Ten common faults in the use of industrial chillers

It is inevitable to encounter malfunctions when using industrial chillers. Below are several common malfunctions and their causes during the use of chillers

Oil pressure alarm occurs during use
Common causes of oil pressure alarm in chillers:
1. The internal parts of the chiller have not been inspected and cleaned, resulting in oil stains, oil pump filters, and other blockages.
2. Insufficient refrigeration oil added to the chiller results in insufficient oil level in the compressor case, and the pump cannot absorb the oil.
3. The cold water engine oil pump is malfunctioning.

High voltage alarm that occurs during use
Common causes of high pressure alarm in chillers:
1. The cooling water flow rate of the chiller is too low or the temperature is too high to take away the condensation heat of the compressor.
2. The refrigerant charge in the chiller is too high, and the liquid occupies the effective condensation area, resulting in an increase in condensation pressure.
3. The condenser in the chiller has been in use for too long and has not been regularly inspected, resulting in severe fouling on the heat transfer surface and excessive internal dirt in the condenser. At the same time, the condensation pressure increases. So it is necessary to regularly inspect and clean the interior of the chiller to avoid malfunctions.

Low voltage alarm that occurs during use
1. The internal system of the chiller lacks refrigerant.
2. The internal of the chiller was not regularly inspected, resulting in clogged filters.
3. Insufficient air volume of the chiller fan.
4. Failure to regularly check the condenser in the chiller resulted in frost formation.
When purchasing a chiller, the expansion valve is too small.
5. Failure to regularly check the capillaries and expansion valves in the chiller caused blockages.

Thermal protection of the compressor during use
Common reasons for compressor thermal protection in chillers:
1. During the use of the chiller, there is a phase loss in the power supply voltage, motor overload, and abnormal power supply pressure.
2. Insufficient return air volume in the chiller system, resulting in insufficient cooling of the motor.
3. The temperature of the chiller motor is too high.

The refrigeration effect of the chiller is poor when in use, and it cannot meet the refrigeration requirements
Common reasons for poor performance of chillers
1. Failure to regularly inspect the chiller, causing internal blockage, valve not opening, electromagnetic valve failure, and other reasons.
2. The compressor in the chiller has malfunctioned.
3. The chiller did not add enough refrigerant.
4. When starting up and using, the expansion valve opens too large or too small.

Exhaust alarm of chiller during use
Common causes of exhaust alarm in chillers
When using a chiller, the cooling water volume is insufficient or the water temperature is too high.
2. Excessive condensation pressure and temperature in the chiller can cause an increase in exhaust temperature.
3. The suction pressure of the chiller is too high or too low.
4. Excessive non condensable gas appears in the chiller system.

Severe frost formation on the evaporator during use
Common causes of evaporator frosting in chillers
1. The evaporator has sufficient air flow, resulting in poor heat exchange efficiency.
2. Excessive refrigerant on the evaporator surface leads to poor heat exchange efficiency.
3. During the use of the chiller, the operating temperature is too low or too high, resulting in severe frost formation.
4. The evaporator is not regularly inspected or cleared, and there are too many impurities inside, which affects heat exchange and leads to frost formation.
Abnormal oil return of the chiller

Common causes of abnormal oil return during the use of chillers
1. The exhaust temperature of the chiller is too high, which leads to a decrease in oil separation efficiency
2. There are many impurities in the filter of the chiller, and the return oil pipeline is blocked.
3. The oil separator in the chiller has been used for too long, resulting in a decrease in efficiency.
4. The chiller does not have a return oil bend, resulting in oil storage in the evaporator or other pipelines.

The chiller has a compressor suction temperature that is too high
Common causes of high suction temperature of the compressor during the use of chillers
1. The refrigerant in the chiller has overheated or is insufficient in the evaporator.
2. The pipeline of the chiller is blocked.
3. The chiller has a throttling mechanism malfunction.

Refrigerant selection for chillers
Choose the refrigerant model guided by the manufacturer, and inject the refrigerant in a quantitative manner (usually using the weighing method for refrigerant injection). Excessive or insufficient refrigerant can affect the cooling effect of the chiller.

Source: Meier chiller