American Chillers and Cooling Tower Systems

Manufacturer of industrial process chillers
for medical, dry cleaning, aerospace,
food processing and more...

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BREWERY GLYCOL CHILLERS

BREWERY GLYCOL CHILLERS
American BCK Series

Brewery chillers used in the fermentation and pull down (cold crashing) process typically circulate 28°F degree glycol for 33°F degree beer. Brewery chillers run at temperatures below 32°F (freezing) and thus require propylene glycol (food grade HVAC type anti-freeze)

1 HP to 80 HPBrewery Glyocl Chiller Picture 11 HP

Packaged Brewery Chiller with tank and pump all in one package

    • Popular with brewers because of its all-in-one design
    • Offers a simplified installation
    • Set the chiller, run wires, connect the fluid supply and return lines, fill with water/glycol and start-up

Modular Brewery Chillers with tank and pump(s) ship separate. Ideal for growing breweries

    • Allows a brewery with rapid growth plans to add chiller modules as the brewery grows, without replacing the chiller
    • Matching present needs without over sizing – saves on budget and electricity
    • When the roof can’t support the weight of the glycol tank and pump(s)
    • When chiller is located a long distance from brew tanks
    • Can be added to an existing system as a booster chiller
    • Our sales engineers can help select components that work best for each brewery

Split Brewery Chillers keep the hot condenser air outdoors and all fluid components indoors. The indoor and outdoor units are connected with refrigeration line sets

  • Multiple circuits are available in single phase power for sizes above 5 tons when 3 phase power not available

American Brewery Chillers are engineered with premium refrigeration components, similar to the critical systems required to run supermarket refrigerators and freezers. We use Copeland Scroll Compressors (in most sizes) which are superior to hermetic compressors (used by many competitors) in reliability and efficiency and comes with a 5 year warranty.

Each American Chiller ships with a chiller remote control panel for indoor installation so the brew master can easily control the chiller.

SIZING A BREWERY GLYCOL CHILLER
Follow this “Brewery Glycol Chiller Sizing” Link for assistance, formulas and helpful information for sizing your chiller.

Standard Features

  • Heavy duty welded, steel frame with powder coat finish and laminated brushed aluminum cabinet
  • U.L. Listed, and EPA Compliant, eco-friendly R404a refrigeration condensing unit (“green” refrigerants are available)
  • Single refrigeration circuit with Copeland scroll compressor(s) with crankcase heater(s)
  • Refrigerant receiver and suction side accumulator to eliminate refrigerant slugging in compressor
  • Air cooled, horizontal discharge, oversized condensers with flooded head pressure controls for low ambient operation to -20F˚
  • Weather proof electrical panel with single point power connection
  • 24 vac control circuit with component sequenced terminal strip for easy troubleshooting
  • Remote control panel for indoor installation provides lighted on/off switches and digital thermostat
  • UL stainless steel brazed plate evaporator insulated against condensation with 3/4″ closed cell insulation
  • Auto reset low pressure safety; manual reset high pressure safety
  • Externally equalized thermal expansion valve, liquid line filter drier, and sight glass
  • Low water flow compressor interlock safety locks out compressors in low flow condition
  • Non-ferrous water lines with FPT connections insulated with 3/4” closed cell insulation
  • High density, polyethylene reservoir insulated with closed cell insulation
  • High head centrifugal process pump rated at 40 psi at 2.5 GPM/ton
  • Internal bypass valve for temperature stability and to prevent pump dead heading
  • Systems leak checked, pressure tested, run tested under load and shipped operation ready
  • Brass wye strainer included (ships loose)
  • Warranty: one (1) year limited parts, five (5) years limited compressor warranty
  • Ships fully crated to minimize damage risk during shipping

Available Options

  • Condenser coil coating for corrosion protection in salt air environments
  • Dual, scroll compressor sets
  • Dual refrigeration circuits
  • Redundant chiller options
  • EC fan motors
  • Cabinet mounted fluid pressure and temperature gauges and refrigeration pressure gauge
  • Inhibited propylene glycol concentrate in 55 gallon drums or 5 gallon carboys
  • Magnum microprocessor controller for building automation control & full chiller analytics
  • Dual pumps with lead/lag control
  • Castors for portability (sizes 1 HP to 5 HP)
  • R448, R407c, R404a, R410a refrigerant
  • Custom options and configurations available

Package Chiller Specification Sheets

Brewery Glycol Chillers PDF Spec Sheet Downloads

Single Refrigeration Circuits
(C/F for dual circuit chiller data)nomenclature-commercial-chillers

Size Model
1.0 HP CAVCS010_BCK  1 & 3 phase
2.0 HP CAVCS020_BCK  1 & 3 phase
2.5 HP CAVCS025_BCK  1 & 3 phase
3.0 HP CAVCS030_BCK  1 & 3 phase
4.0 HP CAVCS040_BCK  1 & 3 phase
5.0 HP CAVCS050_BCK  1 & 3 phase
7.6 HP CAVCS076_BCK  3 phase
8.5 HP CAVCS085_BCK  3 phase
11 HP CAVCS110_BCK  3 phase
15 HP CAVCS150_BCK  3 phase
20 HP CAVCS200_BCK  3 phase
24 HP CAVCS240_BCK  3 phase
30 HP  Consult Factory  3 phase
 40 HP  Consult Factory  3 phase

 

Modular Chiller Specification Sheets

Brewery Chillers PDF Spec Sheet Downloads

Single Refrigeration Circuits
(C/F for dual circuit chiller data)nomenclature-commercial-chillers

Size Model Electrical
1.0 HP CAVSS010_BCK  1 & 3 phase
1.5 HP CAVSS015_BCK  1 & 3 phase
2.0 HP CAVSS020_BCK  1 & 3 phase
2.5 HP CAVSS025_BCK  1 & 3 phase
3.0 HP CAVSS030_BCK  1 & 3 phase
4.0 HP CAVSS040_BCK  1 & 3 phase
5.0 HP CAVSS050_BCK  1 & 3 phase
6.0 HP CAVSS060_BCK  3 phase
7.6 HP CAVSS076_BCK  3 phase
8.5 HP CAVSS085_BCK  3 phase
11 HP CAVSS110_BCK  3 phase
15 HP CAVSS150_BCK  3 phase
20 HP CAVSS200_BCK  3 phase
24 HP CAVSS200_BCK  3 phase
 30 HP  Consult Factory  3 phase

 

Installation Examples

How To Pipe Chillers in Parallel:

Two or more chillers may be installed in a parallel piping system to provide more capacity of a single chiller or redundancy and multi-staging of compressors. Normally the load on the chilled water system dictates the system capacity and the part load capacity of the process is the factor to determine the staging of the chillers on temperature. The thermostats can be set a few degrees apart. If one chiller cannot maintain the fluid temperature, the second chiller will stage on upon temperature rise and a third, etc. The diagram below illustrates the concept of parallel piping of the chillers on a common header system. The main header must be sized for the total flow rate and good practices dictates a maximum flow rate of 7 Ft/sec. When adding a chiller to an existing manifold system, also consider the ability of the pump to provide enough total flow and pressure to satisfy the process and the continuous flow through the chillers.  how to pipe chillers in parallel

Installing A Bypass Loop

Purpose:

  1. To provide a continuously circulating water flow through the chiller coil, tank and piping system. This is necessary to maintain the reservoir at the cold temperature setting. The system should be balanced so that the flow through the bypass loop while maintaining sufficient flow to the process.
  2. To establish the minimum operating pressure of the cooling water supply to the process machine. This is a result of setting the continuous flow at maximum. This also establishes a high pressure supply to the process machine and a low pressure return to the chiller for good circulation through the process machine heat exchangers. The differential pressure between the supply and return should be a minimum of 20 psi.
  3. To allow the chiller refrigeration to cycle on and off freely, and independently of external demands for flow and temperature.

Where To Put The Bypass:

The bypass valve must be located at the end of the line, with the process machine connections between the bypass and the pump. The illustration below shows a modular chiller system with a process machine correctly connected to the piping between the pump and the bypass. The pressure to the process machine (s) will be the same every inch in the line between the bypass and the pump. Two machines can be connected and their supply pressure will be the same. The picture shows the bypass before the process machine connections and the pressure will be lower to the machine when the bypass is open. The drop in pressure will increase as the bypass is opened and set for optimum flow to the chiller. The process machine heat exchangers very likely will starve for cooling as a result.

 Installing-A-Bypass-Loop

Starving the Chiller:

The process will get more pressure and flow as a result of closing the bypass – But what happens to the chiller? The chiller will starve for flow causing the water temperature to be very cold coming out of the chiller but at a reduced flow that will cause the loop temperature to swing wildly between cold and hot! The purpose of the flowing loop has been defeated and the chiller can not maintain the reservoir and loop temperature at an even temperature.

Bypass Line Size:

The piping connections on the chiller are the correct size for the supply and return header lines based on sound engineering principles of flow, pressure drops, and fluid velocity. Reducing the line size from the recommended causes higher velocities, higher pressure drops, reduced supply pressure to the process, and fluctuations in the supply temperature. download-now-button

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About Glycol

GLYCOL IN CHILLERS Glycol or other inhibitors are required for medium temperature brewery applications. What type of glycol is best? American Chillers recommends Inhibited Propylene Glycol which is food safe, works as an anti-freeze, but also includes rust inhibitors and other additives that keeps your pump seals lubricated and fluids and chilled water system running in optimal condition. Other glycols may be acceptable. NEVER USE AUTOMOTIVE OR RV ANIT-FREEZE IN CHILLERS. Glycol will reduce chiller capacity. Questions about what glycol concentration and/or type to purchase? Contact and American Chillers sales engineer for assistance.

Glycol Correction Factors

All Heat exchangers experience a capacity loss when the fluid is a higher specific gravity than water. Glycols are heavy, syrup like fluids at full concentration, and become thinner when mixed with water. However, the mixed solution of water-glycol will be thicker, heavier, than the water alone was. Thus, to achieve the same heat exchange inside the heat exchanger , requires more surface area or a larger heat exchanger. American Chillers heat exchangers are engineered for full rated capacity with the use of 30% glycol solutions. Our heat exchangers start out with 30% more surface area capacity than the heat exchangers used by other manufacturers so you still have full capacity with 30% water-glycol solutions. If you are using glycol concentrations above 30%, consult factory prior to purchasing your chiller for chiller selection assistance.

Propylene Glycol

Leaving Temperature Degrees F 30% 40% 50%
Capacity Factor Pressure Drop Factor Capacity Factor Pressure Drop Factor Capacity Factor Pressure Drop Factor
20 - - 0,8 1,74 0,74 2,07
30 0,92 1,39 0,87 1,63 0,82 1,94
40 0,93 1,36 0,89 1,55 0,85 1,83
45 0,94 1,35 0,9 1,53 0,87 1,81
50 0,94 1,33 0,91 1,51 0,88 1,75
55 0,95 1,31 0,92 1,5 0,89 1,73
60 0,95 1,31 0,92 1,47 0,9 1,68
70 0,96 1,27 0,93 1,43 0,91 1,63
Minimum leaving fluid temperature 25°F 10°F -10°F
Minimum ambient 10°F -4°F -20°F

 

Glycol Capacities and Correction Tables

propylene-glycol-capacity-correction-factor-table

* At standard ARI 590 conditions: 54°F entering fluid temperature, 44°F leaving fluid temperature, 95°F ambient temperature, 0.0005 fouling

capacity reductions factors

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Warranty

What Is Covered:

1. All parts are guaranteed to be free of defects in material and workmanship for 12 months from date of  original purchase.

2. Scroll compressors are guaranteed to be free of defects in material and workmanship for 60 months from date of purchase.

3. Labor: during the first 30 days after startup, American Chillers will reimburse the owner for any reasonable labor charges incurred for the replacement of a warranted part, according to the rate schedule.  A time allowance of 30 minutes, for one technician is allowed for the diagnosing of a malfunction. Consult customer service for the labor rate schedule .

4. During the first 30 days after startup, American Chillers will pay for regular, ground shipping of any covered part shipped to the customer. Express shipping and air freight charges are the responsibility of the customer. After 30 days, the customer is responsible for shipping defective parts back for credit and for the shipping charges from American Chillers to the customer.

What is not covered:

1. shipping costs after the initial 30 days. Express shipping charges over regular ground charges are not covered.

2. Labor charges of a helper during repair; truck, mileage, and transportation charges; time over 30 minutes to diagnose a problem’s cause.

3. Labor rates in excess of pre-negotiated wholesale rates, usually no more than 70% of regular retail. American Chillers does not pay retail labor rates.

4. Loss of business or added expense for cranes, lifts, permits, or contractor services arising from the repair or replacement of a failed part.

5. Failures caused by external factors beyond the control of this manufacturer and the component manufacturer.

6. Supplies used to effect the repairs such as solder, nitrogen gas, dyes, bubble soap, and leak detector.

7. Part or component failure must be a result of manufacturing defect or normal wear and tear. Parts that fail due to causes external to the chiller, such as improper installation, improper start-up, electrical supply problems, leaking or broken pipes and tube erosion from excessive fluid velocity, freezing or poor water quality, failure to maintain clean filters, contractor or owner negligence, etc., are not covered by this warranty.  American Chillers will not reimburse the customer for locally purchased parts through another vendor without prior authorization. A replacement part, however, may be provided upon return of the defective part, only.

8. Electrical parts sent as replacement may not be returned for credit.

9. Glycol, replacement glycol, the labor to add glycol to the chiller and chiller damage resulting from improper freeze protection or freezing are not covered by the chiller warranty.  

Policy Regarding Replacement Parts:

American Chillers will provide a replacement part for any covered defective part as per the above conditions. Customers are responsible for shipping charges after the first 30 day period. Replacement parts may be new or reconditioned, at the discretion of American Chillers. All warranty claims must be processed through American Chillers.  The replacement part will be warranted for the remainder of the original part warranty or a minimum of 90 days.

Compressors:

Compressor returns must have the connections securely plugged or pinched and soldered shut to prevent any oil, leakage during shipment. Failure to follow this procedure will void the warranty on the compressor. A $50.00 handling fee will be assessed for compressor warranty returns.

To Make A Warranty Claim: 

All warranty claims must be processed through American and all parts returned for credit must have a Return Material Authorization (RMA) number. To make a warranty claim, contact American Chillers between the hours of  8:00 a.m. – 4:30 p.m. (Eastern time), Monday – Friday.  American Chillers will issue an RMA number. The RMA number must be clearly marked on the outside packaging or the package will be refused. Return parts must be packaged securely to avoid shipping damage. Parts damaged during shipment will not be credited.

Payment No parts will be shipped without payment.

Parts must be paid for prior to shipment. American Chillers will accept VISA and MasterCard. Credit will be issued for the cost of the part, less any applicable freight and handling charges, after the defective part(s) are returned, freight prepaid, if the part failed due to a defect of material or workmanship. Return parts must be received within 30 days of making the claim. No credit or refunds will be given after 30 days.

Warranty policies may vary by customer, equipment and/or job. Refer to your sales documents for details specific to your chiller.