Enjoy a Cool Summer with a Perfect HVAC System

With summer season round the corner it is important to check the effective functioning of your heating and cooling system so that it provides a comfortable environment. It is a good idea to schedule a professional service who can guide you with various tips on how to perform a regular maintenance of your HVAC system or tell you if any of the heating and cooling parts need an upgrade with new coils or new parts.

Checklist of items of your HVAC System

Here are some of the pointers to keep in mind when you hire a professional service and check if they inspected the important parts before they wrap up.

• One of the important parts to be checked while evaluating the efficiency of your HVAC system is the condenser coil. Over a period of usage your condenser coil may not work as expected. For instance, even after setting your thermostat level to provide an optimal cooling temperature if the room feels warmer then it is time for an upgrade or replacement of your condenser coil.
• The next crucial factor to be checked is the evaporator coil. In general, the coil leakage is the one of the common problems found in the evaporator coils. This can be easily identified if your refrigerant level is too low than the normal range. 
• Some of the reasons of the coil leakage are rust and corrosion build up in the building parts which are unavoidable in certain situations. 
• In some of the HVAC systems, chilled water coils are used for a comfortable and energy efficiency cooling method and also used for dehumidification. But in winters these chilled water coils may tend to freeze in extreme winter conditions. Thus, proactive measures help to prevent these coils from freezing. 
• However, diligence care should be taken while installing these chilled water coils for longer durability like measuring the height of casing accurately, determining the number of rows and the fins and so on. 

Thus, it is important to keep your HVAC parts up and running to give you a cool summer season.

Condensing Units and Its Types

Condensing units can be categorised into three types namely water, air and combination of both air and water based on how the heat is removed from the condensing unit. Let us see briefly about each type.

Air Cooled Type

This type of air-cooled types is used in small companies and for household applications. Air cooled are suitable for low capacity which is under 20 tons only. There are several benefits in using air-cooled condensing type units like it does not require a separate water piping units or water disposal system. This type is economical, and it will not have any scaling issues which is caused by some mineral deposits. Easy to install and it gives less initial set up cost. Thus, the overall maintenance expenses are much less when compared to other types of the condensing unit. However, these air-cooled type has few disadvantages as well. For instance, the compressor lifetime is relatively short that is when more cooling is required, it will not be available or sufficient. Also, it needs high power per ton of refrigeration.

Water cooled Type

Water cooled type is another form of condensing unit which further is sub divided into three categories which are ‘shell and condensing coil’, ‘double tube’, and thirdly ‘shell and tube’. The most widely used model among these three categories is shell and tube type. These are available from as low as two-ton capacity to a higher capacity of two or more hundred tons. This is possible by the unique design of the model which requires only a little power consumption per ton of refrigeration and also the compressor has a longer lifespan when compared to a previous model that is the air-cooled type. For a high capacity application, a water-cooling tower is generally used.

Evaporation Type

This evaporation model is a mixture of water- and air-cooled type condensing units. Thus, in all these types the air blows through an effective condenser coil for these conducting units which in turn transfers the heat into the outdoor air. The presence of a high-pressure liquid refrigerant makes the condenser coil to make a U-turn, and it reverts to the evaporator coil.

How to Maintain Your Deep Freezer

In order to provide high cooling capacity for residential and small commercial places a chest freezer which is made up of chilled water coil is used. For example, these are used in a deep freezer which in turn is used in various places like small commercial shops like meat outlets to freeze the meat and poultry products from decaying for several weeks and in ice parlours and other food and medicine shops which all have time-sensitive products. Also, these chest freezers come in handy when planning an outdoor picnic and store food fresh for a couple of days without getting spoiled.

However, maintaining these deep freezers is essential in order to avoid any major appliance repair bill in the future and also a regular check on these products ensures them to function to its full potential.

•    When it comes to cleaning your refrigerator, cleaning your condenser coils for water coolers is mandatory. You can use a professional help also twice a year for deep cleaning, or you can vacuum the coils at a quick setting by unplugging your freezer.

•    If not cleaned for years together, these coils can easily get accumulated to dust and debris which affect the air circulation which results in poor cooling effects inside the freezer and also cuts down the life of the appliance.

•    Many frost-free models are available in the market today. In many manual defrosting freezers people tend to use any sharp objects to quickly remove excess ice chunks in the walls of the freezer, but this is a bad practice as it will not only leave a scratch on the appliance but also result in permanent damage which may lead to replacing the appliance.

•    Also, all the deep freezers come with a strong door gasket for a firm and concealed protection which does not allow any outside air to enter these freezers. But if these gaskets are intact wrongly or not correctly sealed, then the freezer needs to work additional time in order to maintain the cold temperature consistently inside the freezer box. However, this can be avoided by regular maintenance of these door gaskets by soaking the gaskets in warm soapy water which in turn clears any debris quickly. Replace them immediately if you spot any wear or tear around the rubber seal.

•    Provide enough room for your freezer to help it run at its full capacity. That does not stack other items on top of your deep freezer which automatically forces your appliance to work harder to maintain the cooling temperature inside it that leads to higher energy bills.

•    Thus, provide a clutter-free environment which makes sure there is enough air circulation for the compressor and the condenser.

An Insight About Coils used in Refrigeration Applications

A coil in a refrigerator plays a vital role in the overall performance of the electrical appliance. Before seeing its function, let us briefly see how does a refrigeration work in general and what are the key components used to have an efficient cooling system. The primary purpose of using a refrigerator both in commercial and household is its high cooling capacity which prevents the food from any bacteria attacks and avoids spoiling of food for a more extended period. Hence, an effective cooling system is vital in all refrigeration appliances. The condensing coils in the condensing unit of a refrigerator is another critical component which helps to convert the refrigerant into a liquid form and helps in reducing its overall temperature.

How does a refrigeration work?

Basically, refrigeration works on two principles, one is heat and evaporation process, that is when a liquid evaporates into vapour it absorbs the heat from the nearby surrounding environment. And the other principle is compression of a gas. When a gas is compressed, it gives out heat energy when it is changed into a liquid state.

·         Coolant or Refrigerant

The main component known as the refrigerant or coolant is a liquid which facilitates a continuous refrigeration cycle. It is a specially designed chemical component which can be transferred from hot gas or cooling liquid accordingly throughout the cycle.

·         Inside Refrigerator

The coolant or the refrigerant that is in a liquid state passes through an expansion valve, which helps to convert it into a cooling gas due to the decrease in pressure and it allows to pass through the inside of the refrigerator through the internal heat exchange coil. Its job is to absorb the heat generated from the food items and vaporizes into a gas that flows back to a compressor unit.

·         Outside or Behind the Refrigerator

Once the refrigerant which is in a gas state flows through a compressor and creates a hot, high-pressure gas. The coil behind the refrigerator helps to dissipate its heat thus it feels hot to touch at the back of the fridge.

The process repeats as the refrigerant travels back to the expansion valve in a liquid state and once again become a cooling gas due to drop in pressure and travels inside the refrigerator and repeats the whole process again.

The Role of Coils in Refrigerator

Every refrigerator primarily uses two types of Coilsin Refrigeration Appliances, one is inside the fridge known as, ‘Internal heat exchange coil’ and at the back of the refrigerator known as ‘External heat exchange coil.’ These coils are responsible for carrying the main component, the refrigerant from one part of the fridge to another.

Also, a thin copper coil is used in the expansion valve which helps in decreasing the pressure on the liquid refrigerant.

Uses of Aluminium Coil

Aluminium coils are widely used in a diverse range of appliances from the cladding and insulation in the construction industry to the truck bodies in the transport industry. Aluminium coils come in a variety of alloys. Aluminium is one of the popular materials used across the industries due to its cost-efficiency and versatility that can be modified to use in plenty of the manufacturing units.

• Aluminium Tube

Aluminium tubing can be bent and used readily for various purposes and has excellent welding ability. Most of the aluminium coil manufactures use both heat treat, and non-heat treat alloys for aluminium tubing. Aluminium tubing is used in many industries like engines, Solar power, Steam generators, Refrigerators, Air conditioning and heating system, ventilation, Reboilers and so on.

• Industrial Uses

Various industries utilized these aluminium coil materials for their businesses from a renowned, reliable and trusted aluminium coil supplier for all their industrial purposes. Let’s take a look at some of the industries.

• Solar Power

Aluminium’s proven benefits in construction, transportation industries and many other industries have made extrusions for solar frames and mounting systems as well. Extrusion techniques which are used to create objects of a fixed cross-sectional profile, are mostly used in both photovoltaic (PV) and concentrated solar power (CSP) mounting systems and frames. These extrusions utilize aluminium for a number of advantages like low maintenance costs, lightweight, corrosion resistance and also, they incorporate the ability of the extrusion process to place metal where it is functionally required for strength, fastening and other purposes.

• Transportation Industry

Alloy aluminium coils are used in automobile industries, which provides a robust material to many parts like car doors, windows, automobile engine parts, radiator, panels and wheel hub. They are also used in subway vehicle and high-speed train’s car body structure material and other ship material as well.

• Packaging

Aluminium has a wide range of usage in food package industries and for consumer products packaging needs as well. These are used in metal cans, beverage, barrels, lids, bottles, medicine, cosmetic and so on.

• Electronic applications

Many electronic applications have successfully implemented the alloy aluminium coils like in bus wiring, electrical components, air conditioning, cable, conductor, refrigerator and so on.

• Construction Industry

As aluminium is known for its corrosion resistance, sufficient strength, excellent process and welding performance, these are commonly used in building structures, windows, doors, ceiling and decorative surface like colour coating sheets, decorative pattern plates, aluminium curtain wall plate etc.

Coils for Efficiency and Performance

Nothing short of perfection is desirable in today’s age. Total perfection and efficiency come as a result of all the perfect parts of a system. Customers look for such a manufacturer for its condenser coils for Chillers who can manufacture them with quality and efficiency.

A condenser is a unit which can be of varying size. The condenser coil for chiller is used to literally condense a substance or change a substance from gaseous state to its liquid state. Condenser coils are used in various places such as air conditioning systems, industrial processes, chillers and many more heat exchange systems. Chillers are essentially a machine that removes heat from a liquid and this liquid is circulated to cool the equipment.

Hydrophilic coated coils are known for being highly effective and are also known for their high performance. These coils are very efficient under high performance. Coil coating is a very highly effective industrial process where coils of metal are continuously and efficiently coated with coil. Coil coated metal is effectively more durable and corrosion resistant. Hydrophili ccoated coils are considered one of the most durable and corrosion resistant products.

Big companies who buy the coils as parts for use in their electronic products generally buy them in huge quantities from the leaders of manufacture for condenser coils for Chillers, and Hydrophylic coated coils. These coils are specially manufactured items mostly in a state of the art manufacturing units.  Many manufacturing units have capacities of millions of coils per annum. Along with quantity, these state of the art manufacturing units also produce the best quality condenser coils for chillers and hydrophilic coated coils. Many companies in India are also a valued exporter of coils to USA, Canada and Europe.

Manufacturing of coils specific to the customer specification and demands are mostly not easy and go through a number of processes. Product development and quality control are two very important phases during the manufacturing of condenser coils for Chillers and Hydrophylic coated coils. The product development team works very closely with the customers to understand the requirements, constraints and objectives. It is very important to understand the requirements of the customers as well as the purpose for which they need the coils as it plays an important role in the manufacturing process.  Simulations are made and samples are tested before the manufacturing begins. Simulations are made with the help of latest computer technology. The parameters are tweaked according to the customer requirements, constraints and the design is made. The simulations are run using the software program to make sure that theoretically the design meets the objectives of the customer. The simulations that succeed in meeting the design parameters are taken to the customer for approval and after that samples are finally made. The samples go through a very rigorous quality control and test process before they are approved.  

        

Quality norms are very important while manufacturing the condenser coils for Chillers and Hydrophylic coated coils. All coils should be doubly tested for leaks at various pressures and with leak detection machines. All possible scenarios of the usage should be tested before the design is finally approved. A world class laboratory is used to measure and ensure that compliance and design requirements are met. Strength testing machines should also be used to test the hydrophilic coated coils and latest equipment’s should be used to test for contamination. Only the manufacturing unit which provides these facilities should be used for mass production of the units since they are a vital part in the success of the whole component.

Why Choose Copper For Your Condenser Coil?

Copper has been the ultimate choice for air conditioning and refrigeration systems. The usual reasons are:

• The level of copper’s heat transfer is high
• It consumes less refrigerant
• Machinability
• It can resist corrosion

The innate characteristics of copper perfectly meet the needs and demands of the air con and refrigeration industry. Product enhancement of copper condenser coil has been done to maximise its potential in terms of operating efficiency and competence, and to remove or minimise harmful emissions. 

Although this has been used time immemorial, its popularity gets stronger and stronger because of its modern form:

• Maximised strength
• Its resistance to corrosion
• Light characteristics

Copper has been utilised in all types of heat exchangers for so many years. The modern form was changed to ensure that it is compliant to the requirement of the market and some regulatory measures. Due to its evolution copper was transformed to a cost effective, resource efficient and eco friendly unit. 

Why copper is a better choice than aluminium

This has been a never ending debate, aluminium condenser coil vs copper condenser coil. Here is the truth; some manufacturers are turning to aluminium, which they say is the better option, because it is cheaper and has higher transfer properties. But after sometime consumers will then realise that this actually requires higher maintenance expenses. There is no good reason why would you choose cheaper if it cannot provide you the quality you need. 

When you talk about thermal conductivity, copper is actually eight times better compared to aluminium. In terms of repair, aluminium is not as repairable as copper, as sometimes aluminium material cannot be repaired at all. If aluminium condense coil gets broken, the only option you have is replacement.

To give you a summary of why you have to choose copper over aluminium, read the bulleted points below:

• Copper offers far maximum strength compared to its counterparts 
• Copper is a lot more reliable than any other types of metal, including aluminium
• Copper is very easy to maintain
• Heat transfer is excellent for copper than aluminium
• Copper has great resistance to any mechanical and external damages unlike aluminium
• Copper is a lot easier to repair, considering that when copper gets broken soldering is enough to fix it, whereas for aluminium, welding should be done to fix it (in case it is still fixable). Welding aluminium is a very sensitive and delicate process, if it is performed wrongfully, damage can be bigger, hence engineers may recommend replacement instead
• Copper cools down and heats up a lot faster than aluminium, hence copper is ready to use anytime you need it
• Aluminium is far fragile than copper, hence breakage is more possible to aluminium

The condensing unit can be maintained and cleaned very easily, hence it saves you huge amount of money for maintenance and time. Copper can instantaneously transfer heat outside so that inside cooling will get boosted while corrosion is not being an issue.