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Small Chiller-An Ultimate FAQ Guide by TopChiller.

What is Small Chiller?

A Small Chiller is an outstanding portable cooling unit that ensures the cooling of various industrial applications with different heating loads.

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It has a compact design to minimize the need for larger installation space. Its small footprint occupies less space. It is a highly durable cooling system with easy installation and low maintenance costs.

Different processing machines are integrated for continuous heat dissipation, such as metalwork, drilling, milling, and injection molding.

Small Chiller Fabricated by TopChiller

What are the Basic Components of a Small Chiller?

Small Chiller discharges heat from an application using essential components as listed below:

Compressor

A hermetic scroll compressor is the fundamental component of a refrigeration circuit. It compresses the refrigerant to increase its temperature and pressure. The scroll compressor contains two scrolls that rotate over each other for refrigerant compression. It is equipped with a crankcase heater and rubber vibration isolator.

Condenser

An air-cooled condenser is preferably used to dissipate excess heat from an application. It features seamless copper tubes that extend over aluminum fins. Aluminum fins are hydrophilic, ensuring protection from corrosion. Fresh ambient air circulates over copper coils, absorbing heat from the refrigerant. After condensation of the evaporated refrigerant, the air releases it into the environment.

Evaporator

The evaporator is factory insulated and optionally features anti-freezing material. The evaporator efficiently mediates the heat exchange between refrigerant and coolant. The plate-type evaporator is preferably installed and occupies less space than the shell and tube-type heat exchanger. The refrigerant leaves the evaporator with low pressure and temperature.

Axial Fans

Axial fans are equipped with drive motors and ranked with an IP54 protection rating. Axial fans maintain the airflow rate for final heat discharge from the refrigerant.

Electric Panel

The electric panel consists of a microprocessor controller, breakers for the compressor, fan motor protection, and compressor contactors.

Small Chiller Control Panel

What are the Key Features of a Small Chiller?

A Small Chiller is configured with some basic features for entailing a cooling effect as given below:

• Compact design made of corrosion-resistant stainless steel.
• Condenser coils designed with copper and aluminum fins.
• Scroll compressor ensuring energy-efficient refrigerant compression.
• PHE and tube-in-tube heat exchangers occupy little space.
• Microprocessor control unit for regulating the whole unit.
• Air-cooled condenser for final heat discharge from the chiller.
• Expansion valves for releasing refrigerant pressure.
• Emergency alarms protect the unit components from damage by indicating a problem.
• Lockable caster wheels for easy movement of the Small Chiller.
• Small footprint design occupies little space for installation.
• Environment-friendly, easy installation, and maintenance.

Small Chiller Compressor

How Does a Small Chiller Work?

A Small Chiller is a small-sized portable cooling unit efficient in providing a cooling effect for various applications. Its working process is as follows:

Step 1

It dissipates the system’s heat using two fluids, coolant and refrigerant, which circulate in the refrigeration cycle for heat release. The plate-type heat exchanger receives water from the required application as a coolant. The water heats up and enters the heat exchanger, absorbing the system’s heat.

Step 2

Liquid refrigerant circulates in convoluted tubes immersed in plates. The coolant circulates over the refrigerant, transferring its heat to the refrigerant.

Step 3

The liquid refrigerant converts into a gaseous form and leaves the heat exchanger. The chilled water moves out and enters the application’s duct system to mediate the cooling effect.

Step 4

The scroll compressor further processes the evaporated refrigerant. It increases the temperature and pressure of the gas efficiently. The scrolls rotate to compress the refrigerant.

Step 5

A condenser containing copper coils and aluminum fins receives the incoming refrigerant and dissipates its heat through ambient air circulating over the condenser.

Step 6

The condensed refrigerant releases pressure through the expansion valve and enters the evaporator to cool down the coolant for the next refrigeration cycle.

Small Chiller Applications

What are the Advantages of Using a Small Chiller?

A Small Chiller offers various advantages for industrial applications, especially those with limited installation space:

Efficient Space Utilization

Its compact design and small footprint require minimal installation space, benefiting applications with limited room for a chiller setup.

Extended Service Life

The body is made of stainless steel material, copper coils, and aluminum fins to protect the unit from corrosion, ensuring durability and long service life.

Emergency Alarms

In case of temperature, pressure, or voltage fluctuations, the microprocessor unit activates emergency alarms to prevent extensive damage to the Small Chiller.

Noise-Free Operation

The installation of a scroll compressor ensures efficient and noise-free operation.

Noise-Free Small Chiller

Which Accessories can be Integrated With Small Chiller?

Though Small Chiller is a compactly designed, reliable, and energy-efficient unit, some accessory options can be integrated to increase its working efficiency as per application needs. These accessory options include:

• Water Circuit Electric Heater
• Remote Condenser
• Electric Heater Impregnated with Coils for Defrosting
• SS Covering
• Tube-in-Tube Type Heat Exchanger

Small Chiller Applications

What are the Applications of Small Chiller?

The chilled water supplied by Small Chiller helps release heat from various small-scale applications such as:

• Semiconductors
• Laser Industry
• Plastic Industry
• Metalworking
• Drilling
• Milling
• Injection Molding
• Biopharmaceutical
• Laboratories

Small Chiller Scroll Compressor

Which Compressor is Used in Small Chiller for Refrigerant Compression?

A scroll compressor is preferably used in Small Chiller for reliable and energy-efficient operation. It consists of a crankcase heater to maintain oil temperature and vibration isolators to ensure noise-free operation.

The scroll compressor comprises two scrolls. One scroll rotates over the fixed scroll unit, ultimately compressing the refrigerant.

What is the Function of the Microprocessor Controller in a Small Chiller?

The microprocessor is the controller unit of a Small Chiller that regulates the chiller’s cooling operation. It is programmed with setpoints required for the regular operation of the whole unit.

All basic features of the chiller are programmed into the microprocessor at the factory. The microprocessor displays any setpoint changes, whether related to temperature, pressure, or voltage. Emergency alarms, integrated with the microprocessor, alert the operator of problems before they cause significant damage.

Air Cooled Condenser Small Chiller

Which Type of Condenser is Used for Heat Discharge in Small Chiller?

The condenser is crucial in the refrigeration cycle, ensuring the condensation of gaseous refrigerant into the liquid phase. The Small Chiller mainly features air-cooled condensers.

Air-Cooled Condenser

An air-cooled condenser includes copper coils and aluminum fins, making it hydrophilic and corrosion-resistant. Fresh air, good ventilation, and suitable ambient temperature favor the installation of the air-cooled condenser.

The gaseous refrigerant with high temperature and pressure enters the copper coils of the condenser. Simultaneously, ambient air circulates over the coils, absorbing heat to condense the refrigerant into the liquid phase. The liquid refrigerant cools down after heat liberation, leaves the condenser, and enters the evaporator to cool down the water.

What is the Heating and Emergency Mode of Small Chiller?

A Small Chiller operates with different modes such as cooling, heating, emergency, quiet, and forced operation modes. Here is how the heating and emergency modes work:

Heating Mode

In heating mode, the refrigerant gets heated in condenser coils. The heat exchanger condenses the refrigerant by dissipating heat, with cooled water and heated refrigerant circulating in the heat exchanger. The refrigerant transfers its heat to the circulating water, heating it and producing a warming effect.

Emergency Mode

The emergency mode activates in case of malfunction. Mainly, it ensures regulated operation of the electric heater, switching it off when sufficient heating is achieved.

Heat Exchanger Used in Small Chiller

Which Type of Heat Exchanger is Used in Small Chiller?

Small Chiller is designed compactly for small spaces. For this reason, plate-type heat exchangers are preferable.

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PHE

The plate-type heat exchanger contains tubes within plates, occupying less space. The refrigerant flows inside the tubing, creating a turbulent flow for fast heat exchange between water and refrigerant. The plate heat exchanger is corrosion-resistant and can be impregnated with anti-freezing chemicals optionally.

Tube-in-Tube Heat Exchanger

A tube-in-tube heat exchanger is also installed based on application needs. It comprises two tubes coiled together compactly, reducing the unit’s overall size.

What is the Thermostat of Small Chiller and How Does it Work?

The thermostat is a temperature-regulating unit that maintains the chiller’s heating or cooling mode within the required range. It operates on the thermal expansion principle: an increase in temperature causes thermal expansion, triggering switches to power off. The unit resumes operation after the temperature is stabilized.

Small Chiller Environmental Friendly Refrigerant

Which Steps Should be Followed While Charging and Discharging Refrigerant in Small Chiller?

The Small Chiller is charged with refrigerant at the factory. Incorrect refrigerant charging can affect compressor performance. The refrigerant is discharged during maintenance or installation by following these steps:

• Remove the outer casing and attach the charging valve with a hose to start discharging.
• Cut off the power supply and ensure not to start discharging until the chiller’s complete processing stops.
• Follow protective measures to avoid frostbites during discharging.
• Once discharging is complete, create a vacuum. Prevent air from entering by removing the connected hose if the vacuum is not generated.
• Connect the vacuum pump, manometer, and charging valve to add a vacuum.
• Ensure the pressure is less than 80Pa to detect any pipe and tubing leaks.
• If no leakage is found, charge the refrigerant in liquid state to avoid composition changes and operational deviations.

Why is a Small Chiller Suitable for Your Small-Scale Applications?

Small Chiller is efficient in dissipating heat from a system, similar to large-sized chillers. However, it is more desirable for small-scale applications due to the following features:

Compact Design

It is designed to compactly integrate all components, aiding its installation in small spaces.

Lockable Caster Wheels

Its small size and caster wheels enable easy movement and installation. The wheels can be locked to secure the unit in position.

Small Footprints

Its small footprint design occupies less space while offering efficient cooling for small-scale applications.

Space-Saving PHE

The plate heat exchanger occupies less space and increases the heat exchange rate for small-scale applications using a turbulent flow principle.

Lockable Heavy-Duty Caster Wheels for Small Chiller

How Can You Increase the Service Life of Your Small Chiller?

Damage or failure of any component may disrupt the industrial budget. Implementing the following measures can increase its service life:

Check for Leakage

Regularly monitor the unit for any leakage in pipes and tubes of refrigerant or coolant. Repair any leaks to prevent significant losses.

Cut Off Power Supply When Not in Use

Disconnect the power supply and store the unit safely when not in use. Dust accumulation in the evaporator can decrease its service life.

Monitor Wiring and Voltage

Regularly check the wiring, power supply, and phase changes to prevent reverse compressor action. Maintain voltage within the specified range to avoid short-circuit damages.

Protection from Corrosion

Ensure no dust accumulation and avoid contact with chemicals to prevent corrosion.

Which Safety Measures Should be Followed for Operating Your Small Chiller?

Follow these safety measures when operating a Small Chiller:

• Do not operate the unit with wet hands to avoid electric shocks.
• Cut off the electric supply before cleaning to prevent electric shock damages.
• Do not place gas cylinders or pressurized sprays near the chiller to avoid explosions or fires.
• Do not operate the Small Chiller with little or no water in it.
• Use specialized electric circuits for the power supply instead of mobile terminal boards.
• Avoid placing anything on top of the chiller to prevent objects from falling.
• Choose a location with good ventilation for chiller installation to enhance efficiency and save energy.
• Ensure no obstruction in the air inlet and outlet. Air blockage decreases the unit’s efficiency and may cause it to stop.
• Disconnect the power supply and remove the plug when the chiller is not in use to prevent dust accumulation and heat exchanger issues.
• If the Small Chiller is damaged, avoid self-repair to prevent extensive damage, explosions, or electric shocks.

How to Increase the Working Efficiency of Your Small Chiller?

A Small Chiller efficiently provides cooling for various industrial applications. Its efficiency can be further enhanced by considering the following:

Daily Monitoring

Regularly inspect and monitor the unit daily. Record component performance and repair or replace any parts that detract from performance.

Maintenance and Cleaning

Clean all components daily to prevent dust accumulation that may hinder performance.

Heat Exchanger Cleaning

Clean the heat exchanger’s tubing and optionally apply anti-freezing material to prevent rust and ensure efficiency.

Preheat Compressor Oil

Preheat the compressor oil for about eight hours before starting the chiller to prevent mixing oil with refrigerant, thus increasing compressor efficiency.

Small Chiller Monitoring

What is the Start-Up Procedure of Small Chiller?

Before starting operation, consider the following for Small Chiller:

• Inspect the general appearance and internal piping to ensure no damage occurred during shipping.
• Verify the accessories integrated with the chiller for increasing capacity or other purposes.
• Perform tests to detect refrigerant pressure in each part and identify any leakage.
• Cut off the power supply for testing the unit. After testing, preheat the scroll compressor for about eight hours.
• Preheat the lubricating oil about eight hours before starting to prevent mixing with refrigerant and damaging the compressor.
• Ensure the compressor oil temperature is not above ambient temperature. If higher, check for damaged heating tape and replace or amend it.
• Check the power supply’s phase sequence. Correct any disturbances before starting the Small Chiller to protect the scroll compressor from reverse rotation.
• Finally, check the electric supply, heat load, oil temperature, and mode before start-up.
• Start the Small Chiller and observe the compressor, fan motor, and expansion valve.
• If high temperature and pressure occur, stop the operation.

How to Size a Small Chiller for Your Applications?

Small Chiller deals with different heat loads of industrial applications. Consider the following while sizing the chiller:

Heat Load

Inspect your application’s heat load and select a unit matching the heating load. Prefer