More dust and poor water quality in the chiller environment will affect the normal operation of the equipment, and even lead to downtime. In order to increase the operating power of the chiller, it is necessary to create high-quality conditions for use and effectively maintain the operating power of the air-cooled chiller.

When using the chiller, if there is a lot of dust and other problems in the environment during the operation of the equipment, the normal operation of the equipment will be affected after the equipment enters the water-cooled chiller. In order to prevent the chiller equipment from being affected by dust in the environment and a large amount of scale due to long-term lack of maintenance, companies need to conduct professional inspections on chillers on a regular basis.

A layer of solid or ooze builds up, called fouling, which adds additional fouling thermal and flow resistance, increasing required heat transfer area, power consumption and maintenance cleaning costs. Due to the large number and wide range of heat exchangers, the fouling of heat exchangers has a great impact on one-time investment, metal material consumption and energy consumption. In today's emphasis on energy saving and emission reduction, it is particularly important to minimize the impact of dirt.

During the operation of the water-cooled screw chiller, on the water side of the heat exchange equipment, especially in the condenser of the open circulating cooling water system, there are slightly water-soluble or water-insoluble minerals, such as calcium carbonate, calcium sulfate, silicic acid Calcium, iron oxide, phosphate, etc. Adhering to the inner surface of the heat transfer tube to form scale; dust, silt, algae, microbial communities and even leaves, weeds, etc. The sediment mixed into the water is deposited on the inner surface of the heat transfer tube, forming sludge. Fouling on the water side mainly includes scale and sludge. Fouling increases the heat transfer resistance of the heat transfer surface, directly affects the heat transfer effect, increases the condensation temperature or reduces the evaporation temperature, resulting in increased energy consumption and reduced cooling capacity of the refrigerator. The thickening of the scale layer reduces the cross-sectional area of the flow in the heat transfer tube, increases the water flow velocity and the roughness of the tube wall, leads to an increase in the flow resistance on the water side, and increases the power consumed by the pump.

The accumulation of dirt will also cause local corrosion or even perforation of the heat exchange surface, which seriously threatens the safe operation and service life of the water-cooled chiller. In the heat exchanger design of water-cooled chillers, the presence of dirt increases the heat transfer resistance, reduces the overall heat transfer coefficient of the heat transfer tube, and increases the energy consumption of the compressor. Therefore, it is necessary to compensate for the reduction of the overall heat transfer coefficient by increasing the heat transfer area to ensure sufficient heat transfer. The correct choice of fouling factor has a great influence on the cost, energy consumption and operation cost of heat exchange equipment. Unfortunately, despite ongoing scientific research on fouling, to date there is no generally accepted value for the fouling factor that can be accurately used in heat exchanger design.

In the design of heat exchangers, the choice of fouling factor is often based on experience rather than science. Based on operating experience with a particular system under the same or similar operating conditions, or based on measurement data obtained from actual equipment under the same operating conditions, or based on test data obtained from testing with prototype or model equipment in the laboratory, or using the recommendations of authoritative institutions It is reasonable to estimate the data.

In order to avoid similar failures of chillers, it is necessary to complete the treatment of water sources and environmental dust in time. It can provide a comfortable environment for the chiller, and pay attention to the maintenance of the chiller. Even if the enterprise runs the chiller for a long time without any rest time, the equipment can also maintain stable operating performance and truly achieve the goal of quickly reducing the space temperature.

A screw chiller, also known as a screw compressor chiller, is a type of water chiller utilized for cooling applications in various industries, including injection molding. The semi-hermetic screw compressor is the core components of a screw chiller.  It operates based on the principle of a rotary screw compressor, which is a positive displacement compressor. The screw compressor consists of two interlocking helical rotors that compress the refrigerant gas to raise its pressure and temperature.

According to different heat dissipation methods, screw chillers are divided into air-cooled screw chillers and water-cooled screw chillers. Under the same cooling capacity requirement, the purchase cost of water-cooled screw chillers is lower than that of air-cooled screw chillers. As far as chiller installation is concerned, air-cooled screw chillers are easier to install.

Here are some key features of a screw chiller:

Cooling capacity: Screw chillers are available in a wide range of cooling capacities to meet the specific requirements of injection molding machines. They can handle high cooling loads efficiently, making them suitable for industrial applications. Oumal screw water chiller cooling capacity from 100kw to 1000kw.

Air cooled screw chiller cooling capacity from 90kw to 600KW.

Energy efficiency: Screw chillers are known for their energy efficiency. They can achieve high cooling capacities while consuming relatively less electrical power compared to other types of chillers.

Temperature control: Screw chillers offer precise temperature control, allowing for stable and consistent cooling of the process water used in injection molding machines. This helps maintain the desired temperature for optimal molding conditions. Oumal screw chillers use Siemens PLC controller. Intelligent control, simple operation.

Reliability and durability: Screw chillers are robust and designed for continuous operation in demanding industrial environments. They are built with durable components and feature advanced control systems to ensure reliable and trouble-free performance.

Modular design: Many screw chillers have a modular design, which allows for easy scalability and flexibility. This means that multiple units can be combined to provide higher cooling capacity if needed, making them suitable for expanding operations or varying cooling requirements.

Advanced control options: Screw chillers often come with advanced control options, such as microprocessor-based controllers or touch screen interfaces. These controls provide intuitive operation, real-time monitoring, and the ability to set and adjust various parameters for optimal performance and energy savings.

Noise reduction: Screw chillers are designed with noise reduction features to minimize the operating noise levels. This is important in industrial settings where noise can be a concern.

Overall, screw chillers offer efficient and reliable cooling solutions for injection molding machines, helping to maintain consistent process temperatures and optimize the production of high-quality plastic parts.

Water-cooled chillers are essential for maintaining optimal temperatures in various industrial and commercial settings. When choosing a chiller, understanding its efficiency ratings is crucial. Chiller efficiency ratings are standardized metrics used to measure the energy efficiency of chillers. Here are three common efficiency ratings:

Seasonal Energy Efficiency Ratio (SEER): SEER is typically used to measure the energy efficiency of air conditioning and heat pump systems. It represents the cooling output of a chiller during a typical cooling season (in British thermal units or BTUs) divided by the energy consumed in watt-hours. SEER takes into account the varying operating conditions throughout the cooling season, including part-load conditions.

Energy Efficiency Ratio (EER): EER is another metric used to evaluate the energy efficiency of chillers, similar to SEER. It represents the cooling output in BTUs divided by the electrical power input in watts under standard rating conditions. Unlike SEER, EER is measured at a specific operating condition, typically at 100% load capacity.

Coefficient of Performance (COP): COP is a measure of the ratio between the cooling or heating output of a chiller and the energy input. For cooling applications, COP is the ratio of cooling output in BTUs to the energy input in watt-hours. A higher COP indicates a more energy-efficient chiller since it produces more cooling per unit of energy consumed.

It's important to note that the specific definitions, calculation methods, and rating conditions may vary depending on regional standards and regulations. When comparing chillers, it is advisable to consider the appropriate efficiency rating for your specific application and region.

It's worth mentioning that SEER and EER are commonly used for air-cooled chillers, while COP is often used for water-cooled chillers.It should be noted that the energy efficiency ratio of a chiller is affected by operating conditions, ambient temperature, cooling load, and the manufacturer's technology and design level. When choosing a chiller, in addition to the energy efficiency ratio, other factors such as cooling capacity, control accuracy, reliability, and maintenance requirements should also be considered comprehensively to meet specific application needs.

The importance of traditional industries in our lives is becoming more and more obvious, and the importance of related equipment that assists traditional processing industries is also becoming more and more obvious. Air-cooled chillers have become an indispensable presence in the plastics processing industry. An excellent chiller can greatly improve the surface finish of the plastic products we see now, and can also greatly reduce the probability of marks, textures and internal stress on the surface of plastic products, ensuring that the plastic products that reach consumers will not shrink or appear. In the case of deformation, choosing an air-cooled chiller can also help more convenient demoulding and product molding when processing plastic products, which greatly improves the production efficiency and product quality of the industry. Air-cooled chillers have become an indispensable refrigeration auxiliary equipment for manufacturers in the plastics industry.

Therefore, the normal operation of the industrial chiller is very important, and the lack of refrigerant will affect the cooling effect of the chiller. Air cooling is the cause of insufficient refrigerant in the chiller.

1. The newly installed chiller is not filled with refrigerant as required.

2. The air tightness of the system is not good, resulting in refrigerant leakage.

3. Improper operation and maintenance may lead to refrigerant leakage.

Insufficient refrigerant in an industrial chiller can lead to several harmful consequences, including:

Reduced cooling capacity: The refrigerant is responsible for absorbing heat from the process fluid and transferring it to the environment. If there is not enough refrigerant, the cooling capacity of the chiller will be reduced, leading to higher process fluid temperatures and decreased efficiency.

Increased energy consumption: When the chiller is not operating at full capacity, it may need to run for longer periods to maintain the required temperature, resulting in higher energy consumption and increased operating costs.

Component failure: Running an industrial chiller with insufficient refrigerant can cause the compressor to overheat and eventually fail. This can result in costly repairs and extended downtime.

Reduced lifespan: Operating an industrial chiller with insufficient refrigerant can cause excessive wear and tear on the system's components, reducing its lifespan and requiring more frequent maintenance.

Safety hazards: Low refrigerant levels can cause the chiller to operate at higher pressures, which can create safety hazards for workers and potentially lead to equipment damage or failure.

Overall, insufficient refrigerant can have significant negative impacts on the performance, efficiency, and safety of an industrial chiller. It is crucial to ensure that the chiller is properly maintained and that refrigerant levels are regularly checked and adjusted as needed.

Water-cooled chiller is a cooling water device that can provide constant temperature, constant current and constant pressure. A chiller is a machine that achieves refrigeration through vapor compression or absorption cycles. These liquids can flow through heat exchangers to cool the air or equipment. The industrial chiller can always output ice water with a lower temperature than the ambient temperature. It can be used wherever cooling is required, either direct cooling or indirect heat exchange. The main components of a water-cooled chiller are compressor, condenser, evaporator, water pump, and water tank.

Chillers have a wide range of applications. The chiller can be used to cool the injection mold, improve the quality of plastic products, cool the vacuum coating, control the temperature of the vacuum coating machine, cool the food industry, fast cooling processing, chemical industry, effectively control the temperature of chemicals, cooling buildings, concrete fast Cooling and condensation, etc.

According to the application, the chiller can be divided into industrial chiller, screw chiller, electroplating chiller, oxidation chiller, laser chiller, coating chiller, welding professional chiller, ultrasonic chiller, extruder chiller, injection molding chiller Special chiller, chemical chiller, electrophoretic paint chiller, pharmaceutical chiller, food chiller, stainless steel chiller, circuit board chiller, blister chiller, coating chiller, according to the working conditions Divided into air-cooled chillers, water-cooled chillers, low-temperature chillers, constant temperature chillers, etc.

Advantages and disadvantages of piston chillers

According to the different types of chiller compressors, industrial chillers can be divided into fully enclosed scroll chillers, semi-enclosed piston chillers, and semi-enclosed screw chillers. All kinds of compressors have their advantages and disadvantages. Today, Omar Refrigeration will take you to talk about the advantages and disadvantages of piston chillers.

Piston chiller is a chiller with semi-hermetic piston compressor as the main engine. The unit is composed of refrigeration compressors, condensers, evaporators, thermal expansion valves, etc., and is equipped with automatic energy regulation and automatic safety protection devices. The piston compressor device system is relatively simple, and this type of compressor is generally used more in low temperature conditions. For general piston compressors, the brands we use are Bitzer Semi-hermetic Piston compressor, Copeland Semi-hermetic Piston compressor, or Dorin semi-hermetic Piston compressor.

Advantages of piston chillers:

1. Wide range of applicable pressures; strong maintainability.

2. Using multi-head, high-speed multi-cylinder, the performance can be improved.

3. The material is simple, the general metal material can be used, the processing is easy, and the cost is lower than that of the screw chiller.

Determination of piston chiller:

1. There are many parts and wearing parts.

2. The compression ratio is low, the cooling capacity of a single machine is small, and the cylinder unloading adjustment cannot be adjusted steplessly.

3. It has a reciprocating motion up and down, and the vibration is large, and the weight index per unit cooling capacity is large.

4. It is very sensitive to liquid shock.

The effect of temperature on electroplating production is very important. If the temperature of the electroplating process is not well controlled, the quality of the coating on the surface of the electroplating products will be greatly affected. Temperature regulation and cooling, constant temperature insulation, so as to stabilize the production and efficiency of electroplating. Therefore, the surface treatment chiller, namely electroplating chiller, is commonly known as refrigerator, freezer, chiller, ice water machine, cooler, etc. So what are the characteristics of electroplating chillers?

The special chiller for electroplating generally chooses an air-cooled box-type chiller, which is easy to install and move, without a cooling tower, and is generally installed next to the electroplating equipment. The electroplating chiller uses two cooling methods, one is direct cooling and the other is indirect cooling. Due to the particularity of the electroplating industry, the electroplating solution is corrosive, so the evaporator, pipeline, water tank, Water pumps are all made of anti-corrosion stainless steel, and heat exchangers are generally made of titanium tubes to meet the needs of long-term stable use. It helps to stabilize the metal ions, make the metal ions quickly attach to the electroplated parts, continuously increase the density and smoothness, reduce the number of electroplating, and improve the productivity.

Oumalchiller specializes in industrial cooling systems, providing customized industrial cold water system solutions, providing various industrial chillers, plastic industry chillers, electroplating industry chillers, pharmaceutical industry chillers, food industry chillers, surface treatment chillers, welcome to consult .

The exhaust temperature of the compressor is the temperature of the exhaust gas after the compressor does work (compresses the gaseous refrigerant). It is usually fixed within a range. By observing the temperature change, the working condition of the compressor can be predicted and the occurrence of safety-threatening events can be prevented. . The exhaust temperature is an important parameter in the operation of the refrigeration compressor of the industrial chiller, and it must be strictly controlled. If the exhaust temperature is too high, it will cause the special refrigeration compressor of the industrial chiller to overheat, especially for the piston of the piston chiller. Refrigeration compressors have a serious impact, and the main hazards are shown in the following aspects.

1. Excessive exhaust temperature of the compressor will directly reduce the gas transmission coefficient, increase the shaft power, and reduce the viscosity of the lubricating oil, which will cause abnormal wear on the bearings, cylinders, and piston rings, and even cause burning of bearing bushes and cylinders.

2. Once the exhaust temperature of the compressor is too high, it will directly lead to thermal decomposition of lubricating oil and refrigerant under metal catalysis, and generate acid substances, free carbon and moisture that are harmful to the compressor. Free carbon is deposited on the exhaust valve, which not only destroys its tightness, but also increases the flow resistance. If the carbon residue of the pineapple is taken out of the compressor, it will block the capillary and the dryer. Acids will corrode various components of the chiller refrigeration system and electrical insulating materials, and moisture will block capillaries.

3. The chiller operator should check the overheating of the compressor. If the overheating is serious, the piston will be over-expanded and stuck in the cylinder, and it will also cause the built-in motor of the hermetic compressor to burn out.

4. The high discharge temperature of the compressor will directly affect her service life, because the chemical reaction speed will increase with the increase of temperature. Generally, the temperature of the electrical insulating material will rise by 10℃. Then her service life will be reduced by half , which is particularly important for hermetic compressors.

Causes of overheating of compressor discharge temperature:

1. The refrigeration system is short of oil

Insufficient supply of lubricating oil and lack of oil in the system will cause the machine head to not be properly cooled, resulting in an increase in exhaust temperature. By checking the oil level of the lubricating oil, it can be judged whether the lubricating oil is sufficient, and an appropriate amount of lubricating oil should be added according to the equipment regulations. If the oil separator is damaged, replace it.

2. The temperature control valve fails to work

The function of the temperature control valve is to automatically control the opening and closing of the valve according to the oil temperature. If there is a fault, the lubricating oil is directly sprayed into the machine head without passing through the condenser, which will cause the exhaust temperature to rise. The solution is to check and repair and replace the thermostatic valve.

3. The quality of lubricating oil deteriorates

Deteriorated lubricating oil will cause the oil film of the screw compressor to become thinner and not form a sufficient lubricating oil film, resulting in abnormal operation of the compressor, abnormal noise, etc. The solution is to replace the oil with new oil.

4. The cooling system is blocked and the heat dissipation is poor

Blockage or poor heat dissipation of the cooling system will cause internal scaling, resulting in poor heat dissipation, resulting in the inability of exhaust heat to dissipate, resulting in high temperature; similarly, damage to the cooling fan will also cause the cooling system to fail to dissipate heat in time.

The solution is to check the cooling system, remove dirt or repair the exhaust fan.

5. Detect control pipeline failure

This is caused by blockage of the air filter, failure of the temperature detection system, abnormal operation of the unloading valve, etc.

The solutions are: cleaning or replacing the air filter; checking whether the increase in the unit load causes over-temperature; checking the working condition of the unloading valve and adjusting it; testing, repairing, and replacing the system temperature detection system circuit.

The industrial chiller machine has become one of the essential equipment for cooling in most production enterprises, and the screw chiller is a large-scale industrial refrigeration equipment. Screw chillers are divided into air-cooled screw chillers and water-cooled screw chillers. Compressors, condensers, and evaporators are important components of screw chillers. When purchasing a screw chiller machine, you must first understand the main control parameters of the screw chiller, such as refrigeration coefficient, cooling capacity, refrigerant, input power, etc. When choosing a screw chiller, we must consider the cooling capacity, the user's operating voltage, the outlet water temperature, and the condensing temperature. Use this to determine the model of the compressor, as well as the energy of the evaporator and condenser.

The actual cooling capacity of the screw chiller equipment is related to the following factors:

1. Chilled water outlet temperature and the water flow

2. Inlet water temperature, flow rate and fouling coefficient of cooling water

When choosing a screw compressor chiller, in addition to considering the cooling capacity, the installation environment should also be considered. In this way, it is determined whether to choose an air-cooled screw chiller or a water-cooled screw chiller. Under the same cooling capacity requirement, the energy efficiency ratio of the water-cooled screw chiller is higher than that of the air-cooled screw chiller. Therefore, There will be differences in the model of the compressor, which leads to the higher cost of the compressor of the air-cooled screw chiller than that of the water-cooled screw chiller, and the cost of the air-cooled condenser is also higher than that of the water-cooled shell and tube condenser. So how to determine whether to choose a water-cooled screw chiller or an air-cooled screw chiller?

From the perspective of the purchase cost of the screw chiller, the price of purchasing a water-cooled screw chiller is lower than that of an air-cooled screw chiller.

If you consider the installation environment, the air-cooled screw chiller is easy to install, without the need to install a cooling tower, and it is suitable to install the air-cooled screw chiller in places where water resources are scarce.

From the perspective of the maintenance of the screw chiller, the later maintenance cost of the water-cooled screw chiller is higher, and the technical requirements are higher. If there is no professional staff, in the process of installing and using the water-cooled screw chiller, It is easy to cause various problems in the chiller due to problems such as water flow, while the maintenance of the air-cooled screw chiller is relatively simple. Regularly clean the condenser and check the machine regularly.

Through the above analysis, do you know how to choose a suitable screw chiller? If you don't know how to choose when purchasing a screw chiller, Call us： +86 15112554736 to get the professional suggestion.

An important step in the commissioning of screw chillers and scroll chillers is the charging of refrigerant. Generally, Oumal screw chillers are filled with the specified type of refrigerant before leaving the factory. After the chiller arrives at the chiller installation site, first check whether the screw chiller is damaged during transportation, check the high and low pressure gauges, and confirm whether the chiller is in good condition. If it is found that the refrigerant is insufficient or leaking, you need to find out the leak place and fix it, and then add the specified type of refrigerant according to the product instructions. For some screw chillers, the refrigerant needs to be emptied for transportation due to transportation problems. Therefore, after the machine arrives at the installation site, the refrigerant needs to be added again, and the appropriate refrigerant must be added according to the manufacturer's requirements. Before adding refrigerant, the air in the screw chiller system should be evacuated before adding refrigerant.

In the debugging process of the screw chiller, the following issues need to be paid attention to the following points: .

1. Check whether the valves in the refrigeration system are in normal opening state, especially the exhaust shut-off valve, do not close it.

2. Open the cooling valve of the condenser and the cold water valve of the evaporator, and the flow of chilled water and cooling water should meet the requirements of the manufacturer.

3. Before starting, observe whether the power supply voltage of the unit is normal.

4. Start the unit according to the installation instructions provided by the screw chiller manufacturer,

5. The safety protection installed in the refrigeration system should be used correctly, such as high and low pressure protection devices, water flow switches for chilled water and cooling water, safety valves and other components. If damaged, they should be replaced in time.

6. If an alarm occurs in the screw chiller, it should be stopped immediately for inspection. If it cannot be solved, contact the chiller manufacturer in time.

If you have purchased an Oumal screw chiller and do not know how to debug it, please contact your salesperson directly to guide the installation online.

If you have more questions of the debugging the chiller and installation the water cooled screw chiller, please email: oumal@oumal.com or contact Whatsapp: +86 15112554736.