Water-Cooled Condensing Unit
A water-cooled condensing unit is a crucial component in refrigeration and HVAC (Heating, Ventilation, and Air Conditioning) systems, designed to convert refrigerant from a gaseous state to a liquid. Essentially, a condensing unit is an integrated device consisting of a compressor and a condenser, along with additional components such as electrical panels, controllers, receivers, and pipes. It functions as an external cooling unit within the refrigeration cycle. In a water-cooled condensing unit, the condenser utilizes water as the cooling medium. The refrigerant gas flows through the condenser, where it comes into contact with water circulating through internal pipes within the shell. Heat is transferred from the refrigerant to the water, cooling the gas and converting it into a liquid. These units are highly efficient in transferring heat and are commonly used in large-scale refrigeration systems, industrial HVAC applications, and settings where water resources are readily available and cost-effective.
Types of Condensing Units
Condensing units are essential components of compression refrigeration systems, playing a significant role in maintaining thermal comfort. These units are primarily categorized into two types: air-cooled and water-cooled condensing units.
Air-Cooled Condensing Unit
In this type, the condenser, which acts as a heat exchanger, is cooled by air flow. Fans installed in the unit blow air over the condenser coils, dissipating the refrigerant’s heat into the surrounding environment. Air-cooled condensing units are characterized by their simple design, low maintenance requirements, and the absence of a need for water. Due to these advantages, they are commonly used in residential and commercial refrigeration as well as HVAC systems.
Water-Cooled Condensing Unit
Unlike air-cooled units, water-cooled condensing units use water to cool the condenser. The heated water from the condenser is directed to a cooling tower or another heat dissipation system, where it is cooled and recirculated. Water-cooled condensing units are favored for their higher cooling capacity and efficiency, making them ideal for larger industrial HVAC systems. These units perform exceptionally well in hot and dry regions where ambient temperatures are elevated.
Technical Specifications of the Water-Cooled Condensing Unit
When reviewing the technical specifications of water-cooled condensing units, factors such as cooling capacity, refrigerant type, condenser material, and controller type are important. Below are the technical specifications for the ATCS series AL water-cooled condensing unit:
- Cooling Capacity: 2.5 to 185 kW
- Refrigerant Type: R507, R502, R134-A, R404-A, R22
- Condenser Material: Shell made of seamless pipes, internal pipes made of copper or seamless steel
- Controller Type: Analog or digital
- Noise Level: Designed for quiet operation
- Condenser Working Temperature: 40°C
- Evaporator Working Temperature: -45°C to +12.5°C
Components of the Water-Cooled Condensing Unit
Let’s take a closer look at the components of a water-cooled condensing unit and their functions:
- Compressor
The compressor is responsible for compressing the refrigerant gas, increasing its pressure and temperature. As pressure rises, the refrigerant’s temperature also increases, and the hot gas is directed to the condenser. Various types of compressors, including piston, rotary, scroll, and screw, are used in condensing units. The ATCS series water-cooled condensing unit uses compressors from global brands such as Bitzer, DWM, Maneurop Danfoss, Copeland, and Refcomp, all available for ordering. - Condenser
The condenser converts the high-pressure, hot refrigerant gas into a liquid. The gas enters the condenser and loses heat to the surrounding environment (either air or water), turning into a liquid. The water-cooled condenser in this unit is of the shell-and-tube type, with seamless pipes in the shell and copper or seamless steel internal pipes. Baffles inside the shell improve heat transfer efficiency. The headers at both ends are easily accessible for maintenance or tube replacement. Condensers are pressure-tested with nitrogen at 450 psi. - Receiver
The receiver stores excess refrigerant liquid. It holds surplus refrigerant and injects it back into the system when pressure decreases. - Electrical Panel
The electrical panel controls and protects the electrical components of the system. It houses circuit breakers, contactors, relays, thermostats, and other control equipment. - Water Pump (for Water-Cooled Condensers)
The water pump circulates water through the closed-loop system, facilitating heat transfer in the condenser. - Valves and Controls
The ATCS condensing unit is pre-assembled and ready for installation, with all valves and controls included, such as vibration absorbers, manual valves, solenoid valves, sight glasses, filter dryers, high/low-pressure controls, and compressor oil pressure controllers from Danfoss Denmark. The system is pressure-tested with nitrogen at 450 psi before shipment. Oil separators and liquid separators are also available for order.
Cooling Capacity Range of the Water-Cooled Condensing Unit
The ATCS series water-cooled condensing unit offers a cooling capacity range from 2.5 kW to 185 kW. It is compatible with various refrigerants, including R507, R502, R134-A, R404-A, and R22. Additionally, custom-designed condensing units with specific capacities can be manufactured upon request.
Applications of the Water-Cooled Condensing Unit
The ATCS water-cooled condensing unit is compatible with Freon-type refrigerants and is ideal for various applications, including HVAC systems, clean rooms, cold storage for low temperatures, fresh food, meat, poultry, fish, shrimp, fruit, vegetables, pharmaceutical storage, and freeze tunnels. It is capable of achieving temperatures ranging from -45°C to +12.5°C. Additionally, the ATCS unit is used for refrigerant distillation, storage, and transfer in industrial refrigeration and HVAC systems. Depending on the required cooling capacity and the temperatures of the water and the room, the appropriate unit can be selected from the product catalog, offering a wide range of capacities to suit diverse cooling needs.
Design of the Water-Cooled Condensing Unit
The design of a condensing unit must comply with international standards to ensure optimal performance and safety. For instance, the condensing units from “Atlas Refrigeration” are designed in accordance with the American National Standard ANSI/ASHRAE 15, ensuring they meet the required industry benchmarks for quality and efficiency.
American National Standard ANSI/ASHRAE 15: Pressure Vessels
For manufacturing condensing units, the company utilizes advanced, original equipment and components from renowned global brands. For instance, compressors from trusted names like Refcomp, Copeland, and Danfoss are employed to ensure high performance and reliability.
In situations where an air-cooled condensing unit is unsuitable or where space limitations prevent its installation, a water-cooled condensing unit becomes an ideal alternative. In this system, the condenser uses water instead of air to cool the refrigerant. The water used in the condenser must either be single-use or have its temperature reduced through a cooling tower for efficient heat dissipation.
The price of a water-cooled condensing unit is influenced by several factors, including the manufacturer’s brand, the equipment used, and the cooling capacity. Key factors that affect the price include:
- Manufacturer’s Brand
- Cooling Capacity
- Type of Equipment Used
- Dimensions
- Currency Exchange Rates
Water-Cooled Condensing Unit Catalog
The Water-Cooled Condensing Unit Catalog provides all the necessary technical information to help you select the right unit for your needs. It includes details such as the evaporator and condenser temperatures, cooling capacity, and the type and model of the condenser. Additionally, the catalog contains information on the compressor model and brand, refrigerant type compatibility, electrical specifications, unit dimensions, and performance data. By referring to the catalog, you can find the most suitable unit based on your specific requirements and operational conditions.
Difference Between Condensing Unit and Chiller
The difference between a condensing unit and a chiller lies in their functions within cooling systems. A chiller is a system that cools water, which is typically used for air conditioning or industrial processes. The chiller removes heat from water, which is then circulated for cooling.
A condensing unit, on the other hand, is a key component of a refrigeration cycle responsible for cooling the refrigerant. The refrigerant, initially a gas, is cooled in the condensing unit and converted into a liquid, which is then returned to the refrigeration cycle to absorb more heat. While both systems are involved in cooling, a chiller cools water, while a condensing unit cools the refrigerant.
Advantages and Disadvantages of the Water-Cooled Condensing Unit
The table below outlines the advantages and disadvantages of a water-cooled condensing unit:
| Advantages | Disadvantages |
| Compact and suitable design | High water consumption |
| Easy installation | Requires more maintenance |
| Affordable price | Higher maintenance due to scaling |
| Higher efficiency than air-cooled | Limited in areas with low water supply |
| Long lifespan |
Conclusion
In conclusion, the water-cooled condensing unit stands out for its efficiency, versatility, and reliable performance across a range of applications. Whether for industrial cold storage or advanced air conditioning systems, it provides excellent cooling capabilities, particularly in hot climates and space-constrained environments. If your project demands optimal performance and reliability, the water-cooled condensing unit is the ideal choice.
To prevent scaling, it is recommended to use softened or filtered water and perform regular maintenance on the pipes and condenser.
The required capacity is calculated based on refrigeration load and operating temperatures. It is recommended to consult with refrigeration experts at Atlas Refrigeration or refer to the product catalog for further guidance.
Yes, it is possible. However, it requires systems such as cooling towers with optimized water consumption or the use of recycled water.
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