply.

Visual and or Audible Alarm

These alarms help in telling about the out-of-spec operation circumstances. Two different types of alarms exist:

Audible Alarm

A simple buzzer can trigger alarms.

Visual Alarm

An audible sound is emitted, and a beacon is flashed.

Reverse Flow Piping

For open-circuit operations, a reverse flow Portable Water Chiller is the best choice. The process functions as the reservoir keeping the flow circuit is nearly the same.

The water is returned to the pump suction under the action of gravity. Since the chiller lacks a reservoir, so external level control and water makeup are required.

Portable Water Chiller Emergency Stop

What Type of Alarms is Present in a Portable Water Chiller?

When the controller detects an alarm, both the specified and displayed process variables alternately flash on display.

When a safe state is reached, these alarming problems should be solved. When a power-up situation exists, additional warnings are displayed, such as RST being flashed on the controller’s display.

The alarm stage is the last place where information is sent to the user. The “on” LED flashes whenever an alarm is triggered.

The controller has three sorts of alarms built-in, which are discussed below:

1-First Alarm Type

The first sort of alarm is a sort of annunciating cycling, and it’s the most common. However, the compressor will continue to run even if this alert is triggered.

This is followed by code flashing contrary to the process variable. These alarms are discussed below:

DtA

The change from the setpoint alert will turn on for a more extended period than allowed by the deviation temperature setting (dT).

This is when the time exceeds deviation temperature ignore time (dtt).

TAH

A warning alert will flash when the process temperature exceeds the alarm setting (htA).

2-Second Alarm Type

Before latching and needing a reset, the second annunciating type will follow three cycles in one hour. This sort of alert is the PAL low refrigerant pressure alarm.

The strobe and the bell will energize when the system is under low pressure. But when the pressure is restored, they will turn off.

PAL

When the lower refrigerant pressure switch detects a low pressure for an extended period, the (Pressure alert low) flashes (lpl), it will cycle thrice in an hour.

3-Third Alarm Type

Latching type alarms are the third type of alarm. The compressor is automatically cut off when this alarm goes off, and it must be individually reset when the problem is fixed.

This sort of alarm indicates excessive sensor and pressure failure. When the alarm is on, the following lights will flash:

RSt

Flashes after a power loss are restored.

PSH

The high-pressure refrigerant switch is illuminated with flashes. A manual reset of the high-pressure switch may be required to recognize this latching alarm.

SF2

It tells that the process temperature sensor is indicating range exceeding.

THS

Indicating that the compressor has been turned off due to the process’s high temperatures, which might cause harm to the compressor (Hts)

FAL

When the low flow state continues for a more extended period than allowed, the flow alarms low light flashes, which must exceed the low flow of ignoring time.

TAL

As soon as the sensor for leaving water senses a temperature lower than the low-temperature alarm setpoint, the compressor is switched off (spl).

The compressor maintenance alarm serves as the final alarm. The run light flashes, but the display would not show that an alert has occurred.

How to Replace the Components of your Portable Water Chiller?

For replacing your Portable Water Chiller components, follow these steps:

• Disconnect the power source.
• Open the chiller and locate the component to be replaced.
• Remove the component.
• Install the new component at its designated place properly.
• Close the chiller.
• Turn on the power source.
• Check if the replaced component is working correctly or not.

Portable Water Chiller Parts Replacement

What are the Precautions Related to a Portable Water Chiller?

When using a Portable Water Chiller, you should consider some essential precautions.

Remember that following these precautions will provide you with trouble-free operation and use. Some of these points are:

• You must get well familiar with your Portable Water Chiller and its user manual for easy operation and usage.
• The owner must see that the equipment is properly installed, operated, and maintained.
• Examine the warning and safety notices of your unit. Operator injury or death and severe mechanical damage might happen if all warnings are not observed.
• Due to the excessive refrigerant charge and voltage, all safety measures must be followed throughout the installation, starting, and service period.
• It should only be installed, started, and serviced by professionals.
• Precautions in the labels, handbook, tags, manuals, and stickers on the equipment should be followed during the operation.
• Wear safety goggles and gloves while working.

Some Important Warning Labels

Some important warning labels always displayed on the unit for safe operation are:

• Dangers of excessive voltage.
• Under-Pressure refrigeration system.
• Only technical expertise is required to repair the system.
• You might be injured by misusing this equipment.
• Before installing or servicing your equipment, always turn off the power and isolate the area.
• The refrigerant in this device is under high pressure.
• Refrigeration leaks can cause physical harm and property damage if released under high pressure.
• When operating on or around this equipment, use caution.
• In line with ASHRAE/ANSI Standard 15, install all refrigerant relief valves accordingly. Follow the complete Safety Code for Mechanical Refrigeration.
• There should be plenty of ventilation for the unit operation
• It is dangerous to inhale refrigerants. This is because the accumulation of refrigerant in a confined environment can disturb oxygen levels oxygen. As a result, workers might suffocate.

What are the Control Errors and their Solution of a Portable Water Chiller?

The different control errors often observed in a Portable Water Chiller and discussed below:

Error No 1

Control is not lit up, and the system is not operating.

Solutions

• Plug the power cord correctly.
• Look for any power cord damage.
• Check fuses and breakers.
• Check the voltage and power being supplied.
• See the TIC indicator lights. Replace if needed.

Error No 2

The control is lit up, but the compressor is not operating.

Solutions

• Observe the primary supply voltage.
• Check the fuses.
• Observe the phase to phase voltages.
• Look at phase continuity and compressor wiring.

How to Troubleshoot your Portable Water Chiller?

For troubleshooting your Portable Water Chiller, follow these guidelines:

High Discharge Pressure

Remove the unwanted condenser gas.

Compressor not Working Efficiently

Charge the refrigerant.

Low Suction Pressure

Replace the suction switch.

Poor Outlet Temperature

Decrease flow to rate capacity.

Heavy Noise Production

Install it on a leveled surface.

Low Water Trip

Rectify the tank problem.

Inefficient Portable Water Chiller Temperature

Protect from heat and provide sufficient ventilation.

Portable Water Chiller Troubleshooting

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