FAQ

Industrial chillers are devices used to cool equipment, processes or environments. They are commonly used in industries such as plastic processing, electronics manufacturing, food processing, medical equipment, HVAC (heating, ventilation and air conditioning). During long-term use, industrial chillers may have various problems that affect their normal operation. The following are common problems with industrial chillers and their possible causes and solutions:

1. The chiller has poor refrigeration effect or no refrigeration
Possible reasons:
Refrigerant leakage: Insufficient or leaking refrigerant in the system will lead to reduced refrigeration capacity.
Condenser or evaporator dirt accumulation: Too much dirt on the surface of the heat exchanger leads to reduced heat exchange efficiency.
Compressor failure: The compressor is damaged or the performance is reduced, and the refrigerant cannot be effectively compressed.
Expansion valve failure: The expansion valve is blocked or improperly adjusted, resulting in abnormal refrigerant flow.
Insufficient water flow: Insufficient cooling water or chilled water flow affects the heat exchange effect.
Solution:
Detect whether there is refrigerant leakage, replenish refrigerant and repair the leak.
Clean the condenser and evaporator regularly to remove dirt and scale.
Check whether the compressor is working properly, and repair or replace it if damaged.
Check whether the expansion valve is blocked or improperly adjusted, and replace it if necessary.
Make sure the water pump is running normally, check whether the water path is blocked or the water level in the water tank is normal.
2. The compressor starts frequently or does not start
Possible reasons:
The pressure protection device frequently operates: high pressure or low pressure protection causes the compressor to start and stop frequently.
Power supply problem: unstable voltage or circuit failure.
Compressor overload protection: motor overheating or overload.
Controller failure: abnormal thermostat or PLC control system.
Solution:
Check whether the high and low pressures are normal, adjust or clean the condenser.
Ensure that the power supply voltage is stable and check whether the wire connection is loose or damaged.
Check whether the compressor is overheated, clean the condenser and check the cooling fan or water pump.
Check whether the thermostat setting is correct and replace the controller if necessary.
3. Poor heat dissipation of the condenser leads to high pressure alarm
Possible reasons:
Condenser blockage or scale accumulation: dust, oil or scale accumulation affects heat dissipation.
Insufficient cooling water flow: cooling water pump failure or water pipe blockage.
Air-cooled chiller fan failure: fan damage or insufficient speed.
Ambient temperature is too high: the cooling environment temperature is too high, affecting heat dissipation.
Solution:
Clean the condenser and perform regular maintenance to ensure heat exchange efficiency.
Check the cooling water flow, clean the water circuit, and check whether the water pump is normal.
Check whether the fan is operating normally and replace the fan motor if necessary.
Ensure that the chiller is installed in a well-ventilated environment to avoid high temperature environment affecting heat dissipation.
4. Low pressure alarm, system pressure is too low
Possible causes:
Refrigerant leakage: Insufficient refrigerant in the system causes low pressure alarm.
Evaporator frosting or icing: Poor heat exchange of the evaporator causes low pressure.
Expansion valve blockage: Reduced refrigerant flow.
Filter blockage: Refrigerant circulation is blocked.
Solution:
Check whether the system has leaks, add refrigerant and repair the leak.
Clean the evaporator and check whether the fan or water flow is normal.
Replace or adjust the expansion valve.
Check whether the filter is blocked and replace it if necessary.
5. Water flow alarm or water pump failure
Possible causes:
Water pump damage: Water pump motor burns out or mechanical failure.
Water filter blockage: Impurities in the water block the pipe or filter.
Water level is too low: Insufficient water in the water tank causes the water pump to fail to operate normally.
Flow switch failure: The flow switch is damaged or improperly adjusted.
Solution:
Check whether the water pump is working properly. If it is damaged, repair or replace it.
Clean or replace the water filter to ensure that the water path is unobstructed.
Check the water level in the water tank and add enough water.
Check whether the flow switch is normal and replace it if necessary.
6. The chiller is too noisy or vibrates abnormally
Possible causes:
Compressor failure: Damage or aging of internal parts of the compressor.
Fan damage: Bearing wear or deformation of fan blades.
Water pump noise: Water pump bearing damage or poor water flow.
Equipment installation problem: Uneven ground or loose fixation, resulting in resonance.
Solution:
Check the operating status of the compressor and replace or repair it if necessary.
Check whether the fan and water pump bearings are damaged, lubricate or replace them.
Ensure that the chiller is installed firmly to reduce resonance.
7. Electronic control system failure
Possible causes:
Thermostat failure: Temperature sensor damage or parameter setting error.
Circuit failure: Control circuit board failure or loose wiring.
PLC or inverter abnormality: Control system program error or hardware failure.
Solution:

Check whether the thermostat is normal and replace it if necessary.
Check the circuit board and wiring to repair the poor contact problem.
Reprogram or replace the PLC/inverter.
8. Frost or ice on the chiller
Possible reasons:

The evaporator temperature is too low: it may be that the refrigerant flow is too large or the temperature setting is too low.
Insufficient chilled water flow: causes uneven heat exchange of the evaporator.
Low ambient temperature: causes frost on the evaporator surface.
Solution:
Adjust the expansion valve to control the refrigerant flow.
Increase the chilled water flow and check whether the water pump and pipeline are normal.
Appropriately increase the set temperature to avoid overcooling.
Conclusion:
Common problems of industrial chillers involve multiple aspects such as refrigeration system, water circulation system, and electrical control system. Regular maintenance, cleaning of condensers and evaporators, and checking of circuit and water circuit status can effectively reduce the occurrence of failures and improve the working efficiency and service life of the chiller.