Chiller Units Industrial

      There are many plastic products factories, or friends who need chiller to cool the circulating water and circulating oil used by the machine. When buying chiller units industrial, they often do not know what type of chiller to use to achieve the refrigeration effect of their requirements, or they do not know what kind of machine is more suitable for their own production workshop. So now, let me tell you some simple selection methods. I hope I can help my friends.

1. Classification of chiller units industrial:

First of all, what types of chiller units industrial are there? The chiller produced by general manufacturers is divided into water cooling and air cooling.

Air coolers, in its body contains heat preservation water tank and water pump, no need to add cooling tower to heat. Very easy to install and move. But it has higher requirements for the working environment. First of all, because it is cooled by hot air circulation, if the ventilation effect of the installation workshop is not good, it will directly affect the refrigeration effect of the chiller. In addition, if you want to put the chiller in a dust-free workshop with humidity requirements, then I advise you to change to water-cooled. Because wind coolers, they blow steam out of the roof to cool the heat.

Water coolers, and can be divided into open chiller, sealed (some called box chiller) and screw chiller. First of all, it should be declared that water-cooled chiller should be equipped with cooling water tower and pump to extract hot water for heat dissipation. In order to achieve better cooling effect. Open water chiller, but also install another water tank, sealed type is not necessary, because he has a built-in water tank. The open type is generally installed outside the workshop for easy maintenance, but because it is not beautiful enough, the sealed water-cooled chiller is produced. Sealed water cooler is a box structure, easy to install, easy to use, more popular in the current customer base. But if your requirements for refrigeration capacity are very large, it is necessary to choose a screw chiller. At this time, we generally call it a chiller. Most manufacturers, if you require more than 100HP for the compressor of the chiller, we will recommend you to use a screw chiller.

2.The difference between wind coolers and water coolers

2.1 Take a look at supporting equipment

Basic configuration of chiller units industrial: equipped with single chip control system, built-in compressor filter dryer and expansion valve, maintenance hand valve interface and other devices, to ensure reliable and safe operation of the machine convenient maintenance.

The supporting equipment of the wind cold water cooler is the frozen water pump separator and water collector, and the water cold water cooler needs the special cooling tower water collector and water separator in the machine room. The supporting equipment required by the water cold water cooler is more, and the early equipment investment is larger. Generally speaking, the wind cold water cooler with the same size is cheaper than the water cold water cooler.

2.2  in the use of the environment

Because there is no need to install cooling water tower, the air cooler is suitable for the environment with poor impurities, so the noise of the air cooler is large.

Water coolers have low noise and are suitable for the environment with good water quality because of the need to install cooling water tower. If the water quality is poor, it is easy to block the machine waterway, causing greater economic losses.

2.3 refrigeration technology

Because the heat transfer efficiency of water is much greater than that of air, the energy efficiency of water-cooled chiller is 300 to 500 kcal/h higher than that of air-cooled chiller.

2.4 in terms of power consumption

The total power consumption of the water-cooled chiller (including the power consumption of the cooling pump and the cooling tower fan) is about 25% lower than that of the air-cooled chiller.

Because the heat transfer temperature difference of water cooler condenser is generally 4℃-8℃, while the heat transfer temperature difference of wind cooler is generally 8℃-15℃, at the same outdoor environmental temperature, the water temperature of cooling circulating water is lower than that of outdoor air, so the condensation temperature of air-cooled unit in normal operation is much higher than that of water cooler. Thus, the power consumption of the air-cooled unit is larger than that of the water-cooled unit at the same cooling capacity.

2.5 in terms of heat dissipation

Wind coolers rely on the top of the electric fan for heat dissipation, environmental requirements, such as ventilation, humidity, temperature can not be 40°C, air ph value, etc., and water coolers need to use water tower to disperse water for heat dissipation.

2.6 In refrigeration technology

There are four universal wheels at the bottom of the wind cold water cooler, which can be easily moved and reduce the floor area. The water cold water cooler needs to be connected to the cooling tower before it can be used. Therefore, the water-cooled chiller occupies a large area and needs to provide a machine room, and the water-cooled chiller must be placed indoors.

2.7 in cleaning and maintenance

Within a certain range of dirt accumulation, the shell and tube condenser used by water coolers has a small impact on the heat transfer efficiency. Therefore, the unit performance decreases with the occurrence of dirt in a small range, the cleaning cycle is long, and the relative maintenance cost is low. However, the heat transfer efficiency of finned condenser used by wind coolers is greatly affected by the accumulation of ash scale. Dust filter grids must be set before the heat dissipation finned tubes, and frequent cleaning is required.

2.8 Maintenance

Due to the high operating pressure of the air-cooled unit, it is generally installed outdoors, and the operating environment is relatively harsh, which is inferior to the water-cooled chiller in terms of maintenance and reliability. If the machine has the problem of alarm or convenient temperature control, it is necessary to send engineers to visit and make a quotation for maintenance according to the site situation, so the maintenance cost of water coolers and air coolers also depends on the specific situation.

Both air-cooled chillers and water-cooled chillers are more choices in the industrial refrigeration industry. If you choose a chiller in an actual factory, you still need to use different environments, temperature control ranges, required cooling capacity, heat dissipation, etc. All factors to consider whether to choose an air-cooled chiller or a water-cooled chiller.

3. Operation instructions of the chiller

3.1 During installation, please check whether the machine is damaged, and choose a suitable place to facilitate installation and future maintenance.

3.2 The installation site of the unit must be the floor, installation pad or foundation, its level is within 6-4mm, and can bear the operating weight of the unit.

3.3 The unit should be placed in a computer room with a room temperature of 4.4-43.3°C, and there should be enough space around and above the unit for routine maintenance.

3.4 At one end of the unit, there should be a draining space for cleaning the condenser tube bundle, or a door opening or other suitable openings can be used.

3.5 Select the water pipe with the appropriate diameter, the cooling system and the cold water system when the unit is running at the maximum power, and connect them correctly.

3.6 For common applications, the speed of water flow through the evaporator and condenser is allowed to be between 1.0-3.6m/s.

3.7 Under any load conditions, the water flow should remain stable.

3.8 The design and installation of all chilled water and cooling water pipes should be carried out in accordance with conventional methods, and the chilled water pump should be located on the inlet pipe of the unit to ensure positive pressure and flow in the unit. Vibration-absorbing pipes should be installed to ensure proper elasticity during piping, and also to prevent the water from the evaporator from being drained when the pump is stopped.

3.9 The piping should have a firm support independent of the chiller to avoid stress on the chiller components. The hanger should be set to facilitate pipe alignment.

3.10 In order to reduce noise and vibration, it is best to install vibration isolators on the pipeline.

3.11 In order to use the chiller economically and effectively, it is recommended to ask water treatment experts to analyze the water quality of the evaporator and condenser. Poor water quality will cause fouling and affect heat transfer, or produce corrosion deposits, breed organic matter, and affect the performance of the unit. Increased operating and maintenance costs.

3.12 In general, proper water treatment and regular cleaning of the tube bundle can maintain its good performance. If the existing water quality conditions cannot be improved by appropriate methods, then it is necessary to consider allowing the tube bundle to have a larger fouling factor or designation. Specialized construction materials.

3.13 Please install a filter at the inlet of the water pipe and clean it regularly.

3.14 After the leak test is completed, all nozzles must be treated with anti-rust treatment.

4.The equipment of the chiller:

4.1 Compressor;

4.2 Pump;

4.3 Computer PC board, touch control, safe and convenient;

4.4 Thermostat: LCD temperature control electronic board;

4.5 Expansion valve, filter;

4.6 One 304 stainless steel water tank with a built-in outer cover of thermal insulation material;

4.7 Electrical appliances

4.8 Safety protection system

◎Compressor delay start protection

◎Ice water pump overload and indicator light

◎Compressor overload protection

◎Motor reverse protection and indicator light

◎Compressor overload protection and indicator light

◎Insufficient refrigerant protection and indicator light

◎Refrigerant high pressure safety valve

◎ Poor heat dissipation protection and indicator light

◎Fault alarm buzzer

5. The role of chillers on plastic machinery:

5.1 The chiller is used in the cooling of plastic processing machinery molding molds, which can greatly improve the surface finish of plastic products, reduce the surface marks and internal stress of plastic products, make the products not shrink or deform, facilitate the demoulding of plastic products, and accelerate the finalization of products. Thereby greatly improving the production efficiency of the plastic molding machine;

5.2 The chiller is used in CNC machine tools, coordinate boring machines, grinders, machining centers, combined machine tools and various types of precision machine tool spindle lubrication and hydraulic system transmission media cooling. It can accurately control the oil temperature, effectively reduce the thermal deformation of the machine tool, and improve the The machining accuracy of the machine tool.

6. Warm reminders for the selection of chillers:

6.1 The temperature difference of the standard chiller is 5 degrees, (20 degrees to 15 degrees), if a FCA-10 chiller has a standard chiller flow rate of 3.5 cubic meters per hour. So when you try this chiller, you can't just look at the flow of the chiller, but also the temperature you need. If the temperature you try is dropped from 58 degrees to 7 degrees, and the temperature difference is large, then Reduced chilled water flow per hour from 3.5 cubic meters to more than 1 cubic meter. If you need a chiller with a flow rate of 3.5 cubic meters per hour, choose a larger model.

6.2 When trying out the chiller, it depends on whether you are cooling directly or indirectly. Direct cooling is to put the water directly into the chiller, and the frozen water comes out directly to cool the product you need. The effect of direct cooling is obviously better. Indirect cooling is equivalent to putting water in a basin, placing a small basin on top of the basin, and placing the product to be cooled in the small basin. Relatively speaking, the effect of indirect cooling is less. Therefore, you should take this into consideration when choosing a model.

6.3 Some users use the pool for cooling, which has the following disadvantages:

(1) The water quality is poor, and it is easy to block the water channel of the machine, causing greater losses.

(2) Waste water resources and increase user costs.

(3)When the weather is too hot, the water temperature cannot meet the requirements, affecting product quality and efficiency.

7. The application of chiller units industrial

In recent years, with my country's accession to WTO, the manufacturing industry has entered a golden period, and the requirements of product quality have also been greatly improved due to the fierce market competition. In fact, in the process of improving products, manufacturers often overlook a subtle but important factor. In the production process, due to the continuous generation of heat by machinery, molds and industrial reactions, when the temperature exceeds the tolerance level of the material, the product quality will be unstable. Take plastic products and electroplating production as an example. The cooling time in the production of plastic products accounts for more than 80% of the whole cycle. , The importance of reducing the cooling time can be seen from this, the frozen water can absorb heat in time, so that the temperature of the mold cavity can be quickly reduced, the product setting can be accelerated, and the opening surface can be shortened. In electroplating production, chilled water can reduce the temperature of the electroplating solution and keep the temperature constant within a certain range, so that the metal molecules can quickly attach to the surface of the plated parts with a stable current, so that the product is smooth and the density is increased.

Industrial chillers (temperature range: +20°C TO -25°C adjustable) are widely used in a variety of industrial production -- 1. Chemical (science) industry 2. Plastic products, plastic containers, film making, plastic steel profiles, pipes, wires , cable sheath, tire industry 3. Electroplating and machine tool cutting fluid cooling industry 4. Pharmaceutical industry 5. Electronics industry 6. Hardware industry 7. Food and beverage industry 8. Footwear industry 9. Laboratory 10. Medical equipment 11. Optics instruments, etc.

1. Chemical Industry

It is mainly used for the cooling and cooling of chemical reaction kettles (chemical heat exchangers), to take away the huge heat generated by chemical reactions in time to achieve the purpose of cooling (cooling) to improve product quality.

2. Manufacturing industry of plastic products, plastic containers, food packaging films, medical packaging films, etc.

a. In the injection molding process of plastic products (TVs, computers, washing machines, mobile phones, refrigerators, air conditioners, plastic toys, auto plastic parts, etc.) Appearance qualification rate, thus affecting production efficiency, production costs and corporate profits.

b. The production of plastic containers (bottle blowing) and packaging films is even more inseparable from the chiller (ice water machine). If the plastic container cannot be cooled and shaped in time during the production process, the produced container will not be full, the wall thickness will be uneven, the color will not be bright, or even unable to be formed, resulting in lower product quality. In the production of packaging film, if there is no cooling and forming of cold water (wind), qualified products cannot be produced. If the cold water (air) provided by the chiller (ice water machine) is used for cooling, it can not only greatly improve the product quality, but also improve the production efficiency.

3. Cooling of electroplating liquid, hydraulic oil and machine tool cutting tool coolant

a. In electroplating production, the electroplating solution generates heat continuously in the electroplating reaction, so that the temperature of the electroplating solution gradually increases. When the temperature of the electroplating solution exceeds the requirements of the process, it will affect the firmness of the plating on the surface of the produced electroplating products. Uniformity, flatness and surface finish have a greater impact. Choosing to use the chilled water provided by the chiller (ice water machine) to cool and maintain the constant temperature of the electroplating solution will greatly improve the electroplating production process and production efficiency.

b. The cooling of the cooling liquid of the machine tool cutting tool and the control of the temperature of the tool edge will directly affect the service life of the tool and the quality of the product.

4. Pharmaceutical Industry

The pharmaceutical industry is mainly used for the control of temperature and humidity in the production workshop and the removal of reaction heat during the production of APIs.

5. The electronics industry

In the production process of electronic components, it is necessary to keep or cool the components at a specific temperature, so that the performance parameters of electronic components can be controlled in the designed state.

8. How to choose a chiller for an injection molding machine

When domestic vertical and horizontal injection molding machines are used at normal ambient temperature, the condensing temperature of the cooling water of the water-cooled chiller is below 35 degrees, and the condensing temperature of the air-cooled chiller is below 43 degrees.

A: The first way:

1hp water-cooled chiller can be equipped with 80 tons clamping force injection molding machine temperature control at 5-10 degrees;

1hp water-cooled chiller can be equipped with a 100-ton clamping force injection molding machine and the temperature is controlled at 10-15 degrees;

The 1hp water-cooled chiller can be equipped with a 120-ton clamping force injection molding machine and the temperature is controlled at 15-20 degrees;

(The matching of the air-cooled chiller is 0.8 times that of the water-cooled chiller, that is, the 1HP air-cooled chiller can be equipped with an injection molding machine with a clamping force of 64 tons and the temperature is controlled at 5-10 degrees.)

B: The second way:

The 1HP water-cooled chiller can be equipped with an injection molding machine with a single injection volume of 10 QZ, and the temperature can be controlled at 5-10 degrees.

Injection volume 1QZ=28.5g

The above formula is the result summed up by the scriptures. In addition to using the above formula, the salesman should examine the actual situation and choose the appropriate chiller.

C: The matching of chiller and cooling water tower,

According to the actual experience in the past, a 1HP chiller needs a 1.2-ton cooling water tower to take away the heat generated by the chiller.

9. Example application of chiller

The chiller is used in the cooling of plastic processing machinery forming molds, which can greatly improve the surface finish of plastic products, reduce the surface marks and internal stress of plastic products, make the products not shrink or deform, facilitate the demoulding of plastic products, and accelerate the finalization of products. Greatly improve the production efficiency of plastic molding machines; chillers are used in CNC machine tools, coordinate boring machines, grinders, machining centers, combined machine tools and various types of precision machine tool spindle lubrication and hydraulic system transmission media cooling, can accurately control the oil temperature, effectively It can reduce the thermal deformation of the machine tool and improve the machining accuracy of the machine tool.

Features: New imported compressor and high-efficiency shell-and-tube condenser and evaporator combination, super cooling, quiet and power-saving; microcomputer full-function control, easy to operate (optional); unique new design of stainless steel open water tank, Easy and fast cleaning and maintenance Equipped with a precision electronic temperature controller, which can accurately control the water temperature within 3°C to 5°C; complete safety protection devices such as current overload protection, high and low suppression and electronic time delay, and abnormal indication system ; The screen simultaneously displays the cold water outlet, the cold water inlet and the set temperature (optional); there are single, double, and four-machine combinations, with high energy efficiency; after industrial design, the appearance is beautiful.

10. Maintenance and maintenance methods of industrial chillers

(1) Regular monthly maintenance

1. Check whether the voltage is normal or not.

2. Check and record the running current.

3. Measure and record whether the high and low pressure and temperature control temperature are normal. (For parties, high pressure is 1.5MPa/low pressure is 0.45MPa)

4. Check whether the interlocking control circuit device is loose and aging.

5. Check whether the oil level and oil temperature are normal.

6. Check the compressor for abnormal sound and abnormal vibration.

7. Refrigerant system test.

8. Overall commissioning and testing.

9. Regularly check whether the quality of chilled water and cooling water is normal. When the water quality of the water source becomes dirty or deteriorated, please replace the water source in time.

(2) Annual maintenance

1. Clean the condenser (clean it once every six months of cumulative operation).

2. Cleaning the cooling tower (water-cooled cumulative operation to clean once every three months).

3. Check the refrigeration oil and lubricating oil system, and replace and supplement if necessary.

4. Check and maintain the host circuit system.

5. Compressor motor coil insulation test.

6. Check whether the drier filter is normal and whether it is blocked, and replace it if necessary.

7. Check the amount of refrigerant and replenish refrigerant in time.

8. Check and correct the high and low pressure switches.

9. Check and correct the thermostat.

10. Trial operation and general calibration, test whether the superheat is normal and whether there is any abnormal sound of each component.

As for how to choose an industrial chiller, there are mainly air-cooled chillers and water-cooled chillers. Both chillers have their own characteristics. Small-sized chillers can be considered as air-cooled chillers, which are economical and easy to install. Large-sized chillers Water-cooled chillers can be considered, which have good heat dissipation, stable functions and lower maintenance costs.

Product parameters(R407C)

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