Refrigerant or water-cooling systems are used for temperature control in a variety of applications, including those in industrial, food and beverage, and commercial manufacturing in hospitals and clinics.In many cases, the integrity of the end product and the process itself is closely linked to accurate heat management to ensure quality while ensuring safe, efficient, and reliable operation. Engineers and operations managers are in charge of selecting and installing a process coolant system for precision cooling of industrial and low-viscosity refrigerants.
Featuring a unique design, Parker’s Hyperchill range of water cooled refrigerant exchangers ensures extremely precise and accurate temperature control of refrigerants (water, water-glycol mixture, low viscosity fluids). High-quality components in the hydraulic and refrigerant circuits ensure continuous operation and high energy efficiency, even at part load, reducing costs and environmental impact and thus promoting environmental improvement.
Design considerations
When designing a cooling system, a number of factors must be considered. Of these, the location, placement, and distance of the cooler from the application are among the most important. The type of application and the number of refrigerant exchangers needed for the process are other factors that influence system design.
Parker’s engineers agree on the following key points, which plant managers should consider to ensure effective installation and operation of the chiller exchanger and cooling system:
- Location and placement of the refrigerant exchanger
- Frost protection
- Chilled water circuit
- Filling kit options
- Electrical connection
- Remote control panel
- Cooling exchanger startup
Location and placement of the refrigerant exchanger
The location and placement of the coolant exchanger are critical to achieving and maintaining adequate cooling performance. In general, most chiller exchangers can be installed either indoors or outdoors.The Parker Hyperchill and Hyperchill Plus range of precision water chiller exchangers offers a reliable and robust cooling solution for both indoor and outdoor installations. Examination of the degree of protection is part of our recommended guidelines:
Indoor installation
The ICEP002, ICEP003 and ICEP005 refrigerant exchanger models have an inlet protection rating (IP) of 33 and must be installed indoors.
Indoor and outdoor installation
Hyperchill Plus models starting with ICEP007 have an IP54 rating and can be installed indoors or outdoors. The same is true for products in the Hyperchill range.
Positioning of the refrigerant exchanger
To maintain high system performance, it is essential that the area around the refrigerant exchanger is ventilated. The primary objective of the refrigerant exchanger is to remove the heat load from the water circuit by releasing it into the local atmosphere. If the surrounding environment is not adequately ventilated, heat will build up in the circuit, activating the sound alarm of the refrigerant exchanger. The following should be taken into consideration:
- Need to place the refrigerant exchanger in a well-ventilated area.
- Need to make sure that there is sufficient clearance on the sides, back, and above the unit (refer to the owner’s manual for more details on required clearance).
Frost protection
Exposure of a water-cooled system to low temperatures risks frost damage to the cooler and water circuit. Frost protection should be considered under the following circumstances:
- When the refrigerant exchanger is installed outside (and exposed to a low ambient temperature).
- The water temperature setting point is < 7 oC (45 oF).
Two options to avoid possible frost damage:
1.Include the antifreeze resistor option in the refrigerant exchanger specification.
- Applicable from model ICEP007 onward.
2.Add an antifreeze solution (ethylene glycol) to the cooling water.
- The minimum acceptable glycol content is 20% V/V.
- The total volume of glycol must not exceed 40% V/V.
In cases where a chilled water temperature < 7 oC (45 o F) is required, an antifreeze solution should be added to the process water.
The table below provides guidance on the percentage (%) of glycol required to meet specific outlet water temperatures:
If ethylene glycol is used in the chilled water system, it is important to consider the following 6 key factors:
- Do not use automotive antifreeze products. In fact, these products often contain additives that risk reducing heat transfer efficiency and damaging the coolant exchanger.
- Use only glycol-treated products. Untreated products may be corrosive to the water cooling system.
- Do not mix different glycol-based solutions and products from different brands. Different products may contain mutually incompatible inhibitors that are likely to dissociate causing problems for filters and pumps.
- It is important to follow environmental regulations and local regulations. Disposal, groundwater contamination, and water discharge all need to be considered.
- In most installations, shared running water can be used. However, if glycol is used, it is preferable to use deionized, demineralized or distilled water to avoid the risk of any impurities compromising the effectiveness of glycol inhibitors.
- Maintenance and hygiene of the system are two important aspects. The chilled water system should be drained, cleaned and sanitized before adding a new water-glycol mixture.
Chilled water circuit
When designing a complete chilled water circuit, the following points should be followed:
- Isolation valves should be installed at the inlet and outlet of the refrigerant exchanger.
- Circulation piping must be equipped with a regulating valve (see installation diagrams).
- To maintain the proper flow rate throughout the process and into the cooler, a manual bypass with flow control valve should be installed.
- Consideration should be given to using/installing a filter in the circulation pipes that feed into the process.
- The type of filling kit (manual or pressurized environment) should be appropriate for the application.
- The minimum diameter of piping is critical to achieve the expected flow rate.
- Piping material is critical in cases where a nonferrous system is required.
- In the absence of glycol, heating with external pipe tracing may be necessary.
- It is necessary to install automatic vents at the highest points of the water circuit.
- Special care should be taken when connecting piping to the threaded connections of the refrigerant exchanger. When tightening the coolant exchanger connections, it is necessary to ensure that their retention is adequate to avoid damaging the coolant exchanger.
- The pipes should be drained, then checked for leaks with water before refilling with a suitable antifreeze mixture.
Water filling kit options
According to the installation requirements of the refrigerant exchanger, the appropriate water filling kit should be selected. The available options are listed below:
Pressurized water filling kit
This option allows the cooler to be installed in a closed water circuit. The kit includes expansion tank, pressure relief valve, pressure reducing valve, pressure gauge and drain valve.
The refrigerant exchanger can be configured with the water filling kit already installed. Alternatively, the kit can be supplied separately from the refrigerant exchanger.
Note: After commissioning, the water supply can be isolated locally.
Room water filling kit
The ambient water filling kit can be used in open water circuit systems. The filling options are:
- The open-loop design of models ICEP002 to ICEP005 includes a water filler on the top cover and an external visual indicator.
- Models starting with ICEP007 can be supplied with external water filling kit. Alternatively, the kit can be supplied separately.
Electrical connection
Electrical work should be carried out by a qualified technician. Consult the manual before completing the electrical commissioning of the refrigerant exchanger and follow the following guidelines:
- A local disconnect switch should be installed near the refrigerant exchanger.
- The power supply must be protected by appropriate D-type fuse/switch.
- Once the installation is completed, the correct phase rotation of the unit should be verified.
Remote control panel
The Hyperchill range can include a remote control option. The refrigerant exchanger can be remotely controlled at two levels:
Basic control
- Cooling exchanger on/off control
- Coolant exchanger on/off signal
- General alarm signal
Advanced control
- Allows you to control all options of the advanced microprocessor module.
Cooling exchanger startup
Refer to the operation and maintenance guide and follow the prescribed steps. The basic controls include the following:
- Make sure that pipes are leak-proof and have been drained before filling with water (or glycol-based mixture).
- Check the phase protection device of the electrical cabinet. Green and orange indicators should be visible on the device.
Conclusions
Parker Hyperchill water coolers ensure consistently outstanding coolant quality and cleanliness, improve process efficiency and productivity, and reduce maintenance costs and downtime. By adhering to the recommendations of Parker’s engineers outlined above, you are assured of proper installation and excellent performance of the Hyperchill water cooling system.
Parker’s purpose
With more than 100 years of experience serving clients, Parker is often called upon to do its part to help solve the engineering industry’s most complex challenges. We help bring light to our clients’ ideas. We are a reliable partner, working side by side with them to support technological innovations and thus create a better world.
This post was written by James Brown, sales manager for the area pertaining to gases for analytical instruments/gas and compressed air processing, and Filippo Turra, product manager,
Parker Gas Separation and Filtration Division EMEA
Related Content
How to Distinguish a Process Water Cooler from a Chiller
Sizing a Chiller for Your Application – What You Need to Know.
Water Chilling for Temperature Control in MRI and CT Scanners
Refrigerant or water-cooling systems are used for temperature control in a variety of applications, including those in industrial, food and beverage, and commercial manufacturing in hospitals and clinics.In many cases, the integrity of the end product and the process itself is closely linked to accurate heat management to ensure quality while ensuring safe, efficient, and reliable operation. Engineers and operations managers are in charge of selecting and installing a process coolant system for precision cooling of industrial and low-viscosity refrigerants.
Featuring a unique design, Parker’s Hyperchill range of water cooled refrigerant exchangers ensures extremely precise and accurate temperature control of refrigerants (water, water-glycol mixture, low viscosity fluids). High-quality components in the hydraulic and refrigerant circuits ensure continuous operation and high energy efficiency, even at part load, reducing costs and environmental impact and thus promoting environmental improvement.
Design considerations
When designing a cooling system, a number of factors need to be considered. Of these, the location, placement, and distance of the cooler from the application are among the most important. The type of application and the number of refrigerant exchangers needed for the process are other factors that influence system design.
Parker’s engineers agree on the following key points, which plant managers should consider to ensure effective installation and operation of the chiller exchanger and cooling system:
Location and placement of the refrigerant exchanger
Frost protection
Chilled water circuit
Filling kit options
Electrical connection
Remote control panel
Cooling exchanger startup
For detailed information on the refrigeration process, refrigeration solutions, operation and system design, see the interactive video.
Location and placement of the refrigerant exchanger
The location and placement of the coolant exchanger are critical to achieving and maintaining adequate cooling performance. In general, most chiller exchangers can be installed either indoors or outdoors.The Parker Hyperchill and Hyperchill Plus range of precision water chiller exchangers offers a reliable and robust cooling solution for both indoor and outdoor installations. Examination of the degree of protection is part of our recommended guidelines:
Indoor installation
The ICEP002, ICEP003 and ICEP005 refrigerant exchanger models have an inlet protection rating (IP) of 33 and must be installed indoors.
Indoor and outdoor installation
Hyperchill Plus models starting with ICEP007 have an IP54 rating and can be installed indoors or outdoors. The same is true for products in the Hyperchill range.
Positioning of the refrigerant exchanger
To maintain high system performance, it is essential that the area around the refrigerant exchanger is ventilated. The primary objective of the refrigerant exchanger is to remove the heat load from the water circuit by releasing it into the local atmosphere. If the surrounding environment is not adequately ventilated, heat will accumulate in the circuit activating the sound alarm of the refrigerant exchanger. The following should be taken into consideration:
Need to place the refrigerant exchanger in a well-ventilated area.
Need to make sure that there is sufficient clearance on the sides, back, and above the unit (refer to the owner’s manual for more details on required clearance).
Frost protection
Exposure of a water-cooled system to low temperatures risks frost damage to the cooler and water circuit. Frost protection should be considered under the following circumstances:
When the refrigerant exchanger is installed outside (and exposed to a low ambient temperature).
The water temperature setting point is < 7 oC (45 oF).
Two options to avoid possible frost damage:
1.Include the antifreeze resistor option in the refrigerant exchanger specification.
Applicable from model ICEP007 onward.
2.Add an antifreeze solution (ethylene glycol) to the cooling water.
The minimum acceptable glycol content is 20% V/V.
The total volume of glycol must not exceed 40% V/V.
In cases where a chilled water temperature < 7 oC (45 o F) is required, an antifreeze solution should be added to the process water.
The table below provides guidance on the percentage (%) of glycol required to meet specific outlet water temperatures:
If ethylene glycol is used in the chilled water system, it is important to consider the following 6 key factors:
Do not use automotive antifreeze products. In fact, these products often contain additives that risk reducing heat transfer efficiency and damaging the coolant exchanger.
Use only glycol-treated products. Untreated products can be corrosive to the water cooling system.
Do not mix different glycol-based solutions and products from different brands. Different products may contain mutually incompatible inhibitors that are likely to dissociate causing problems for filters and pumps.
It is important to follow environmental regulations and local regulations. Disposal, groundwater contamination, and water discharge all need to be considered.
In most installations, shared running water can be used. However, if glycol is used, it is preferable to use deionized, demineralized or distilled water to avoid the risk of any impurities compromising the effectiveness of glycol inhibitors.
Maintenance and hygiene of the system are two important aspects. The chilled water system should be drained, cleaned and sanitized before adding a new water-glycol mixture.
Chilled water circuit
When designing a complete chilled water circuit, the following points should be followed:
Isolation valves should be installed at the inlet and outlet of the refrigerant exchanger.
Circulation piping must be equipped with a control valve (see installation diagrams).
To maintain the proper flow rate throughout the process and into the cooler, a manual bypass with flow control valve should be installed.
Consideration should be given to using/installing a filter in the circulation pipes that feed into the process.
The type of filling kit (manual or pressurized environment) should be appropriate for the application.
The minimum diameter of piping is critical to achieve the expected flow rate.
Piping material is critical in cases where a nonferrous system is required.
In the absence of glycol, heating with external pipe tracing may be necessary.
It is necessary to install automatic vents at the highest points of the water circuit.
Special care should be taken when connecting piping to the threaded connections of the refrigerant exchanger. When tightening the coolant exchanger connections, it is necessary to make sure that their retention is adequate to avoid damaging it.
The pipes should be drained, then checked for leaks with water before refilling with a suitable antifreeze mixture.
Water filling kit options
According to the installation requirements of the refrigerant exchanger, the appropriate water filling kit should be selected. The available options are listed below:
Pressurized water filling kit
This option allows the cooler to be installed in a closed water circuit. The kit includes expansion tank, pressure relief valve, pressure reducing valve, pressure gauge and drain valve.
The refrigerant exchanger can be configured with the water filling kit already installed. Alternatively, the kit can be supplied separately from the refrigerant exchanger.
Note: After commissioning, the water supply can be isolated locally.
Room water filling kit
The ambient water filling kit can be used in open water circuit systems. The filling options are:
The open-loop design of models ICEP002 to ICEP005 includes a water filler on the top cover and an external visual indicator.
Models starting with ICEP007 can be supplied with external water filling kit. Alternatively, the kit can be supplied separately.
Electrical connection
Electrical work should be carried out by a qualified technician. Consult the manual before completing the electrical commissioning of the refrigerant exchanger and follow the following guidelines:
A local disconnect switch should be installed near the refrigerant exchanger.
The power supply must be protected by appropriate D-type fuse/switch.
Once the installation is completed, the correct phase rotation of the unit should be verified.
Remote control panel
The Hyperchill range can include a remote control option. The refrigerant exchanger can be remotely controlled at two levels:
Basic control
Cooling exchanger on/off control
Coolant exchanger on/off signal
General alarm signal
Advanced control
Allows you to control all options of the advanced microprocessor module.
Cooling exchanger startup
Refer to the operation and maintenance guide and follow the prescribed steps. The basic controls include the following:
Make sure the pipes are leak-proof and have been drained before filling them with water (or glycol-based mixture).
Check the phase protection device of the electrical cabinet. Green and orange indicators should be visible on the device.
Conclusions
Parker Hyperchill water coolers ensure consistently outstanding coolant quality and cleanliness, improve process efficiency and productivity, and reduce maintenance costs and downtime. By adhering to the recommendations of Parker’s engineers outlined above, you are assured of proper installation and excellent performance of the Hyperchill water cooling system.
Parker’s purpose
With more than 100 years of experience serving clients, Parker is often called upon to do its part to help solve the engineering industry’s most complex challenges. We help bring light to our clients’ ideas. We are a reliable partner, working side by side with them to support technological innovations and thus create a better world.
For detailed information on the refrigeration process, refrigeration solutions, operation and system design, see the interactive video.
This post was written by James Brown, sales manager for the area pertaining to gases for analytical instruments/gas and compressed air processing, and Filippo Turra, product manager, Parker Gas Separation and Filtration Division EMEA
Related Content
How to Distinguish a Process Water Cooler from a Chiller
Sizing a Chiller for Your Application – What You Need to Know.
Water Chilling for Temperature Control in MRI and CT Scanners
Parker Hannifin | Parker Hannifin