Maintaining oil temperature within your hydraulic system is critical for performance & longevity
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Unlike leaks, which rank Number 1, the causes of overheating and its remedies are often not so well understood by maintenance personnel and can frequently be ignored.
It is important to understand that where there is pressure drop in your hydraulic system, there is heat being generated. This means that any component in the system that has abnormal, internal leakage will increase the heat load on the system and can cause the system to overheat. This could be anything from a cylinder that is leaking high-pressure fluid past its piston seal, to an incorrectly adjusted relief valve. Identify and change-out any heat-generating components.
Continuing to operate a hydraulic system when the fluid is over-temperature is like operating an internal combustion engine with high coolant temperature, damage is guaranteed. Therefore, whenever a hydraulic system starts to overheat, shut it down, identify the cause and fix it
A common cause of heat generation in closed centre circuits is the setting of relief valves below, or too close to, the pressure setting of the variable-displacement pump’s pressure compensator. This prevents system pressure from reaching the setting of the pressure compensator. Instead of pump displacement reducing to zero, the pump continues to produce flow, which passes over the relief valve, generating heat. To prevent this problem in closed centre circuits, the pressure setting of the relief valve(s) should be 250 PSI above the pressure setting of the pump’s pressure compensator.
Air-cooled systems dissipate heat with flowing air. This type of cooler operates by forcing cold air over hot fluid inside a heat exchanger’s coil or core. Low running cost and simple maintenance are attractive benefits of air-cooled systems. They also eliminate water-contamination problems and minimize corrosion. Additionally, heat generated from air-cooled systems can be used for other purposes.
On the downside, the upfront expense of an air-cooled system typically exceeds that of a water-cooled unit. Air-based versions are also larger and generate more noise, so they can degrade the work environment. What is more, these coolers require ventilation and clean air, and variations in ambient temperature can greatly affect cooling capacity — making steady-state operation more difficult to maintain.
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Water-cooled systems use cold water to remove heat, with hot and cold fluids separated by a barrier. Compared to air-cooled systems of equivalent capacity, water-cooled systems have lower up-front costs. They are also quiet, compact, and do not alter the surrounding ambient temperature. Variations in air temperature have little or no effect on cooling capacity, which allows for greater consistency. Meanwhile, the system’s heated water can be used for other on-site purposes.
Although water-cooled coolers cost less, they generally require clean water. Continuously running water can be expensive, leading to higher operating costs. Other concerns include risk of corrosion and erosion, and increased maintenance. Water-cooled units can also freeze in cold weather, letting water contaminate the oil.
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A hydraulic oil chiller/refrigeration system will maintain hydraulic fluid within a narrow temperature range regardless of the ambient temperature. A chiller uses a brazed-plate heat exchanger with hydraulic fluid on one side and refrigerant to flow on the other. The heat exchanger is designed to produce turbulent flow of the hydraulic fluid for maximum heat transfer to refrigerated plates. The refrigerant cools hydraulic oil rapidly and allows maintaining temperature to within ±0.5° F.
The oil chiller is the most accurate method of maintaining oil temperature however they do take up considerably more space and the capital investment is higher than either Air blast or water cooler systems.
Hydraulic Oil Chiller is a highly reliable temperature maintenance device that ensures the cooling of hydraulic oils for hydraulic-based machines.
It is furnished with a compact stainless steel body and caster wheels optionally for easy movement of the whole unit. It contains a highly developed refrigeration circuit to dissipate the heat from the oil supply.
Temperature controller and digital thermostat are equipped with it as safety components ensuring durability and reliability to deal with the high-temperature load.
Hydraulic Oil Chiller protects CNC, injection molding and broaching machines, etc., by maintaining the oil viscosity and heat dissipation.
Hydraulic Oil Chiller Designed by TopChiller
Hydraulic Oil Chiller is a reliable cooling unit that comes with some basic key features as given below:
Hydraulic Oil Chiller Compressor
Hydraulic Oil Chiller is used to cool the oil of hydraulic machines by connecting it directly with oil pumps or oil supply requiring cooling.
The main components which are involved in the production of the chilling effect are given below:
Compressor
A scroll or screw compressor is integrated to increase the temperature and pressure of the circulating refrigerant. A scroll compressor is highly reliable with its smooth and silent working.
It plays its efficient working by its two rotating parts. One is a fixed scroll, while the other part moves over the other scroll.
Condenser
Both air-cooled condenser and water-cooled condenser can be used for heat liberation collected from heated oil.
The air-cooled condenser discharges heat from refrigerant through air circulated over condenser coils. While the water-cooled condenser releases heat through chilled water circulation coming from the water tank.
Evaporator
Plate type heat exchanger or shell and tube type heat exchanger is installed with Hydraulic Oil Chiller for heat exchange between hot oil and refrigerant. PHE is widely used for heat exchange designed with stainless steel material and brazed joining.
Cooling Fan
The cooling fan protects thermal overloading by releasing temperature and pressure from the refrigerant that leaves the condenser. The phase of refrigerant changes from a gaseous state to a liquid state.
Temperature Controlling Unit
The temperature controlling unit maintains the temperature with a digital screen display. Any temperature change is monitored through an alarm system integrated with the controlling unit.
Hydraulic Oil Chiller Cooling Fan
Most processing machines use hydraulic oils for their normal working and lubrication. During machine processing, the machine oils get heated and may cause a hindrance in the smooth working of hydraulic machines.
So Hydraulic Oil Chiller cools the machine oil in the following way:
Step 1
The water/glycol coolant is installed to cool the heated oil. The hydraulic oil either directly circulates through a chiller or is cooled down by an installed coolant.
Step 2
The glycol/water coolant absorbs heat from hydraulic oil and gets heated. The hot coolant enters inside the plate type/shell or tube-type evaporator for getting cooled back through refrigerant.
Refrigerant and coolant flow in a counter-current manner and exchange heat. The refrigerant absorbs heat from the coolant, and the chilled coolant flows back towards the oil supply/oil pump of processing machines for cooling.
Step 3
After absorbing heat, the heated refrigerant leaves the evaporator with low temperature and pressure and enters the compressor.
Step 4
The scroll or screw compressor receives the incoming vaporized refrigerant and liquefies it by increasing its temperature and pressure. The compressor assists the condenser in condensation of the refrigerant.
The compressed refrigerant discharges out and enters the condenser for finalizing the heat discharge.
Step 5
An air-cooled condenser or water-cooled condenser receives compressed refrigerant that circulates in condenser coils. Air/water circulates over refrigerant, absorbs heat, and condenses it into the liquid phase.
The air dissipates out in the environment. While in the case of water circulation, water moves towards the cooling tower to restore its chilling effect.
Step 6
Expansion valves are also integrated with Hydraulic Oil Chiller to lower the temperature and pressure of the refrigerant before its entrance into the evaporator.
Step 7
After the expansion refrigerant enters the evaporator, the whole process is repeated until the working process may not get completed.
Hydraulic Oil Chiller is a renowned and reliable cooling device for its wide range of industrial applications. It offers an assorted number of advantages for its respective application as given below:
Maintenance of Oil Viscosity
The heat produced by processing machines decreases oils’ viscosity, resulting in oil leakage in different machine parts.
The refrigeration circuit of the Hydraulic Oil Chiller circulates the machine oil configuring the cooling effect with extra heat dissipation.
Durability
High-temperature production in the machine may cause molding and damage to machine components. When a chiller is installed, it makes the constant dissipation of heat from the machine, ensuring longer service life.
Increase in Working Efficiency
Maintenance of recommended temperature by Hydraulic Oil Chiller increase working efficiency and machine productivity. The whole machine is lubricated with oil, assuring the machine’s working at peak efficiency.
Reliability
It assists machine to face lower shutdowns, increase machine uptime, and ultimately reduces the need for machine repairing and maintenance.
Air Cooled Hydraulic Oil Chiller
Air Cooled Hydraulic Oil Chiller is a cooling unit that dissipates the heat from refrigerant through air circulating over condenser coils.
The air-cooled condenser is designed with aluminum fins and copper tubules in which the refrigerant flows. The heated refrigerant enters with high pressure and temperature.
Ambient air over condensing coils absorbs heat from refrigerant when it circulates in coils.
The condensed refrigerant moves toward the evaporator to complete the refrigeration cycle. While air directly discharges out in the environment.
Water Cooled Hydraulic Oil Chiller
When environmental air is very corrosive and dusty, and ambient temperature greater than 55˚C, the water-cooled condenser is preferred to integrate with chiller.
A water-cooled condenser consists of tube-in-tube coils. Refrigerant enters these coils after compression through the compressor.
Chilled water also circulates in tubing over condenser coils. After dissipating heat from the refrigerant, the water moves towards the cooling tank to cool back again.
Water Cooled Hydraulic Oil Chiller
A Hydraulic Oil Chiller is widely used for an assorted number of applications requiring oil cooling that is used for processing of machines as given below:
Applications of Hydraulic Oil Chiller
A refrigerant is a chemical compound that is mostly available in the liquid state and can readily absorb heat from a system.
For heat dissipation from a system, refrigerant is also installed in Hydraulic Oil Chiller. The R134A, refrigerant, R404, R410A, and R407C refrigerant can be used optionally for efficient heat absorption from hydraulic oil.
Refrigerant is the essential component of the refrigeration cycle that mediates the overall processing of the chiller.
Refrigerant circulates heat in the refrigeration cycle by changing its phase and finally discharges heat from the system.
Hydraulic Oil Chiller Refrigerant
Hydraulic Oil Chiller ensures the cooling of hydraulic oils by dissipating the heat produced by machine tools while working.
Its ambient temperature controlling range is 10˚C to 50˚C. Its cooling capacity ranges from 1.75KW to 50KW.
Some hydraulic-based machines use oils that get heated with time, cause a change in machine characteristics and ultimately make it useless for further processing.
The Hydraulic Oil Chiller is configured to bear the high heat load with its specific temperature controlling range. So it feasibly discharges heat from hydraulic oils.
A compressor is an integral unit of the refrigeration cycle that puts compression over refrigerant and increases its pressure to assist the condensation of refrigerant in the condenser.
Two types of compressors are being used for reliable and energy-efficient working of the Hydraulic Oil Chiller as given below:
Contact us to discuss your requirements of hydraulic oil chiller manufacturers. Our experienced sales team can help you identify the options that best suit your needs.
1-Scroll Compressor
A scroll compressor is a highly effective and noise-free working unit that reduces power consumption and other costs under its simple design. The scroll compressor consists of two rotating parts.
One scrolling unit is fixed while the other rotates over the scroll compressor’s fixed part, ensuring noise-free working.
The optimized compressor is specially designed for a hydraulic chiller to bear the load easily.
2-Screw Compressor
The screw compressor also consists of two rotating spiral screws. It compresses the incoming refrigerant efficiently by positive displacement rotary movement of screws.
Screw compressor has replaced reciprocating compressors requiring a little volume of compressing gas, ensuring no volumetric loss of refrigerant.
Chiller Models Based on Number of Compressors
Based on workload, three different models of Hydraulic Oil Chiller are available:
For safe, protective, and efficient working, different accessories options are integrated with Hydraulic Oil Chiller as given below:
Hydraulic Oil Chiller Flow Switch
The digital thermostat is a temperature regulating unit with a digital display screen. The thermostat is set with ‘ON’ and ‘OF’ switches based on required cooling adjustments.
A digital thermostat regulates the high/low temperature of the oil.
Alarms and oil temperature sensors are configured with a thermostat that rings when a change occurs in oil temperature.
Two types of heat exchangers/evaporators can be used for heat exchange between refrigerant and coolant in Hydraulic Oil Chiller oil as given below:
Shell and Tube Type Heat Exchanger
Shell and tube-type heat exchanger consists of a shell and a bundle of tubules inside the shell.
The refrigerant flows inside the tubules. At the same time, the other fluid, either coolant or direct oil supply, flows over tubules for heat exchange.
The refrigerant absorbs heat from the oil and converts it into refrigerant gas. At the same time, the coolant moves back towards the working machine.
The copper-designed shell and tube type is resistive to corrosion but occupies an ample space as compared to PHE.
PHE (Plate Heat Exchanger)
The brazed plate heat exchanger is an efficiently working evaporator by configuring the turbulence flow of fluid. The plate-type heat exchanger consists of the plate in which firmly impregnated tubules.
One fluid flows in plates while the other fluid is in tubules. The heat gets exchanged between fluids from hot to cold fluid.
The evaporated refrigerant leaves the heat exchangers to recover its liquid phase. At the same time, the other fluid or coolant turns back to the system.
PHE occupies less space than shell and tube-type heat exchangers with its reliable design and working efficiency.
Hydraulic Oil Chiller Plate Heat Exchanger
Two types of condensers are used for heat dissipation from Hydraulic Oil Chiller that is given below:
Air Cooled Condenser
When there is low ambient temperature, and the environment is clean from dust and rusting factors, the air-cooled condenser is preferred to use.
The air-cooled condenser consists of copper tubing with aluminum fins ensuring protection from corrosion.
Air circulates over condenser coils containing compressed and vaporized refrigerant.
Air absorbs the heat from the refrigerant to cool it down for the continuation of the refrigeration cycle and spreads in the surrounding environment ensuring refrigerant cooling.
Water Cooled Condenser
In case of high ambient temperature, the water-cooled condenser is installed for efficient heat release from the system.
It consists of a tube-in-tube system where the refrigerant and chilled water circulate. Heat exchanges between refrigerant and water.
Refrigerant gets cooled after heat liberation and leaves the condenser to enter the evaporator for heat discharge.
While water with absorbed heat flows back in the cooling tank for recovering its cooling from coming with the next refrigeration cycle.
Some of the hydraulic based machinery is configured with hydraulic oil that may get heated and cause different problems as:
Hydraulic Oil Chiller sort out these problems in the following way:
Hydraulic oil used in machines heats up periodically because the machine releases heat while operating. The dissipating heat lowers the viscosity of the oil.
Oil becomes thin with decreased viscosity, resulting in internal oil leakage with different machine parts damages.
The heat produced by heat stock and gear causes the spindle to heat up and deviate from its working position.
Hydraulic Oil Chiller maintains oil’s viscosity by dissipating heat produced during machine processing.
The refrigeration circuit of the chiller cools down the hydraulic oil resulting in the maintenance of oil viscosity.
The coolant from the chiller maintains the machine’s temperature, prevents the oil from degradation, and ensures the longer service life of the machine.
Hydraulic Oil Chiller Refrigeration Cycle
Conventional Method of Oil Cooling
In the conventional method, the machine’s hydraulic oil is cooled down by using a cooling tower in the heat exchanger. The cooling tower discharges the heat from incoming heated oil in the heat exchanger.
But the drawback of this conventional method is that the temperature of water in the cooling tower does not remain constant. With time oil temperature deviates, resulting in a decrease the working efficiency.
The heat exchanger gets clogged due to a change in water quality. So the heat does not dissipate completely from hydraulic oil, affecting the working efficiency of working machines.
In the conventional method, a shell and tube-type heat exchanger is used to cool the oil circulating over the refrigerant in exchanger tubes.
Hydraulic Oil Chiller for Oil Cooling
Thus for better machine performance, Hydraulic Oil Chiller is being used that constantly maintains the viscosity and temperature of processing machines. It is featured with a gear pump that mediates the oil supply towards the chiller from the powerpack.
Oil is processed through a refrigeration circuit. Heat is exchanged between the refrigerant and heated oil. After heat discharge, the chilled oil is transferred back into the powerpack.
The brazed plate heat exchanger is being used to ensure rapid and efficient cooling of the oil. PHE is compact, covering less space than shell and tube-type heat exchangers.
The PHE provides the turbulent flow between oil and refrigerant counter-current flow, ensuring efficient heat dissipation.
The microprocessor is a specialized part of the Hydraulic Oil Chiller installed for automation control.
The microprocessor performs its function through a proactive controlled strategy and ensures the safety of the whole unit by making simple diagnostics.
The factory programmed the microprocessor to regulate the automation system according to the application requirements and features.
The microprocessor is user-friendly to answer questions typed in English. The microprocessor provides options in English for controlling cooling and other features of the Hydraulic Oil Chiller.
Hydraulic Oil Chiller Controller
A Hydraulic Oil Chiller is used for a vast number of industrial applications requiring heat dissipation produced during machine working. Different applications need this chiller of different sizes and types.
It can be sized for an application by keeping in view some critical points as given below:
Ambient Temperature
If the ambient temperature of the environment where the Hydraulic Oil Chiller has to work is less than 55˚C, then select the chiller with an air-cooled condenser.
While if the temperature goes above 50˚C and the environment is with dusty air, then make sure to select the chiller containing water-cooled condenser.
Heat Load
Make sure to calculate the heat load of your application and then select the Hydraulic Oil Chiller according to the cooling capacity and temperature, controlling a range of chiller.
Cost
Consider your budget while choosing the chiller for your application. Always select the chiller that would be suitable and comparable to your budget.
Even after regular maintenance and inspection, Hydraulic Oil Chiller can face some problems and degradation in performance with time.
The problems can be evaporator clogging, refrigerant leakage, reduction in the compressor’s working efficiency, etc.
Some common issues can be troubleshot of a Hydraulic Oil Chiller in the following way:
Chiller is Not Running
If the chiller has stopped running, check out the circuit breaker, electric wires as well as controlled switches.
Inspect the problem, adjust the refrigerant temperature/ pressure and turn ON the chiller.
Low Cooling of Coolant
Check and inspect the cooling of the coolant that discharged out from the evaporator. If cooling does not come close to on set point, the problem would be due to clogging/freezing of the evaporator.
To troubleshoot the problem, use the anti-freezing agent or replace the evaporator with a new one in case of clogging.
The Ringing of Temperature Sensor Alarm
If a high-temperature sensor alarm runs while Hydraulic Oil Chiller is processing, it will be due to a high heating load.
Maintains the heating load at the normal range for smooth flow of chiller.
The Ringing of Low Liquid Alarm
If the low liquid alarm is on while working, the problem would be a reduction in refrigerant level or circulation system.
Troubleshoot this problem by reinstalling the refrigeration or regulating the circulation system at a set point.
Hydraulic Oil Chiller Troubleshooting
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