Key Questions to Ask When Ordering spindle oil chiller

Importance of the chiller selection

In order to operate the chiller stably, it is important to choose one that matches the operating conditions and circumstances of the equipment. It is also necessary to take note of the chiller installation location and the piping distance and shape, etc.

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When selecting a chiller, it is important to match the operating conditions and circumstances with the functions, performance, and specifications of the chiller.
If this matching work is neglected, it is possible that after actually starting operation, the expected performance may not be demonstrated, or it may lead to problems occurring in the devices and chiller to be cooled themselves.
In addition to the set temperature of the workpiece (to be cooled) and the heat value problem, the selection of chiller models is not simple compared to the selection of other equipment, for example, the lifting height differs depending on the thickness, length, and shape of the piping connecting the workpiece and chiller.
Therefore, in this volume, we will introduce a selection method for choosing a chiller suitable for your facility in an easy-to-understand manner.

4 verification and determination processes for chiller selection

As mentioned above, it is important to select a chiller that is suitable for the equipment and work to be cooled. In order to select the most suitable chiller, there is a process of determination to be carried out while checking the operating conditions. Let’s select a chiller which is most suitable for the equipment by following 4 verification and determination processes introduced below.

Structural diagram of chiller and workpiece (subject to cooling)

Chiller selection step 1: Specify circulated water temperature

The temperature of the circulating water is determined from the optimal temperature of the workpiece (device or process subject to cooling by the chiller).

(1) Determine the optimum temperature of the workpiece to cool.
(2) Determine the temperature of the circulating water.

Chiller selection step 2: Determine the installation location [outdoors ⇔ indoors] and cooling method [air cooling ⇔ water cooling]

(3) Decide whether to install the equipment outdoors or indoors, and whether the cooling method should be air-cooled or water-cooled.

○Outdoor installation (PCU-SL Series only)

• If you want to avoid the exhaust heat being discharged indoors (for air cooling)
• If you want to avoid air flowing indoors (for air cooling)
• If there is no space to install indoors

○Indoor installation

• If you want to run the chiller near the facility
• If you want to shorten the piping (reduce the pressure loss, reduce the piping cost)
• If you want to reduce the installation man-hours

●Water cooling [cooling the circulating water by heat exchange with the cooling water]

• When cooling water (tap water, well water, cooling tower, etc.) can be arranged
• When the exhaust and waste heat become a problem (when setting precise air conditioning, deterioration of the work environment, etc.)

●Water cooling [cooling the circulating water by heat exchange with the outside air]

• When cooling water (tap water, well water, cooling tower, etc.) cannot be arranged easily
• When the exhaust and waste heat due to air cooling are tolerable

Features and internal structure diagrams of air-cooled chillers and water-cooled chillers

Chiller selection step 3: Specify cooling capacity

(4) Calculate the capacity required for cooling from the temperature changes in the workpiece, flow rate and temperature difference of the circulating water and so on.
For more information on how to determine the cooling capacity of chiller, refer to the calorific calculation method.

Chiller selection step 4: Check the required lifting height (pump capacity)

The required lifting height (capacity of the pump to deliver circulating water) varies depending on the piping conditions below.
Determine the required “lifting height” based on the piping length (5), pipe diameter (6), and the joints (7) (number of bends), and check whether the pump capacity of the selected chiller is sufficient.
For more information on how to calculate the required lifting height, refer to the lifting height calculation method.

Calorific calculation method

When choosing the capacity of the chiller,
(1) Calorific value of heat load < (2) Chiller cooling capacity
ensure that the condition above is satisfied. The calorific value of the heat load and the cooling capacity of the chiller are calculated by the following equation (calculation examples and reference materials are available).

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(1)  Calorific calculation method

PCU Series calorific calculation method

Calculation example (3)

After undergoing heat treatment, when you want to cool an iron workpiece with a mass of 3 kg from 250 to 40 °C in 3 minutes

Based on the physical properties table below, (2) 0.46, and (4) 250 - 40 = 210
perform unit conversion, (5) 3 min = 180 sec

convert the unit by multiplying the volume by the density i.e. volume [m3] × density [kg/m3] = mass [kg], so (1) × (3) = 3,

and substitute the values above into the formula to derive the value below
( 3 x 0.46 x 210 / 180) x 1.2 (Safety factor) = 1.93 kW

(2) Chiller capacity verification method

The circulating water temperature (set temperature of the chiller), ambient temperature (for air cooling), and cooling water temperature (for water cooling) are verified and calculated from the characteristics graph of the target model.

Example) Determine the cooling capacity of the PCU-R when the circulating water temperature is 25 °C and the ambient temperature is 20 °C.

The cooling capacity determined from the graph above is W. (Selected at a frequency of 60 Hz)

How to calculate the lifting height

The power of the pump required to circulate the cooling water can be expressed by the “lifting height”.
The lifting height varies depending on the condition of the piping connecting the chiller to the load (equipment), but the calculated lifting height must ensure that the pump’s capacity is greater than the piping. A method of calculating the lifting height from the piping conditions, etc. is shown below.

Step 1: Determine the piping length.

Length of piping from chiller to equipment:
3 + 5 + 4 = 12 m × 2 (to and fro) = 24 m…(1)

Step 2: Convert the resistance of the joint to a straight pipe length and add it to the piping length.

Determine the equivalent straight piping length of the joint from the table.

According to the table … Threaded type 90° short elbow 25 A → 1.6 m
1.6 x 4 (point) = 6.4m…(2)
(1)+(2)=24m+6.4m=30.4m…(3)

Step 3: Determine the “water head loss*Hf(m)” from the flow rate and piping diameter, and multiply it by the total piping length in “Step 2”.

The job of an oil cooler is very similar to the radiator in your car, except that we use refrigeration to cool the oil, which chills the coiling loop around the spindle housing, allowing the machines to run at faster speeds. 

The reality of a spindle is that to keep the parts coming out accurately, the temperature must be maintained, and oil is a great medium for controlling heat. Often when a spindle malfunctions or needs to be repaired, your oil cooler may be a part of the problem.

While oil chillers are durable and smart, they need to be regularly maintained to ensure that they are running efficiently and correctly. If an oil chiller goes bad, the spindle will follow, and spindle repair is expensive. Oil coolers and spindles are affected by ambient temperature as well, and this could lead to problems.

When customers call into All World, we can usually diagnose the problem over the . We have an extensive collection of documentation and knowledge to help you through the process. Some of the more common error codes are listed below:

In the case where an oil cooler system is sent in, it is inspected and quoted for the estimated cost of repair. Once the purchase order is received the unit is scrubbed down, cleaned, and flushed. Once the components needed for the repair are changed, the unit is plugged in, run and tested, inspected again and sent back to the customer. Our goal is to create a clean bill of health for each unit that is sent to us for oil cooler maintenance and repair so that they are ready to get back to work. With the efficiency and knowledge of the team, the turnaround time for your oil cooler is usually averaged around 5-10 days upon arrival, though some turnarounds are much faster.

In some cases, the cost of the repair is equal to or close to the price of a new unit. When that happens, All World will offer an option that works as a drop-in replacement. Most replacement options are in stock and are ready to ship same day.

All World services a range of oil chiller lines of various manufacturers, makes, and models, such as Daikin oil chillers, Habor, MAC, Kanto Seiki, Panasonic, Matsushita, and other brands. We have two locations in Georgia and Illinois to better serve our customers.

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