Small Chiller Supply

Providing independence from OEM pricing since 2003!

~ Controlling cost with quality after-market products ~

Attn: FM3523, 7413 E. County Rd 6900,   Lubbock, Texas  79403-7639     (806)  782-4570

 

 

 

 

Main Start

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  ~ SERVICE ~  
   

    Quick Tips

  1. Remove cap tube & consider replacement - (Flush condenser / evaporator separately)
  2. Evacuate & dry nitrogen pressure test before compressor installation with 2 fittings required - (Brazed plate evaporator sections are the worst!)
  3.Check or replace starter contactor block
  4.Inspect circulating pump intake screen (possible blockage)
  5.Test circulating pump volume (use flow meter)

    Service Warnings!

 

  Compressor Change Out Quick Tips
  Glycols Information Page

 

   

    SERVICE WARNING PHOTOGRAPHS

  Brazed plate evaporator Brazed plate evaporator  
   
       
  micro-channel condenser micro-channel condenser  
   
       
  Copper spun screen liquid line filter Ė drier  
   
       
  Inside Water-glycol sediments Outside Water-glycol sediments  
   
       
  Mineral Oil sediments Mineral Oil sediments  
   
       
       

    ***   OEM BRAND SPECIFICS:

 

  Daikin (DAIKIN Hydraulics)
  Daikin Hydraulics North America; All World Machinery Supply, Illinois
  Daikin Global / Daikin Applied / Fluorochemicals / Plant / Hydraulics
   
  Daikin PDF link
   
  Habor Precise
   
  The chiller and other refrigerated products of Habor Precise (once known as Ou Shih Precise) can be supported by some USA available, aftermarket parts. Your challenge, should you own or service one, is Habor's warranty policy. The machine tool distributor is about your only hope. Once that unit leaves the island of Taiwan, the warranty is not a factory issue. The chiller and cooling products of Habor Precise are built in Taiwan and three firms mimic each other in terms of oil cooling products: Habor Precise, Point (Wexton) and KauKan
   
  Kanto Seiki
   
  The chiller and other refrigerated products of Kanto Seiki are built in the Kanto region of Japan. Seiki in Japanese is interpreted as precise or having precision. Popular with Makino, Mazak, SNK, Toyoda, and others. Kanto Seiki is a good product line using mostly standard Japanese components. Kanto Seiki' s "norm" is to keep a design that utilizes constant speed, three (3) phase motors throughout. [Exception = MRSD models with variable speed compressor drive] Control circuitry is 200-220 volts AC, refrigerants R-22 & R-407c capillary tube expansion device until 24,000 BTU/hr. It is not known by this author what the factory has in mind with later model design changes. Design PLUS: "Spider coupled" shafting on circulating motor and pump for closed loop applications as long as the configuration does not crowd the components together.
   
  Kamui
   
  Kamui Company, Ltd. was established in 1960 as a manufacturer of heat exchange equipment. (Shell and tube, radiator, plate type, and immersion heat exchanger designs) Some systems were built with automatic temperature controls.
   
  KauKan
   
  The chiller and cooling products of KauKan are built in Taiwan and three firms mimic each other in terms of oil cooling products: Habor Precise, Point (Wexton) and KauKan
   
  Kouwa or kouwa liquid tuner (KouwaKougyo)
   
  Kouwa has very little internet presence. Their compressor of choice is Sanyo rotary and currently R-407C refrigerants. This chiller brand is popular on Mazak milling equipment.
   
  MAC Ltd
   
  The MAC Ltd line of chiller is OEM and usually a custom configuration for their machine tool customer. There are times when the machine tool builder specifies a MAC Ltd chiller with a layout (configuration) very similar to aftermarket cooling products. In other cases the location of the machine tool mounting does not allow an aftermarket substitution without theft of valuable floor space in the customer operations.
   
  Mitsubishi
   
  Most Mitsubishi chiller machine tool applications are associated with their EDM units. The term used by Mitsubishi is cooling unit. The chillers are 100% OEM and you must approach MC Machinery Systems, Illinois for assistance. There exists a residential line of Mitsubishi split systems in North America but traditional HVAC supply houses would be your contact not a machine tool distributor.
   
  National Temp Regulator
   
  National Temp Regulator is part of the family of companies associated with Matsushita. In 2008 the combined companies decided on the Panasonic name. The Matsushita Family had product and manufacturing acquisitions during the firmís life and includes National Temp Regulator plus Panasonic, the once small consumer products division.
   
  Point (Wexton Precise Industries) North America - Global Machine Parts, Illinois
   
  Point is nearly a carbon copy of Habor Precise in terms of chiller offerings because both founders are native to the island of Taiwan. Both firms compete to supply Taiwanese machine tool builders. (Oil coolers, cutting fluid coolers, EDM machine coolers, water coolers, laser cutting and engraving machine coolers, optoelectronic and medical water coolers, air conditioners. The chiller and cooling products of KauKan are built in Taiwan and three firms mimic each other in terms of oil cooling products: Habor Precise, Point (Wexton) and KauKan
   
  Ryowa Company LTD. (Japan)
   
  Ryowa has had limited market penetration of its chiller into the machine tool industry. It does build some heat exchange components for the likes of Toshiba semiconductor, Mitutoyo Precision measuring tools, and Shinko Electric. However, the real claim to fame is electro depositing of gold onto electronic components. What few Ryowa products that you will see in North American machine shops will have been as a special order chiller or heat exchanger item with Mori Seiki machine tools and on occasion Okuma.
   
  Toshiba
   
  Toshiba is more of a component manufacturer and consumer product producer as opposed to a chiller manufacturer for the machine tool industry. Yes, Toshiba does build some machine tools, but not so much as compared to others. This author has not serviced Toshiba water and oil chillers but they do label some models of rotary compressors under the Toshiba name. The Toshiba name is an acronym for Tokyo Electric Company and Shibaura when they combined in 1939.
   

    Wexton (Point) - See Point (Wexton)

 

  ~ PRIMER ~  
  REPAIR VERSUS BUY: with regard to your machinery cooling needs.A) Hermetic Can Shape. B) Life Expectancy for copper and using an analogy similar to J.D. Powers for overall quality of the chiller/air conditioner. C) Fluid Circuit Definitions D) Scheme or technology choices of chiller manufacturers. E) Refrigerants; past, recent past, present, future.  
  HERMETIC CAN SHAPE: Discern Rotary Compressor versus Piston Compressor by Shape of Can. Is the compressor in question cylindrical like a juice can or "grape" shaped? Rotary compressors are the "juicer" and reciprocating compressors are like the "grape". Their purpose is the same, but the two work differently in principle. Rotary compressors work just like a "one vane" hydraulic oil pump. Sometimes this one vane can be stacked in two for increased output. Never is there any more than one "wipe" per revolution of the vane. Hence, all vane compressors are 2 pole motor driven (the number of poles determines the rpm) and will have two BTU/hr ratings. The greater output is for 60 hertz power sources, the smaller output is based on 50 hertz power. Reciprocating compressors work like the pistons in your automobile engine or in the air conditioning compressor of your vehicle. Outer case shape is always the same in small hermetic chiller compressors if of the reciprocating type.  
  Life Expectancy: copper usage in small chillers and control cabinet air conditioners components.  
  What others have experienced. Electrolytic action; which metals get "sacrificed". Compressor wall thickness; Relating to life expectancy. Vacuum check and pressure check as tools for diagnosing compressors. Hermetic compressor life expectancy;  
  Life expectancy: what end users have experienced.  
  YES* to repair DAIKIN, (oilcon) AK__3, 4, 5, 6, series oil or water-glycol chiller; *On quality and longevity of a chiller product Daikin produces a good machine; Yes to repair. Decision can be tied to the life time expectancy of the machine tool, or determine repair costs versus production loss. PERHAPS* to repair HABOR PRECISE, LCO model oil chiller, industrial; HABOR PRECISE, (oilcon) HBO model oil chiller, industrial; *Compare your decision on a production loss analysis or BTU/hr rating affordability. New units are inexpensive IF they are in-stock. (ZF Industries, Chicago), but larger units can be repaired competitively when comparing the cost of replacement. YES* to repair KANTO SEIKI (oilmatic), oil chiller, industrial; *On a quality and longevity of chiller product Kanto Seiki's OilMatic cannot be beat. Yes to a repair decision. Expected life of chiller can be tied to the life of the machine tool, or determine repair costs versus production loss. YES* to repair MAC, oil chillers commonly found on Okuma and Okuma-Howa machine tools. *On a fixed quote basis or production loss analysis.  
  Life Expectancy: electrolytic reactions; copper wall thickness: An informative, but less than formal survey.  
  manufacturer; type of unit; component. tube dimen. repair? YORK, 3 ton; residential split air conditioner condenser package; compressor or copper tubing. .40" o.d. x .014 wall NO* *upgrade to a higher SEER or replace with equal quality new. ELKAY, ĺ ton; light commercial water chiller unit; evaporator to water tube heat exchange. .40" o.d. x .014 wall yes/NO*** ***only with aftermarket part substitution, otherwise NO. APW - McClean; electronic control cabinet air conditioner; light commercial - condenser, evaporator, and compressor. .40" o.d. x .014 wall PERHAPS* *Parts are affordable. Is your labor? 1/6, 1/3, 2/3 ton. Multiple ton rated units okay to repair.  
  FLUID CIRCUIT DEFINITIONS;  
  With Illustrations for Open Loop, Closed Loop, In-Line, and Drop-In: Open loop chillers are "open" or "isolated" from the heat source. This means that the chiller unit produces "cold" (removes heat) but this "production" does not come into direct contact with the heat source, in most cases a spindle. Instead the spindle oil or "fire" comes into contact with the "water" of the chiller just as if you were using a double pan cooking utensil. The chiller contains your food, and the machine tool produces the heat. There is an OPENING between the "cold production" and the "heat". Closed loop chillers are "sealed" to the heat source. This means that the chiller unit produces "cold" (removes heat) and this "cold production" touches the heat source by means of a circulating fluid. In most cases a spindle and its gear train put out heat from churning of oil, and this oil is drawn out of the gear case to the chiller by means of the chiller circulating pump. The spindle or lubricating oil ("fire") comes into CLOSED contact with the chiller. In Line chillers still contain a loop. It is a closed loop but differs in where the circulating fluid pump is located. This means that the chiller unit produces "cold" (removes heat), and this "production" comes into direct contact with the heat source, in most cases a spindle by contact with a fluid. Instead of the circulating pump location being with the chiller the pump is provided by the "fire" source. TO SUMMARIZE: Open Loop is a DOUBLE-PAN cooking method of heat exchange with the chiller (cook) having a circulating pump to stir. Closed Loop cooling is a ONE pan cooking method and only ONE cook (chiller) stirring food in the kitchen. In Line oil circulation is closed loop / one pan cooling with your guest stirring (circulating) the food. Drop In chillers (heat exchange) is an open loop method of cooling without a circulating pump (cook) at the chiller. The simplest example is warming your coffee with a drop in heater.  
  Scheme of Manufacturers: Why did they do that?  
  Cosmotec -  
  Daikin -  
  Word through the grapevine is that specific models are produced 10 years. The "6" series made this previous statement only a rule-of-thumb. A breakdown of Daikin's features on the various models follow: Chillers Described By Series "1,2,3,4,5,6,7&8". PAST: AK~~3 is no longer built or factory supported as of this entry (2004). The series utilized R-22, had constant speed one (1) phase hermetic compressors, capillary tube expansion device, and a three (3) phase circulating pump motor on the "closed loop" models. If the condenser fan motor was separate from the circulating pump motor, then this fan motor was also single (1) phase. This series is one of the easiest to maintain from off-the-shelf, aftermarket parts. Design Flaw: "Close coupled" keyway shafting connection on circulating motor and pump for closed loop applications. PAST: AK~~4 is no longer built or factory supported. Because it is so similar to the series "5" one can almost exclusively substitute "5" parts unless circuit board components vary. The "4" series utilized R-22, had a constant speed three (3) phase hermetic compressor, capillary tube expansion device, and a three (3) phase circulating pump motor on the "closed loop" models. Many of the parts can be obtained through aftermarket contacts. Design Flaw: "Closecoupled" keyway shafting on circulating motor and pump for closed loop applications. CURRENT: AK~~5 is no longer factory built but is still factory supported. The claim is that the factory will do so until 2012. The "5" series utilized R-22, had a constant speed three (3) phase hermetic compressor, capillary tube expansion device, and a three (3) phase circulating pump motor on the "closed loop" models. Many of the parts can be obtained through aftermarket contacts. This author is unaware of models that may have the condenser fan motor separate from the circulating pump motor. Design Flaw: " Close coupled " keyway shafting on circulating motor and pump for closed loop applications. CURRENT: AK~~6 replaced the "5" series in a marketing strategy of Daikinís. The author does not believe that this series is being manufactured but factory support is available. The "6" series utilized R-407c which is a retrofit gas for R-22. A constant speed three (3) phase hermetic compressor, capillary tube expansion device, and a three (3) phase circulating pump motor on the "closed loop" models. Many of the parts can be obtained through aftermarket contacts. This author is unaware of models that may have the condenser fan motor separate from the circulating pump motor. CURRENT: AK~~7 is replacing the "6" series in a marketing strategy of Daikin's. The author does not have good first-hand knowledge of this series. Factory support is available. The "7" series is believed to have utilized R-407c which is a retrofit refrigerant for R-22. CURRENT: AKS_8 is a radical departure in marketing strategy on the part of Daikin. The "8" series utilizes R-410a refrigerant which is ozone friendly, and the refrigerant is a high pressure application compared to R-22, R-407c, and R-134a. Variable speed, direct current hermetic compressor design provides for a "throttling effect". The expansion device is electronically controlled to enhance this " throttling ", and all control circuitry voltages are direct current. It is not known by this author what type of current the circulating pump motor uses on the "closed loop" models, nor is he aware of the models that may have the condenser fan motor separate from the circulating pump motor. Series "8" chillers are a radical departure from low cost manufacturers who remain with constant speed / on-off operation of their product. This series will keep most customers coming back to Daikin for replacement parts as the unit ages.  
  Habor Precise -  
  This is an interesting group. Usually of closed loop or open loop application this line also includes wall or ceiling mount air conditioners for electronic enclosures. A line of refrigerated air drying equipment is available. The chiller and other refrigerated products of Habor Precise (once known as Ou Shih Precise) can be supported by most any USA, aftermarket part available. Your challenge, should you own or service one, is Habor's warranty policy. The machine tool distributor is about your only hope. Once that unit leaves the island of Taiwan, the warranty is NOT! Check any paperwork you may have should you "not" believe it. L series units utilized R-22 refrigerant, a constant speed one (1) phase compressor, capillary tube expansion device, and three (3) phase oil circulating pump motors if closed loop. The L series has been discontinued from the factory and the current H series provides low up-front costs for machine tool builders. H series units utilize ozone friendly R-134a refrigerant, a constant speed one (1) phase compressor, capillary tube expansion device, and three (3) phase oil circulating pump motors if closed loop. Design Flaw: "Close coupled" flat tang shafting or keyway shafting connections on circulating motor and pump for closed loop applications.  
  Kanto Seiki -  
 

 
  A good product with some models that can cool or heat your fluid media for optimal situations. Larger sizes (BTU/hr ratings) are dedicated to cooling. Kanto Seiki' s "norm" is to keep a design that utilizes constant speed, three (3) phase motors throughout. [Exception = MRSD models with variable speed compressor drive] Control circuitry is 200-220 vac, refrigerants R-22 & R-407c capillary tube expansion device until 24,000 BTU/hr. It is not known by this author what the factory has in mind with later model design changes. Design PLUS: "Spider coupled" shafting on circulating motor and pump for closed loop applications.  
  Mitsubishi -  
  A well built chiller product found on many EDM machines and other Mitsubishi machining centers. With variable frequency drive applied to the compressor it can sometimes be difficult for many refrigeration mechanics to trouble-shoot. Look to your machine tool control "types" for an assist when you bring in the refrigeration tech. Many of the Mitsubishi chiller designs are "in-line" which means the chiller contains the refrigeration circuit but the fluid media circulating pump is located near the heat source. This variable frequency design allows for the cooling load to be adjusted because the compressor is allowed to slow down, giving a "throttle effect" that might otherwise be obtained in refrigeration by the expansion device. These chillers utilize R-22, a three (3) phase hermetic compressor (with "Frequol Drive"), capillary tube expansion device, and valves re-directing fluid to compliment the "throttling" of heat removal.  

 

 

 

 

 

 

 

 

Phone: (806)  782-4570    FAX (806) 829-2847    email: myles.opheim@smallchiller.com