Chiller Solutions to Match Hydraulic Power Pack Brands
Why Choose Our Chiller Unit for Hydraulic Power Pack
- The hydraulic circuit employs stainless steel components and stainless steel plate-type evaporators.
- The standard unit can withstand an ambient temperature of up to 48℃.
- The cooling capacity of the oil chiller ranges from 0.98 kW to 21 kW.
- We have obtained certifications such as ISO9001:2015, ISO14001, ISO45001, CE, FCC, RoHS, and SGS.
- We offer various convenient installation methods such as wall-mounted and base-mounted.
- Our defect rate is controlled at less than 0.3%, which is significantly lower than the industry average.
Professional Supplier Of Chiller Unit for Hydraulic Power Pack
The Chillerone hydraulic power unit chiller has a cooling setup that keeps the temperature steady. The control accuracy is within plus or minus 1℃. This helps stop the oil temperature from climbing too far. When oil runs too hot, its viscosity can drop, and parts can wear faster. With this cooling in place, your hydraulic system runs more steadily. It also helps the equipment last longer.
Chillerone has over 20 years of experience in manufacturing chillers. The team can also do non-standard builds if you need them. Our products ship to 75 countries. We also offer an extra 24-month warranty. Reach out now for a selection plan made for your case and for pricing.
Our Products
This unit does not need a cooling tower or cooling water. It can be set up in many ways. It fits factories that have limited water, as well as small or separate sites.
It handles heat well. That means it can run for long hours even when the workload is heavy. This works for big hydraulic stations. It also fits central cooling setups in factories.
It uses a sealed circulation method to cut down on pollution. It also keeps the temperature steady. This works well for hydraulic setups where the oil temperature matters a lot.
Precise Oil Temperature Control
The Chillerone hydraulic power unit chiller can keep the temperature within plus or minus 1°C. It helps by holding the hydraulic oil viscosity steady. This cuts down on internal leaks. It also helps avoid lower efficiency and faster wear of seals that can happen when the oil gets too hot. As a result, your hydraulic station can keep its oil temperature steady even if it runs under heavy load for long stretches.
Reliable Cooling for Demanding Systems
Our hydraulic power chiller is built for long runs and heavy demand. The evaporator and condenser come from the Chillerone factory. They also passed a 96-hour test at 80Bar pressure. They passed a 72-hour operation test as well. The unit has several safety protections. It can handle hot surroundings without problems. The defect rate is very low, so it keeps running steadily in your hydraulic station for a long time.
Easy Integration & Custom-Matched Cooling
Our hydraulic power unit chiller can dial in the cooling level to fit your hydraulic station. It does this by looking at your oil flow and the pressure. We can adjust the electrical setup, too. Options include different voltage levels and different connection styles. It can be mounted on the wall or set on the base. For control and data, it can be built with a PLC or RS485 links. If your job has special site needs, we can tailor the unit to match those needs.
Applications of Chiller Unit for Hydraulic Power Pack
CNC machines and machining centers put out a lot of heat when they run fast. A chiller keeps the hydraulic oil and the cutting oil at the right temperatures. This helps cut down on heat-related warping. It also supports steady machining accuracy.
Stamping and bending use heavy hydraulic force all the time. This chiller helps keep the heat in check. As a result, the oil does not get too hot. If the oil runs hot, over time, the equipment will wear out sooner
Injection molding machines and extruders often run for hours without stopping. This chiller keeps the oil temperature steady. That helps the hydraulic system react quickly and keeps the production pace consistent.
Heavy machines in construction, offshore work gear, and mining units face tough days. For this kind of use, our hydraulic power chiller is built to cool in a steady way. It helps your equipment run properly outside and through long work cycles.
Rolling mills and continuous casting machines generate a huge amount of heat. They also need to run all the time, day and night, without gaps. For that kind of work, hydraulic power chillers help move heat away in a steady way.
To start, we need key details about your hydraulic station:
Please share the oil flow rate. Also share the oil temperature at the inlet and the outlet. Tell us the target temperature you want to reach. We also need the system pressure and the ambient air temperature.
With these values, we will work out the heat load:
Then we can choose the cooling capacity that fits your case. After that, we will check the pump head. We will also look at the needed pipe connection size and the pressure drop.
Send the parameters above. Chillerone will then build a matching selection plan for your setup.
- If your plant has no cooling water system, or if your machines sit outside, an air-cooled hydraulic power chiller may be the right choice. It is easier to put in place, and you do not need a cooling tower.
- If you deal with a heavy load, hot outdoor weather, or if you want to chill several hydraulic stations from one main location, then water cooling often works better. It can run more efficiently and stay steady.
Send us the on-site details. Then we can help you judge the best option based on overall cost.
Yes, it can be put in place. Before you start the renovation, check the oil flow rate, the working pressure, the size of the connection, and how much space you have for the installation on the old hydraulic unit.
We can supply bypass valve sets and wiring-based control options, like a PLC with RS485, so the chiller can match the existing hydraulic setup. This helps avoid major rerouting of the pipework.
Our standard hydraulic chiller can work in environments up to 48°C. If the conditions are even more severe, we also supply a tropicalized high-temperature version. That unit is rated for 53°C. Chillerone makes this possible by enlarging the condenser heat exchange area. We also adjust how the compressor and fan control their speed.
With these changes, the hydraulic chiller keeps enough cooling margin. It can run without alarm trips or shutdowns in hot, demanding conditions.
- Chillerone can be set up to match your needs. It works across a voltage range of 220V to 480V.
- This can be single-phase or three-phase, and it supports 50Hz or 60Hz.
- For refrigerant, we can offer choices like R410a or R134a. You can also request changes to the interface size. There are options for wall-mounted or base installation.
- We can also align the system with PLC or RS485 communication based on what you want.
To proceed, share the detailed parameters you prefer.
The cost of the chiller unit for a hydraulic power pack changes based on several factors. These include the cooling capacity you need, the oil flow rate, the cooling method, the heat exchanger type, and how much it has to be customized.
We cannot give a rough estimate. Please send us the exact details we should use, like the heat output of the hydraulic station, the oil temperature, the flow rate, and the pressure. After you share that, Chillerone will work out the correct purchase budget and send a full quote.
You should clean the condenser and the filter every six months. You should also check the refrigerant and the pump valves. If the area is dusty or very hot, you may need to do this more often. Regular upkeep helps stop sudden shutdowns. Chillerone can give you step-by-step maintenance guides. They can also do follow-up site visits. This is meant to keep the hydraulic power pack chiller running well for a long time.
How Does a Chiller Unit for a Hydraulic Power Pack Work?
While the hydraulic unit runs, friction and mechanical effort create heat. That heat gets taken in by the hydraulic oil. Warm hydraulic oil goes into the chiller and passes through the oil-side heat exchanger. In that section, heat moves from the oil to the refrigerant or another cooling fluid. They stay in their own paths, so they never mix together. After that, the refrigeration cycle carries the heat out using the condenser.
After that, the chiller runs a refrigeration loop. It uses a compressor, a condenser, and an expansion valve. In the end, the heat leaves the system. It goes out to air or to cooling water. Once the oil is cooler again, it returns to the power pack.
Core flow: hydraulic oil carries heat, the heat exchanger moves the heat, the chiller sends the heat out.
Can a Chiller Directly Cool Hydraulic Oil in a Power Pack?
The oil cooler can reduce the temperature of hydraulic oil using its own oil-side heat exchanger. This is not the same as combining oil with refrigerant in the same space. Below is how the cooling setup works.
Direct Cooling
In this case, the oil cooler cools the hydraulic oil inside its built-in oil heat exchanger. Warm hydraulic oil moves through channels in the unit. Refrigerant runs in a nearby circuit that stays sealed and separate. Heat moves across the metal wall between the two sides, but the fluids never meet. This setup is the usual form of direct oil cooling because the hydraulic oil goes into the cooler for cooling. It does not depend on an extra middle fluid outside the unit.
Indirect Cooling with an Added Water or Glycol Loop
With this style, the hydraulic oil does not go into the main refrigeration loop. Instead, it gives up heat to a coolant in a separate external heat exchanger. After that, the coolant goes to the oil cooler to take part in the final cooling step. This approach fits large shared cooling systems. At the same time, the design has more parts, and it is harder to build and run.
High Pressure Isolation and Safety
The hydraulic system runs at a much higher pressure than the refrigerant side in the oil cooler. Because of that, the unit has an integrated heat exchanger that must handle the pressure safely. It has to keep the two sides separate at all times. If a small leak happens inside, the flow will favor hydraulic oil entering the refrigerant side. Refrigerant or water will not mix into the hydraulic oil. This helps protect the costly pumps and valves.
Do Not Use “Direct Injection”
Do not inject refrigerant straight into the hydraulic oil tank to lower the temperature. This can make the oil turn to an emulsion; then it can break down and harm the whole hydraulic system. No matter what approach is taken, the hydraulic oil and the refrigerant should stay in their own loops. They should trade heat only through the wall of the heat exchanger.
What Is the Ideal Hydraulic Oil Temperature Range for a Hydraulic Power Pack?
The best oil temperature changes with more than one factor. It is tied to the oil viscosity grade, the system pressure, the load, and the air temperature around the unit. In many cases, the safe working zone sits roughly at 40°C to 55°C.
Situation 1: The Oil Temperature Is Too High
If the oil gets too hot, for example, above 60°C, several issues follow. The oil breaks down faster. Oxidation and wear can form sludge and acid. As the oil thins, internal leakage can rise. That lowers volumetric efficiency. Seals also suffer. They can age, get stiff, and start to leak. With bad conditions, parts can fail.
Situation 2: The Oil Temperature Is Too Low
If the oil runs too cold, below 30°C, the flow becomes worse. Viscosity goes up, so the oil does not move easily. The pump may struggle to pick up oil, which can lead to cavitation. Heat loss and higher friction also make the pipe resistance climb. More energy is needed to run the system, and damage to the pump or motor can occur.
For most industrial setups, a common target is about 45°C. This helps keep the lubrication in a good viscosity range and supports strong transmission efficiency. The hydraulic power unit cooling system uses PID control to hold the oil temperature within a narrow band, so the equipment stays closer to the best operating state.
Why Is My Hydraulic Oil Overheating Even Though the Chiller Is Running?
If the hydraulic power chiller runs as expected, yet the oil stays too hot, you should troubleshoot in a planned order.
First, Look at the Chiller Cooling Output
- Is the air temperature around the unit unusually high, which could limit heat release from the condenser?
- For the fan section, does it run correctly?
- If the unit is water-cooled, is the water moving at the right rate?
- Is the water inlet temperature within the allowed band?
- Could the refrigerant be low or leaking?
- Does the compressor work as it should?
- Is the expansion valve partially blocked?
Next, Check How Well Heat Is Moving Through the System
- Is there scale or dirt inside the heat exchanger that blocks flow and cuts heat transfer?
- Is the oil flow too low for normal operation?
- Is the pressure drop higher than it should be?
- Is any bypass valve not in the proper open position?
- Also verify the oil temperature and oil flow sensors.
- Are the readings real, or do sensors report wrong values?
Then, Evaluate the Hydraulic Side Itself
- If all chiller readings look normal, the issue may be in the hydraulic loop. Ask whether the system is wasting energy at high pressure. For example, a stuck overflow or relief valve can cause constant overflow. That wasted energy turns into heat.
- Also inspect the pump, the motor, and the cylinders. Severe wear can cause internal leakage. This internal leakage creates heat due to throttling inside the parts.
In the end, you need to measure the heat generated by the hydraulic system using pressure difference, flow, and temperature data. Then you can tell if the chiller cooling capacity was not chosen to match the load, or if the hydraulic system makes far more heat than the design assumed.
How Can I Prevent the Chiller From Leaking and Contaminating the Hydraulic Oil?
Selection of Materials for Heat Exchangers
Choose the heater parts first. Use 316L stainless steel plates, or use shell-and-tube heat exchangers made from materials that resist corrosion. Avoid carbon steel. It rusts, and rust can worsen when water and oil flow through it.
Pressure Design
Next, set the pressure plan. The hydraulic oil side needs to run at a steady pressure. That pressure should match the level on the refrigerant side, or on the secondary cooling-medium side. If the heat exchanger has a small hole, the higher pressure helps push oil into the water circuit. This helps keep water from getting into the hydraulic oil and causes less of the system.
Factory Test
Then, test the units before shipment. Each unit should pass a strict 80Bar high-pressure test. It should also go through helium leak detection. For the pipe joints, use good welding methods. This helps prevent joint looseness from vibration over time.
Post-maintenance
After installation, keep checking. Look at seals and watch for aging. Also keep an eye on the cooling-medium quality. That helps stop scale and corrosion from building up. You should also check the refrigerant pressure on a regular basis.
Advanced Protection
For very high-risk jobs, use extra protection. A dual-wall heat exchanger can help. In that setup, there is a gap between the oil side and the water side. If the inner wall fails, the leaking medium goes into the gap. The system can then raise an alarm. This gives a second layer of safety.
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