In this article, we will provide a detailed overview of the faults that may occur during the operation of industrial chillers and the corresponding solutions. By reading this article, you will learn how to cope with malfunctions, optimize chiller performance and reduce associated maintenance and energy costs. We hope that this content will provide you with valuable assistance in further understanding and applying industrial chillers.

●Startup Faults: Difficulty in starting the motor or failure to start at all is one of the common failures. Possible causes include power supply problems, internal motor failure, starter failure, etc.

●Electrical Failure: The electrical components of the motor may fail, such as insulation damage, loose wires, loose or corroded terminals, etc. This may cause the motor to fail to work properly or cause safety hazards.

●Bearing Failure: Damaged or worn out motor bearings may lead to abnormal noise, vibration, and unstable motor speed, which may ultimately cause the motor to stop running altogether.

●Overload: prolonged operation of the motor or excessive load may cause the motor to overheat and trigger the thermal protection device, causing the motor to stop working to protect its own safety.

●Motor overheating: motor overheating due to excessive load, high ambient temperature, poor ventilation, unstable voltage and other reasons

Solution

●The solution includes checking the motor temperature and ensuring good ventilation; checking the motor starter or motor control module and repairing or replacing it.

●Insufficient refrigerant flow: Insufficient refrigerant flow or insufficient cooling capacity of the water cooled chiller or air cooled chiller due to blocked pipes, faulty valves or refrigerant leakage.

Solution

●Check the refrigerant flow rate: First, make sure the flow meter in the refrigerant system is working properly and taking accurate readings. If the flow meter shows a lower than normal flow rate, then there may be an insufficient refrigerant flow problem.

●Check for clogged ducks: Check for clogged or narrowed refrigerant ducts. Clogged pipes can be caused by impurities, deposits, or solidified refrigerant. If a blockage is found, the affected section of the pipe needs to be cleaned or replaced.

●Check for valve failures: Ensure that the valves in the refrigerant system are intact and operating correctly. Sometimes, a faulty valve can result in reduced flow or complete shutdown. check that valves are open and make sure they move freely.

●Check for refrigerant leaks: Checking for leaks in the refrigerant system can be done initially by checking for signs of refrigerant leakage around connections, joints and pipes. If there are leaks, the affected parts need to be repaired or replaced and recharged with the proper amount of refrigerant.

2.Insufficient opening or blockage of the expansion valve: Insufficient opening or blockage of the expansion valve will restrict the flow of refrigerant through the evaporator, resulting in insufficient refrigerant in the evaporator, affecting the cooling effect of the water cooled chiller or air cooled chiller.

Solution

●Check expansion valave opening : Check the operating mechanism of the expansion valve to make sure it can move freely and adjust the opening to increase refrigerant flow.

●Check expansion valve: If the expansion valve is clogged with contaminants, it needs to be cleaned. First, shut down the system and remove the expansion valve. Clean the expansion valve with an appropriate cleaner or solvent to remove any dirt or deposits. Then, reinstall the expansion valve and make sure it is ready to operate.

●Replace the expansion valve: If the expansion valve is still a problem after cleaning, it may be necessary to consider replacing the expansion valve. The internal parts of the expansion valve may be damaged or worn out and not functioning properly. Contact your supplier or a professional technician to obtain the proper expansion valve and replace it according to the manufacturer's instructions!

High-pressure protection will cause the chiller to alarm or shut down, and prolonged and frequent high-pressure protection will lead to serious damage to the chiller

1. Air in the refrigeration system triggers high-pressure protection: the presence of air will lead to an increase in the volume of refrigerant in the chiller refrigeration system, thus increasing the pressure in the system. When the pressure exceeds the design range of the system, the high pressure protection will trigger the water cooled chiller or water cooled chiller alarm or shutdown.

Solution

●Industrial chiller system exhaust: By installing an exhaust valve or exhaust device at the proper location of the chiller, air can be periodically discharged from the system.

●Industrial chiller system charge: If the amount of refrigerant in the system is insufficient, this may cause air to enter the system. Always make sure the system is purged of air before charging the refrigerant. When charging the refrigerant, use the proper charging device and method to ensure that the refrigerant enters the system without air.

●Checking and repairing leaks: Leaks in the system can also cause air to enter the chiller system. Inspect the system's connections, pipes, valves and other critical components to find and repair any leaks. Make sure the system is well sealed to prevent air from entering.

2. Poor heat dissipation from the water cooled chiller or air cooled chiller condenser triggers high pressure protection: The water /air cooled chiller's condenser is the component that releases heat from the refrigerant to the surrounding environment. If the condenser does not dissipate heat well enough to effectively remove the heat, it will cause the condenser temperature to rise, which in turn will increase the refrigerant pressure.

Solution.

●Clean the condenser: Regularly clean the surface of the condenser to remove dirt and clogs to ensure that heat can be efficiently dissipated.

3. Industrial chiller refrigerant injection excessive trigger high pressure protection: too much refrigerant will increase the refrigerant mass within the refrigeration cycle, thereby increasing the pressure. When the pressure exceeds the system's designed high-pressure protection setting, the high-pressure protection device will be triggered, stopping air /water cooled chiller operation to prevent system damage.

Solution.

Abnormal oil supply will lead to increased wear and tear of the chiller system components, decreased energy efficiency ratio, and also cause noise and vibration.

1. Oil mist filter inlet clogging leads to chiller oil supply abnormality: impurities in the lubricating oil, pollutants accumulate on the oil mist filter, resulting in oil mist filter clogging.

Solution

2. The oil pressure gauge is not allowed to lead to abnormal oil supply of the chiller: the oil pressure gauge shows abnormal or inaccurate, which may lead to insufficient or excessive oil supply.

●Inaccurate oil pressure gauge: Calibrate or replace the inaccurate oil pressure gauge to ensure accurate display of oil supply status. Regularly check and maintain the accuracy of the oil pressure gauge.

3. Low oil level leads to abnormal oil supply of the chiller: Low oil level may be caused by oil leakage, oil pump failure or other reasons. Low oil level will lead to insufficient lubrication and insufficient oil supply.

Solution

1. The fuse is blown and the circuit is not closed causing the air/water cooled chiller's compressor to fail to start.

Solution

●Check the circuit:First, check the circuit where the fuse is located to make sure all connections are secure and not loose. Check for any other signs of a fault or short in the circuit.

●Replace the fuse: Replace the blown fuse with a new one of the same size as the original. Make sure the new fuse matches the current required by the circuit.

●Restart industrial chiller :After ensuring that the circuit is functioning properly, restart the industrial chiller and monitor its operation. Ensure that the compressor starts properly and that the refrigeration system is operating correctly.

2. The industrial chiller's compressor will not start due to a faulty contactor or solenoid coil.

Solution

●Check the contactor and solenoid coil: First, check the contactor and solenoid coil for any visible signs of damage or failure. Check that the contacts of the contactor are clean and intact, and check that the solenoid coil is not burnt or disconnected.

●Cleaning and maintenance: If the contactor contacts are dirty or oxidized, try cleaning the contacts with fine sandpaper or an electronic cleaner and make sure the contacts are intact. Also, check that the solenoid coil connections are secure and not loose or making poor contact.

●Replacing faulty parts: If an inspection determines that the contactor or solenoid coil is faulty, it must be replaced with a new part that meets specifications. Be sure to use a replacement part of the same specification and type as the original part and that it is installed correctly.

●Check the control circuit: Check the control circuit in which the contactor and solenoid are located to ensure that there are no other faults or shorts in the circuit. Check the relays, fuses, switches, and other components in the circuit to make sure they are working properly and are not faulty.

●Restart the industrial chiller: After replacing or repairing faulty parts, restart the industrial chiller and monitor its operation. Make sure that the compressor can start normally and the refrigeration system operates normally.

3.System activation of the safety protection mechanism causes the chiller's compressor to shut down.

Solution:

Kassel Machinery is a industrial chiller manufacturer with European quality and service at Chinese factory prices. Our product line covers air-cooled chiller, water-cooled chiller, centralized chiller, portable chiller, screw chiller, scroll chiller, mold temperature controller and so on. Our chillers have the advantages of high cooling efficiency, energy saving and good stability. Consult Kassel Machinery, for one-stop cooling solutions.