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Common failures in chiller maintenance

2025-06-20

Common failures in chiller maintenance

During the maintenance of the chiller, in some environments with many dust layers, after the chiller has been used for a period of time, we will find that the chiller is noisy, and there are many dust layers on the accessories. This is a common phenomenon in the use of the chiller. At this time, the chiller is We need to serve it.

First of all, the chiller is a device that provides cold to the outside world, in other words it takes away the heat, so the ventilation environment required by the chiller is very important. The water cycle of the chiller is a simple process, but we must pay attention to the details of the simple process. If the front hood of the chiller is filled with dust, it will affect the heat dissipation of our chiller. Once the heat dissipation is affected The impact will directly cause the cooling effect of the chiller to drop sharply. If we do not remove the ash layer from time to time, on the one hand, it will affect the cooling effect, on the other hand, it will cause the internal components to burn out. After many chillers have been used for a period of time, the poor cooling effect is basically caused by this aspect.


Secondly, the temperature of about 20 degrees Celsius is just suitable for the strong growth of our microorganisms. When we use the chiller, sometimes its temperature is controlled at about 20 degrees Celsius. A large number of microorganisms accompany our water cycle, and some microorganisms are attached to our filter. Above the board, the waterway is not smooth, causing the chiller to produce a lot of noise. Even some microorganisms are attached to the heat exchanger of the chiller, causing the chiller's cooling effect to be poor.

 

Combining the above two points, I must maintain the chiller regularly and clean up the dust and debris in the chiller in time, so that the functions of our chiller can be guaranteed in all aspects, and it can maintain normal operation. The following are common faults in the maintenance of chillers.

 

1. Power failure. If a power failure occurs during the use of the chiller, it may cause the fuse to blow, the phase sequence protector to burn, phase loss, or instability. The solution is simple, that is, to replace the corresponding protector, Or fuse to ensure no phase loss and power supply stability.

 

2. Water pump failure. If there is a water pump failure, it may be caused by the overload protection action on the AC contactor of the water pump, the capacitor burned out, or the water pump itself; it is necessary to deal with the overload problem, replace the capacitor, or the water pump identity problem.

 

3. Water pump failure. If the compressor fails, it may be because the compressor capacitor is burned out and the compressor coil winding is abnormal. At this time, replace the capacitor or unwind the winding to restore it to normal.

 

4. Pressure switch failure, if it is a high and low pressure switch failure, it may be that the filter is blocked, the system is insufficient in winter, the circulating cooling water is stopped, the heat exchange cooling fan stops working, etc., it is necessary to replace the appropriate filter and add refrigerant to the cooling system ; At the same time, check whether the sweat cooling water circulating pump is normal; check whether the fan is working normally, if it is abnormal, repair it as soon as possible.

 

1. Reverse alarm:

1. The three-phase wiring of the power supply is wrong (pay attention to the auxiliary control line), check the wiring problem, turn on the power switch and the water pump switch to burn the fuse, and the circuit is short-circuited. Check the control wire and the main power line. The water pump rotor is stuck. Loosen the motor rotor;

 

2. If the fuse is not installed, install an appropriate fuse.

 

3. The power indicator is damaged, replace the electronic board.

 

2. Compressor failure

 

1. Compressor coil is short and open circuit, replace the matched compressor

 

2. Compressor overload protector automatically trips, adjust the current limit of the protector appropriately within the allowable range and press the reset button

 

Three, water pump failure

 

1. The water pump motor coil is short, open circuit, repair the motor coil or replace the motor

 

3. The overload protector of the water pump automatically trips, and the current limit of the protector is appropriately increased within the allowable range. Press the reset button halfway.

 

Fourth, the compressor is frosting

 

1. If the circulating water is flowing or the valve is not opened, check the water valve and all pipelines to ensure unobstructed flow, and install short-circuit pipelines.

 

2. The circulating water pipe configuration is too small, increase the diameter of the circulating water pipe to ensure the normal water circulation.

 

Troubleshooting of chiller maintenance

1. The temperature sensing wire and temperature measuring body are dirty, wipe the temperature measuring body clean

2. The temperature control meter is damaged, repair or replace the temperature control meter

3. Poor contact of the temperature sensing wire, repair or replace the temperature sensing wire

4. There is no circulating water in the water tank, and a circulating water path is short-circuited between the chilled water outlet and the inlet

5. The temperature control meter is out of control. Replace the temperature control meter. High pressure failure. Poor heat dissipation, dirty radiator, bad air to clean the radiator, improve ventilation conditions, and the cooling fan does not work. Check whether the fan motor is burned out or short circuit. Repair or replace the motor. Damaged, replace the high pressure

Glycol chiller VS water chiller-why chiller use glycol?

2025-06-20

The global demand for industrial process cooling system remains steadily rising. Reliability and minimal downtime are the keys to achieving consistent and profitable industrial and commercial processes. This article will consider the best way to achieve the optimal temperature required for production processes in the metal finishing, medical, brewing, and agricultural industries.

 

Glycol chiller VS water chiller

 

1: How does the chiller work?

 

So, how does the chiller work? The process circulates, but we will start from where the cooling medium is connected to your process equipment.

 

The coolant in the system absorbs the heat energy in the process, which usually causes a phase change to a gas. The gaseous refrigerant is then circulated to the condenser, which discharges heat through evaporative condensation or cooling towers. This heat exchange condenses the cooling medium into a colder liquid, which is sent back to the process heating source to start the cycle again.

 

What type of coolant is used in the chiller?

 

The type of coolant used in the chiller depends on the process requirements and cost considerations. The most popular coolant is water or a mixture of water and another substance with appropriate thermal conductivity (such as a glycol compound).

 

Water: Using water as a coolant is an economical method because in most cases, water can be easily obtained at the lowest cost. Alternatively, pure water (deionized water, reverse osmosis) can be used in a water-based chiller to achieve higher cooling efficiency.

 

Glycol: glycol-based coolants consist of ethylene glycol or propylene glycol. Although the two variants have similar physical properties, do not mix them. The main advantage of glycol coolant is to improve corrosion resistance and antifreeze performance.

 

2: Why use ethylene glycol for cooling

 

Compared with using ordinary water as the cooling liquid, the use of glycol-water mixture as the cooling liquid has many advantages. These advantages are due to its unique physical properties, including a lower freezing point than water.

 

Heat transfer between water and glycol

For water without impurities, its freezing point is 0°C, which is much higher than when pure ethylene glycol becomes solid at -13°C. When the mixture of ethylene glycol and water is changed, the freezing point of the coolant will also change. As an example, 10% ethylene glycol will freeze at -3.5°C, while a 60% ethylene glycol solution will freeze at -52°C.

 

It can be clearly seen from the above analysis that the refrigerant characteristics of ethylene glycol are more suitable for refrigerators that are expected to operate in a low temperature environment. Under these hot conditions, the cooling water can freeze and hinder the circulation of the chiller, while reducing overall efficiency.

 

In contrast, using a glycol-based chiller will take advantage of its antifreeze properties to ensure that the coolant maintains the desired fluid state.

 

3: glycol chiller VS water chiller

 

Both glycol chillers and chillers can be used to satisfactorily dissipate the heat generated during the production process. The fundamental difference between the two types of chillers is the change in their freezing point and thermal conductivity.

 

The freezing point of pure ethylene glycol or a mixture of ethylene glycol and water is much lower than that of pure water. This means that glycol-based chillers are more suitable for low-temperature environments. On the contrary, compared with glycol mixtures, water has a better ability to retain and conduct heat in related processes. As a result, the heat transfer efficiency for water chillers will be higher than glycol chillers.

 

In general, the operator needs to consider the ambient temperature of the location environment before choosing the type of chiller.

 

1. How does the glycol chiller system work?

 

Glycol chiller equipment consists of refrigeration components and pipes containing glycol-water mixture as coolant. The cooling fluid from the refrigeration unit is guided through pipes associated with the heat exchanger surrounding the heating process. After absorbing heat from the related process, the warmed coolant returns to the refrigeration unit for cooling, and then the process is repeated.

 

Glycol content in chilled water system

 

For many types of chillers, ethylene glycol is mixed with water in a 60/40 ratio. A higher percentage of ethylene glycol will greatly enhance the antifreeze performance of the mixture. This is useful in situations where rapid cooling is required. In these cases, the process can be cooled to very low temperatures without freezing the coolant in the pipeline.

 

How does the chiller system work?

 

Conventional water chillers work according to the principle of heat transfer between fluid and solid media. These cooling systems work by endothermic or vapor compression. The basic components of the water chiller system include a refrigeration unit and a piping system for circulating cooling coolant.

 

In the past ten years, oumal chillers have been manufacturing high-quality industrial chillers. With impressive water-cooled and air-cooled chillers, your industrial refrigeration needs will surely be met.

How to clean a water chiller?

2025-06-20

How to clean a water chiller?

As a fixed asset of an enterprise, the chiller is a must for enterprise personnel to maintain it and maximize its usefulness. Because the long-term operation of the chiller will cause thick scale on the surface of the condenser, which will interfere with the normal operation of the chiller. For example, to make its work efficiency low or easy to damage, etc., the necessary cleaning of the chiller is absolutely indispensable.


How to clean the chiller? We have to distinguish between water-cooled and air-cooled. The water-cooled chiller is mainly used to remove the scale of the chiller. The removal cycle depends on the water quality. If the water quality is poor, it is cleaned at least once every 12 months; if the water quality is good, it can be cleaned once every 2 years on average.

 

Air-cooled chillers use air as the cooling medium. Because there is often dust in the air, some of the dust will stick to the outer surface of the condenser fins. After a period of time, the cooling effect of the condenser of the chiller will gradually deteriorate. The local environment is relatively harsh, and it is easier to age quickly. Therefore, the maintenance and cleaning of the chiller should be carried out at regular intervals.

 

The cleaning method of air-cooled chillers is: there are more dirt in the maintenance and cleaning of chillers, and non-corrosive cleaning agents should be used to clean the radiating pipes and fins to achieve the purpose of improving the heat dissipation effect.

So let's briefly talk about the main steps of cleaning the chiller.

 

First, remove the parts

If you want to clean the chiller, you must first disassemble it, because the parts you want to clean are not easy to see inside the collective. The various parts of the chiller cross each other, and the lines are complicated and it is really difficult to dismantle. This is to understand the overall chiller structure.

 

Second, the connection between the cleaning equipment and the condenser

After the disassembly in the previous step, find the direction of the condenser water inlet and connect it to the water inlet or outlet of the water pump, and then use tools to heat the pipe.

 

Third, dosing and cleaning

After making sure that each step is done and the pipes are connected, first add clean water for cleaning for about twenty times, and then drain the sewage and repeat it 3 times. After the cleaning is completed, the most important dosing cleaning is done. Of course, its pH value must be guaranteed between 4-5 and maintained for 2-3 hours. Finally, the medicine is discharged, and then the residual medicine is flushed to keep the pH at 6.5.

 

Fourth, install back to the original state

After cleaning, the installation is completed as it was.

 

The above are the main steps for cleaning the chiller. Is it easy, but I think it’s better to ask professionals to clean it. After all, disassembling the machine can easily cause damage to the parts. If the chiller is broken to clean the machine, it can It's really not worth the gain.

Important parts of low-temperature chiller assembly matters and refrigeration methods

2025-06-20

Commonly used auxiliary accessories for low temperature chillers, including water flow switch, pressure controller, pressure difference controller, temperature controller and solenoid valve, as well as a brief introduction of three cooling methods, liquid vaporization refrigeration, gas expansion refrigeration and thermoelectric refrigeration.


Common auxiliary accessories for low-temperature chillers

1, water flow switch

The water flow switch is used as the control or cut-off protection of the fluid flow in the pipeline. When the fluid flow reaches the set value, the switch automatically cuts off (or connects) the circuit.

2, pressure controller

The pressure controller is used for pressure control and pressure protection. The chiller has low and high pressure controllers to control the working range of the system pressure. When the system pressure reaches the set value, the switch automatically cuts off (or connects) the circuit.

3, differential pressure controller

The pressure difference controller is used to control the pressure difference. When the pressure difference reaches the set value, the switch automatically cuts off (or turns on) the circuit.

4, temperature controller

The temperature controller is used for the control or protection of the unit. When the temperature reaches the set value, the switch automatically cuts off (or turns on) the circuit. In our products, temperature control is often used, and the temperature of the water tank is used to control the startup and shutdown of the unit. There are also temperature controllers that need to be used for antifreeze.

5, solenoid valve

Cut off the system circuit when the compressor is stopped to avoid liquid shock when the compressor is started next time. It is generally used in a larger refrigeration system.

Three cooling methods

1. Liquid vaporization refrigeration:

1) Compression: The normal temperature gas state becomes a high pressure and high temperature gas state.

2) Condensation: High pressure and high temperature gas becomes high pressure liquid

3) Evaporation: High-pressure liquid turns into low-pressure gas, absorbing heat and realizing refrigeration.

 

2, gas expansion refrigeration:

Gas expansion refrigeration uses the adiabatic expansion of high-pressure gas to reach low temperature, and uses the reheating process of the expanded gas at low pressure to refrigerate. Due to the different equipment for gas adiabatic expansion, there are generally two ways: one is to increase the high pressure The gas is expanded by the expander and has external power output, so the temperature drop of the gas is large, and the cooling capacity is also large during reheating. However, the expander structure is more complicated. Another way is to make the gas expand through the throttle valve without external power output. The temperature drop is small and the cooling capacity is small, but the structure of the throttle valve is relatively simple, which is convenient for the adjustment of the gas flow.

 

3. Thermoelectric cooling

When the DC power supply is turned on, the current direction of the upper connector is N-P, the temperature decreases, and absorbs heat, forming a cold end; the current direction of the lower connector is p-n, the temperature rises, and heat is released, forming a hot end. Several pairs of thermocouples are connected to form a commonly used thermopile. With the help of various heat transfer devices, the hot end of the thermopile continuously dissipates heat and maintains a certain temperature, and the cold end of the thermopile is placed in the working environment to absorb Heat, produce low temperature, this is the working principle of semiconductor refrigeration. The solar semiconductor refrigeration system uses the thermoelectric cooling effect of semiconductors to directly supply the required DC power by solar cells to achieve the effect of cooling and heating.


If you need to know more about low-temperature chillers, glycol chillers, screw chillers, chillers, ice water chillers, scroll chillers, piston chillers and refrigerators and other refrigeration products, please contact our OUMAL refrigeration manufacturer, and we will try our best to solve the failure of the chiller for customers. Such as chiller does not refrigerate and other issues, wholeheartedly recommend customers to choose the right chiller products, so that everyone can buy the right machine and solve your industrial cooling water system issue. Welcome to consult us at any time. The oumal industrial chiller water unit adopts original imported configuration, fully automatic computer controller, which can precisely control the temperature of the coating machine. According to customer requirements, different methods of use are developed to produce refrigeration equipment that meets customer requirements to ensure the high quality of plating parts. .

Requirements for adding refrigerant to industrial chiller system

2025-06-20

After the industrial chiller system has passed the vacuum test, the vacuum state in the system can be used to charge the refrigerant.



1. Refrigerant charging

For newly installed systems, refrigerant can be added to the high-pressure end, and the operation method is as follows:

1) Turn on the cooling water system for the condenser, and keep the valve in the system as it was during the vacuum test

2) Connect the steel cylinder containing the refrigerant with the West 14mm×2mm seamless steel pipe (use a red copper pipe when filling with Freon). The mouth of the bottle is inclined downward, and the cylinder is at an angle of 30° with the ground, or the end of the cylinder is raised about 200-300mm.

3) Open the filling valve. When the system reaches a certain pressure (0.1~0.2 MPa for ammonia system; 0.2~0.3 MPa for Freon system), stop charging the refrigerant, and then check the sealing condition of the system at each connection and welding place. If there is no leakage, Can continue to charge refrigerant.

4) Close the outlet valve on the liquid reservoir and continue to charge the refrigerant. When the cylinder pressure and the pressure in the liquid reservoir reach equilibrium, the outlet valve on the liquid reservoir should be opened.

5) Start the refrigerating machine, make the refrigerating device enter the running state, and continue to charge the refrigerant at the same time. When white frost appears on the lower part of the cylinder, it means that the liquid refrigerant in the cylinder is almost completely filled. At this time, the cylinder valve and charging valve can be closed, and the bottle can be changed to continue charging.

6) Unless the outside temperature is very low, it is generally not necessary to pour hot water on the cylinder to increase the pressure in the cylinder when charging the refrigerant, because it is not safe to do so. If you need to speed up the filling speed, the hot water temperature must not exceed 50°C and other methods to heat the cylinder are strictly prohibited.

7) When filling freon, a filter drier must be installed on the special nozzle to reduce the possibility of water entering the system. When charging with high pressure section, never start the compressor, and pay attention to the exhaust valve not to leak, otherwise liquid hammer will occur.

8) When the refrigerant is charged up to 90% of the charging amount, the charging can be temporarily stopped, and the system can be tested to check whether the system dosage has met the operation requirements and avoid unnecessary trouble caused by excessive charging. For the old refrigeration system, when the refrigerant needs to be supplemented, it should be charged from the low pressure side.


2. Leak detection after filling

(1) Leak detection method with test paper Generally, phenolphthalein test paper is used to test the system's welds, flanges, and threaded connections for leaks. Wet the test paper and approach the inspected place. If it turns red, it means that there is ammonia leakage (note that the test paper should not be in contact with the soapy water on the pipe to create an illusion). Litmus paper that turns blue when exposed to ammonia can also be used.

(2) Halogen blowtorch leak detection method Halogen blowtorch is a common tool for leak detection in Freon refrigeration systems. The domestic halogen blowtorch is shown in the figure below, and the method of use is as follows:

1. Add alcohol: first unscrew the base 1 and add anhydrous alcohol with a purity of not less than 99.5% to the inside of the barrel, but the amount of injection should not be too much, just fill 1/2 to 3/4 of the volume of the lamp tube That's it, then the base should be fastened tightly.

2. Light a fire: turn the hand wheel 2 to the right, close the valve core, fill the wine glass, and then light it to heat the lamp tube and the upper part of the blowtorch. After heating a little, check whether the blowtorch is leaking.

3. Fire: When the alcohol in the beaker is nearly finished, turn the hand wheel 2 to the left and ignite the volatilized alcohol in the nozzle in the flame ring 4. At this time, the suction hose 6 of the halogen lamp emits With the sound of gas inhalation, you can start leak detection with a lamp.

4. Use: When testing, move the nozzle of the suction hose 6 close to the inspected place, and move slowly. If there is Freon gas leakage, it will decompose when it meets the flame. At this time, the orange-red flame will turn into green and the color of the flame. The change varies with the amount of Freon leakage, and the darker the color, the more serious the leakage of Freon.



What caused poor refrigerating efficiency ?

2025-06-20

What caused poor refrigerating efficiency?

Sometimes when we use a chiller, but the temperature could not be lower, or After cooling down to a certain temperature, it won’t go down anymore. Let's talk What caused the poor refrigerating efficiency ?


1. Refrigerant leakage

[fault analysis] After the refrigerant leak in the system, the cooling capacity is insufficient, the suction and exhaust pressure are low, and the expansion valve can hear much larger intermittent “squeak” air flow than usual.The evaporator is not frosted or with a small amount of frosting. If the expansion valve hole is enlarged, the suction pressure remains unchanged.After the shutdown, the equilibrium pressure in the system is generally lower than the saturation pressure corresponding to the same ambient temperature.


2. Too much refrigerant is filled after maintenance
[fault analysis] When the refrigerating dose filled in the refrigeration system after maintenance exceeds the capacity of the system, the refrigerant will occupy a certain volume of the condenser, reduce the heat dissipation area, and reduce its refrigeration efficiency. Generally, the suction and exhaust pressure are higher than the normal pressure value, the evaporator is not frosted, and the temperature in the warehouse is slow.


3. Air in the refrigeration system

[fault analysis] The air will reduce the refrigeration efficiency in the refrigeration system. The prominent phenomenon is the increase of suction and exhaust pressure (but the exhaust pressure has not exceeded the specified value). The temperature of the compressor at the inlet of the condenser is significantly increased.


4. Low compressor efficiency

[fault analysis] The low efficiency of refrigerating compressor refers to the reduction in the response of refrigerating volume due to the decrease of the actual exhaust volume under the condition that the working condition remains unchanged.This phenomenon usually occurs on compressors that have been used for a long period of time, with large wear and tear, large clearance of all components, and decreased sealing performance of air valves, which results in the decrease of actual air discharge.


5. The surface of evaporator is frosted too thick
[fault analysis] Long-term use of cold storage evaporator should be regularly defrosted. If the frost is not defrosted, the frost layer on the evaporator tube becomes thicker and thicker. When the whole pipeline is encased in transparent ice, the heat transfer will be seriously affected, causing the temperature in the reservoir to fall below the required range.


6. There is frozen oil in the evaporator pipeline
[fault analysis] During the refrigeration cycle, some frozen oil remains in the evaporator pipeline. After a long period of use, a large amount of oil remains in the evaporator, which will seriously affect its heat transfer effect and lead to poor refrigeration.


7. The refrigeration system is not smooth
[fault analysis] Because the refrigeration system is not clean, after several hours of use, the dirt is gradually silted up in the filter and some mesh holes are blocked, resulting in the reduction of refrigerant flow and affecting the refrigeration effect.
In the system the expansion valve, the compressor suction nozzle at the filter screen also has a small plug phenomenon.


8. The filter is blocked
[fault analysis] When the desiccant is used for a long time, it becomes paste to seal the filter, or the dirt gradually accumulates in the filter, causing blockage.


9. Leakage of refrigerant in the expansion valve sensible temperature package
[fault analysis] After the leakage of the temperature sensor in the expansion valve’s temperature sensor package, two forces under the diaphragm push the diaphragm upward. It is the valve hole closed.


10. Cold air cooling condenser has poor cooling effect in the cold storage
[fault analysis]
⑴The fan is not on.
⑵Parliamentary fan motor damaged.
⑶Torque fan reverse.
⑷high ambient temperatures (40 ℃ above).
⑸Flow of condenser cooling fins blocked by oil and dust.


11. The cooling effect of water-cooled condenser is poor
[fault analysis]
⑴The cooling water valve is not opened or opened too small, and the inlet pressure is too low
⑵Potassium water regulating valve fails.
⑶The scale on the wall of the condenser pipe is thicker.


12. Too much refrigerant is added into the system
[fault analysis] Too many refrigerants lead to a significant increase in the exhaust pressure, exceeding the normal value.


13. Residual air in the system
[fault analysis] The air circulation in the system will lead to excessive exhaust pressure, high exhaust temperature, hot exhaust pipe, poor refrigeration effect, the compressor will operate soon, and the exhaust pressure will exceed the normal value.


14. Stop when the suction pressure is too low
[fault analysis] When the suction pressure in the system is lower than the set value of the pressure relay, its contact action will cut off the power supply.


15. The temperature controller is out of control
[fault analysis] The thermostat fails to adjust or the temperature sensor package is improperly installed.


16. Sudden stop caused by other reasons
[fault analysis] In the process of use and maintenance, it is often necessary to open, close the exhaust, inhale, and store the liquid, etc.


What is a industrial chiller ?

2025-06-20

Industrial chillers are one type of chillers, and chillers can be divided into air-cooled chillers and water-cooled chillers.


Water chiller is a kind of water cooling equipment, which can provide constant temperature, constant current and constant pressure cooling equipment. The principle of the chiller is to inject a certain amount of water into the internal water tank of the machine, and the water is cooled by the chiller refrigeration system, and then a water pump inside the machine injects low-temperature frozen water into the equipment that needs to be cooled, and the chilled water will heat the internal heat of the machine. Take it away and return the high-temperature hot water to the water tank to cool down again. In this way, it is circulated and exchanged and cooled to achieve the effect of cooling the equipment.


In industrial applications, chilled water or other liquid cooling pumps are passed through processes or laboratory equipment. Industrial chillers are used in various industries to control the cooling of products, mechanisms and factory machinery. They are commonly used in injection and blow molding in the plastics industry, metal processing cutting oils, welding equipment, die-casting and machining, chemical processing, pharmaceutical formulation, food and beverage processing, papermaking, cement processing, vacuum systems, X-ray diffraction, electric power Supply and power stations, analytical equipment, semiconductors, compressed air and gas cooling. They are also used to cool high heat energy, such as MRI machines and laser specialized engineering projects, and in hospitals, hotels and campuses. The chillers for industrial applications can be centralized, and each chiller can meet multiple needs for cooling, or be dispersed in each application or device with its own chiller. Each method has its advantages. It may also have a combination of central and decentralized chillers, especially when the cooling requirements are the same for certain applications or use points, but not all.


Distributed chillers have a small area (cooling capacity) usually from 0.2 tons to 10 tons. Central chillers generally have a capacity ranging from 10 tons to hundreds or thousands of tons.

Chilled water is used to cool and dehumidify the air in large-scale commercial, industrial and institutional alliance (CII) facilities. The chiller can be water-cooled, air-cooled, cooled or evaporatively. The use of water-cooled chillers is incorporated into cooling towers, which improves the cooling' thermodynamic efficiency compared to air-cooled chillers. This is due to the high temperature or the wet bulb temperature of the nearby air, rather than repelling the high, sometimes much higher, dry bulb temperature. Evaporatively chillers provide better efficiency than air cooling, but lower than cold water.


Several aspects of the chiller should be paid attention to:


1. Selection of model size of chiller for injection molding machine

When used as a mold cooling of an injection molding machine, it can be calculated according to the injection volume of the injection molding machine. Generally, a 1HP chiller is used for every 6 ounces of injection volume. For example, the customer’s factory is 100T (5.5OZS)×3; 150T(12OZS)×4 units; 200T(23OZS)×3 units; the required chiller size is (5.5×3+12×4+23×3)/6=22.25, that is, a 25HP chiller. When used for cooling of other equipment, it depends on the specific flow rate of the cooling water circulation.


2. Selection of the insulation water tank and water pump of the chiller

Sometimes according to the actual situation of the customer's factory, the box-type chiller may also require an external pump. At this time, the additional pump model must have the same power as the pump that comes with the chiller. If the 10HP box-type chiller comes with a pump power of 2HP, when the pump is added, it must also be 2HP.


3. The temperature of the return water of the chiller should not be higher than 40 degrees. The higher the return water temperature, the greater the damage to the compressor.


Scope of application


Plastic industry: Accurately control the mold temperature of various plastic processing, shorten the plastic molding cycle, and ensure the stability of product quality.

Electronics industry: Stabilize the molecular structure of electronic components on the production line, improve the qualification rate of electronic components, and apply to the ultrasonic cleaning industry to effectively prevent the volatilization of expensive cleaning agents and the damage caused by volatilization.

Electroplating industry: control the electroplating temperature, increase the density and smoothness of the plated parts, shorten the electroplating cycle, increase production efficiency, and improve product quality.

Machinery industry: Control the oil temperature of the oil pressure system, stabilize the oil temperature and oil pressure, extend the oil quality use time, improve the efficiency of mechanical lubrication, and reduce wear.

Construction industry: supply chilled water for concrete, make the molecular structure of concrete suitable for construction purposes, and effectively enhance the hardness and toughness of concrete.


Vacuum coating: control the temperature of the vacuum coating machine to ensure the high quality of the coated parts.

Food industry: used for high-speed cooling after food processing to adapt to packaging requirements. In addition, there are control of the temperature of fermented food and so on.

Pharmaceutical industry: In the pharmaceutical industry, it is mainly used to control the temperature control of fermented drugs. Pharmaceutical companies should make full use of chiller equipment, continue to strengthen technological innovation based on their advantages, and enhance the cost-effectiveness of chillers, so as to better serve the pharmaceutical sector.

 


Working Principle of the water chiller

2025-06-20

Chillers are divided into air-cooled chillers and water-cooled chillers. The working principle diagram of air-cooled chillers is as follows

working principle of air-cooled chiller


Working Principle of air-cooled chiller

The air-cooled chiller uses a shell and tube evaporator (or tank with coil) to exchange heat between water and refrigerant. The refrigerant system absorbs the heat load from the water and cools the water to produce cold water. The heat is brought to the finned condenser through the action of the compressor. Then it is lost to the outside air by the cooling fan (wind cooling)


Features of air-cooled chillers

1The air-cooled chiller does not need to be installed with a cooling water tower and is suitable for environments with poor impurities. (It is easy to mix impurities in the cold water tower, and the dust will block the cooling water circulation loop, causing the cooling capacity to drop).

2Air-cooled chillers are most suitable for areas with poor water quality, and can save other accessories for chillers.

3With a large-capacity condenser, it can be easily operated even in heat.

4Minimize floor space and easy installation

5The air-cooled chiller adopts a top-out air design.

The working principle diagram of the water-cooled chiller is as follows:

water-cooled chiller working principle

Schematic diagram of the principle and flow of water-cooled chillers

The water-cooled chiller uses a shell and tube ( or tank with coil ) evaporator to exchange heat between water and refrigerant. The refrigerant system absorbs the heat load of the water and cools the water to produce cold water. The heat is brought to the shell and tube condenser through the action of the compressor. The refrigerant exchanges heat with the water, so that the water absorbs the heat and then takes the heat out of the cooling tower through the water pipe to dissipate (water cooling)


Features of water-cooled chillers:

1. High-quality compressors are the heart of industrial chillers (brand-new original compressors from Europe, America and Japan, with built-in safety protection, low noise, power saving and durability).

2. The box-type evaporator has a built-in automatic water replenishment device, which saves the need for the expansion water tank in the engineering installation to facilitate installation and maintenance, and is suitable for special occasions such as large temperature difference and small flow.

3. The water-cooled condenser is made of the latest high-efficiency externally threaded copper pipe, with large heat dissipation and small size. Using the latest CAD/CAM processing technology, with CNC machining center to complete the production, compact structure, high reliability, beautiful appearance, high efficiency and energy saving.

4. Industrial chiller unit configuration: equipped with a single-chip control system, built-in compressor dryer filter and expansion valve, maintenance hand valve interface and other devices, to ensure the reliable and safe operation of the machine to facilitate maintenance and repair.

5. The multi functional operation panel of the industrial water chiller is equipped with ammeter, control system insurance, compressor switch button, water pump switch button, electronic temperature controller, various safety protection fault lights, unit start-up and operation indicator, simple operation and convenient use . Industrial chiller unit configuration: equipped with a single-chip control system, built-in compressor drying and expansion valve, maintenance hand valve interface and other devices, to ensure the reliable and safe operation of the machine, and facilitate maintenance and repair.

Selecting the Right Chiller for Your Process – What We’ve Learned at OUMAL

2025-06-20

In industrial production, stable process cooling isn’t just a support function — it’s often the difference between smooth operation and costly downtime. At OUMAL Refrigeration Machinery Co., Ltd, we’ve worked with customers across injection molding, extrusion, thermoforming, and more. Over time, one thing has become clear: choosing the right chiller matters.

Not All Cooling Needs Are Created Equal
Different industries — even different machines — have very different cooling requirements. For example, a customer running a small injection molding line may only need a compact 8 ton chiller to maintain mold temperatures within a tight range. These chillers are space-efficient and offer precise control, making them a practical choice for localized cooling tasks.

On the other hand, when the scale increases or when multiple machines share a cooling circuit, something like a 15 TR chiller tends to be a better fit. We’ve seen these used successfully in mid-sized production lines where reliability and steady performance are non-negotiable.

For large plants, especially those operating around the clock, a 100 ton water cooled chiller can provide both capacity and energy efficiency. Water-cooled systems require more infrastructure — including cooling towers and proper piping — but in return, they offer stable performance in high ambient environments and over long production runs.

Built for Industry, Backed by Experience
What sets OUMAL apart is not just the equipment itself, but the way we build around customer needs. Our manufacturing team can handle a wide range of options and customizations, which means the chiller you receive isn’t off-the-shelf — it’s made to work the way you do.

We’ve served customers in over 20 countries, including the US, Australia, Saudi Arabia, Vietnam, and Brazil. The variety of applications we’ve supported — from blown film to compound mixing — gives us the insight to ask the right questions before making a recommendation. Our goal is always to match cooling performance with process demand, rather than over- or under-sizing.

Long-Term Value Comes from the Right Start
One thing we often remind our partners: a properly selected chiller does more than control temperature. It protects your equipment, shortens your cycle times, and helps maintain product consistency. That’s especially important in processes where a few degrees can mean the difference between a good batch and scrap.


Whether you’re starting with a single machine or upgrading an entire line, OUMAL is ready to help you choose wisely — whether that’s an 8 ton, 15 TR, or 100 ton water cooled chiller.


China chiller manufacturer

What Is an Air Cooled Chiller – A Practical Explanation from the Factory Floor

2025-06-20

When someone new joins our engineering team, one of the first questions they usually ask is: “So what’s the difference between air cooled and water cooled chillers—and which one’s better?”


It’s a good question. And after installing, maintaining, and even troubleshooting both systems in dozens of customer factories, here’s how we usually explain it.


Let’s Start with the Basics

An air cooled chiller is essentially a cooling unit that uses ambient air to remove heat from a circulating liquid—usually water or a water-glycol mix. It's often used to keep production equipment or buildings at a stable temperature.

There’s no need for a cooling tower or a complex water pipeline. It uses built-in fans to get the job done.

This setup is widely chosen in:

  • Injection molding plants

  • Food packaging lines

  • Laser processing workshops

  • HVAC systems for commercial buildings

If you’ve got space outside and want to avoid dealing with water quality issues, air cooled is probably the better call.

air cooled screw chiller

What’s Inside the Unit?

Rather than listing textbook components, here’s what we see under the cover of atypical air cooled water chiller we ship:

  • A compressor that acts like the system’s engine

  • An evaporator that draws heat out of your process water

  • A condenser with aluminum fins, cooled by strong fans

  • An expansion valve to adjust refrigerant pressure

  • A control panel—the brain of the system

Some models include water pumps and tanks. Others are modular—you can connect them to existing infrastructure.


Here’s How It Works (Simplified)

Let’s say you’re using a CNC machine that heats up during operation. Here’s how the air cooled chiller steps in:

  1. The warm water comes back from the CNC.

  2. It enters the evaporator inside the chiller.

  3. The refrigerant in the evaporator absorbs that heat and turns into a gas.

  4. The gas gets compressed—its temperature and pressure rise sharply.

  5. That hot gas goes through the condenser. Fans blow outside air across coils, removing the heat.

  6. The refrigerant turns back into a liquid, and the cycle repeats.

Your machine keeps running cool—and you don’t need a water tower or much operator attention.


Why Do Customers Choose Air Cooled Units from Us?

Some of our long-term clients choose air cooled chiller systems for one reason: they just work.
Even without an in-house technician, these systems are straightforward to install, easy to control, and rarely break down when used correctly.

Clients also appreciate that we offer:

  • Tailored sizing based on actual load

  • Remote monitoring options

  • Short lead times, even for custom orders

  • Reliable after-sales support (yes, even overseas)


As a practical air cooled chiller supplier, we’re not here to sell what’s biggest or most expensive—we help customers find what runs stably for years.

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