Chiller Maintenance

Industrial chillers are widely used in industrial refrigeration equipment. Their maintenance is very important to ensure their normal operation and extend their service life. The specific maintenance measures and cycles are as follows:   Daily maintenance of the industrial chillers Wipe the outer shell of the chiller regularly to check for signs of damage, deformation or corrosion. Check whether there are blockages at the inlet and outlet of the chiller, such as dust, debris, etc. If there is a blockage, it should be cleaned in time to ensure good ventilation. Check whether the pipe connection of the chiller is firm and whether there is damage, deformation, or leakage on the appearance. Especially for pipe joints, valves and other parts, ensure good sealing. If there is a problem, the pipe should be replaced in time to prevent leakage or affect the cooling effect. Check the operating status of the chiller, such as whether the compressor, water pump and fan have noise and abnormal sounds. Check the outlet water temperature and return water temperature of the chiller to ensure that the temperature is within the set range. Check the pressure of the system, including the refrigerant pressure and water pressure, to ensure smooth water circulation.   Regular maintenance of the industrial chillers For some important parts of the chiller, special attention should be paid during maintenance: 1. Condenser of the chiller The condenser of the water cooled chiller is prone to scaling, and the condenser of the air cooled chiller is prone to dust accumulation. These two factors will not only affect the heat dissipation effect of the chiller, resulting in a decrease in cooling capacity, but will also affect the increase in the power of the chiller and easily damage the compressor of the chiller. Therefore, the condenser must be cleaned regularly, and the specific maintenance time should be determined according to the actual use environment of the customer.   2. Compressor of the chiller After the compressor of the chiller has been running for 1,000 hours, check whether the compressor refrigeration oil is normal; whether the current is normal during operation; and whether there is any abnormal sound during operation.   After the machine has been used for a certain period of time, due to various factors, the pressure switch needs to be tested to see whether it can alarm high and low pressures. For the electric control box, the dust inside should be blown clean regularly, and the screws should be checked for looseness to avoid damage to the machine.   Attached is the regular maintenance schedule for common parts of Hengde chillers Item Maintenance Period Clean the condenser 3 months Check the chilled water pump 3 months Check the wires (corner insulation)  1 month Check the cooling water supply (water-cooled) 1 week Check various safety protection devices 1 month Check the operating current of the compressor and water pump 3 months   Choose Hengde, Choose Perfect Industrial Chillers!

Chillers are essential in industrial, commercial, and laboratory applications, providing precise temperature control for processes, equipment, and cooling systems. However, even high quality industrial chillers can experience faults over time. Knowing the common chiller faults, their causes, and effective troubleshooting techniques can help operators minimize downtime, improve efficiency, and extend equipment lifespan.   Below is a practical guide for operators, maintenance teams, and facility managers on industrial chiller troubleshooting. Frequently Asked Questions on Industrial Chiller Troubleshooting Q1: My industrial chiller powers on but does not start. What could be the cause? A: This can happen due to micro-break trips, main power switch tripping, or reverse phase protection activation. To troubleshoot: Check and confirm the fault, replace or repair faulty components. Inspect the main power switch: if the line is grounded or short-circuited, repair or replace the affected parts. Verify the compressor, water pump, and motor; repair or replace if grounded. For reverse phase protection, ensure the compressor, water pump, and fan rotate in the correct direction; swap any two phases if needed. Measure the three-phase voltage with a multimeter to confirm.   Q2: Why does my industrial chiller trigger a high-pressure alarm? A: High-pressure alarms can occur due to several reasons: Dirty condenser or high ambient temperature: Keep air temperature below 40℃ and cooling water below 35℃; clean the condenser regularly. High-voltage switch fault: Press the reset switch after confirming safety. Overfilled refrigerant: Check and adjust the refrigerant charge. Cooling water pump failure or water system fault: Repair or replace the water pump.   Q3: What causes a low-pressure alarm on my industrial chiller? A: Common causes include: Insufficient refrigerant or system leaks: Inspect pipelines, repair any leaks, and refill refrigerant if necessary. Low water flow or insufficient water causing evaporator freezing: Ensure the water tank is full and valves are open; if frozen, melt ice with warm water—never hit the ice. Chilled water pump failure or pipeline blockage: Check and repair the pump and pipelines.   Q4: What triggers an overload alarm? A: Overload alarms may result from: Abnormal voltage:  Inspect and stabilize the three-phase power supply. Faulty water pump or compressor: Repair or replace. Overload relay set too low or damaged: Adjust or replace. Poor or loose line contacts: Tighten screws and ensure proper electrical connections.   Q5: Why does my industrial chiller display a water flow alarm? A: Possible reasons include: Air trapped in the water pump, preventing drainage or pump damage: Drain or replace the pump. Clogged water filter:  Clean the filter. Water shortage or damaged pipelines: Inspect and repair the system.   Q6: My industrial chiller output temperature is too low. What should I do? A: Causes may include: Water temperature setting is too low: Reset to the desired value. Water temperature probe is open or short-circuited: Inspect and replace if necessary.   Q7: The industrial chiller cooling seems weak. Why? A: This may happen if the cooling load is too small or the system refrigerant is insufficient or faulty:  Consider selecting a chiller with appropriate capacity and inspect the refrigerant system. Quick Reference: Industrial Chiller Troubleshooting Table Status / Fault Possible Causes Solutions Power ON, no startup Micro-break trip Check and confirm the fault, replace or repair Main power switch tripped 1) The power load line is grounded or short-circuited; 1) Replace new parts; 2) The compressor, water pump, or motor is grounded. 2) Repair or replace if fault is confirmed after inspection. Reverse phase protection 1) The compressor, water pump and fan are in reverse direction; 1) Swap any two phases of the power supply; 2) Phase loss. 2) Use a multimeter to measure whether the three-phase voltage is normal. High pressure alarm 1) High-voltage switch tripped. 1) Clean the condenser, keep the air temperature below 40℃/cooling water below 35℃; 2) High-voltage switch fault. 2) Press the high pressure reset switch to restart the compressor. 3) Overfilling of refrigerant. 3) Check whether the refrigerant charge is too much. 4) Cooling water pump fault or cooling water system fault. 4) Repair or replace the water pump. Low pressure alarm 1) Insufficient refrigerant or system leakage; 1) Check if the system is short of refrigerant or if there are leaks in the system pipelines, check for leaks and repair them; 2) Insufficient water flow or lack of water in the system causes the evaporator to freeze. 2) Check if the water tank is short of water and if the valve is open to the maximum. If the evaporator is frozen, drain the water and add warm water to melt the ice. Do not hit the ice with hard objects. If the copper pipe is penetrated, the compressor will be damaged! 3) Failure of the chilled water pump or pipe blockage. 3) Check the chilled water pump and pipeline system. Overload alarm 1) Abnormal voltage; 1) Check and repair the unstable voltage and missing phase of the three-phase power supply; 2) Faulty water pump or compressor; 2) Repair or replace; 3) Overload relay setting is too low or damaged; 3) Re-adjust the current value or replace; 4) Line contacts are poor or loose. 4) Re-tighten the screws. Water flow alarm 1) There is air in the water pump and it does not drain water or it is damaged; 1) Drain or replace the water pump; 2) The water system filter is clogged. 2) Clean the water filter; 3) The system is short of water or the pipeline is damaged. 3) Check and repair. Output temp too low 1) The water temperature setting value is too low; 1) Reset the temperature value; 2) The water temperature probe is open or short-circuited 2) Check the probe and replace it. Cooling weak 1) The cooling load of the unit is too small; 1) Reselect a chiller with appropriate capacity; 2) The system refrigerant is insufficient or faulty. 2) Check the system and repair it.   Note: For safety and optimal performance, industrial chiller maintenance and repairs should always be performed by qualified professionals. Regular industrial chiller inspections and preventive servicing reduce risks of faults and extend system life. For more industrial chiller maintenance methods, please refer to: How To Maintenance The Industrial Chiller   About NANJING HENGDE ELECTRICAL EQUIPMENT CO., LTD NANJING HENGDE ELECTRICAL EQUIPMENT CO., LTD is a trusted professional in the Industrial Chiller field, specializing in designing and manufacturing high-quality chillers for various industrial applications. With over 20 years of experience, Hengde provides reliable temperature control solutions, including water chillers, air chillers , mold temperature machines, and customized systems to meet the needs of factories worldwide. Their expertise ensures efficient, durable, and safe operation for all industrial cooling requirements.

During winter, low ambient temperatures pose several challenges for chillers. Proper usage and maintenance are essential to ensure stable operation, extend the equipment's lifespan, and reduce operational costs. Hengde, a leader in the refrigeration equipment industry, has extensive experience in the research, production, and maintenance of chillers. Below are the key points and maintenance guidelines for industrial chiller use in winter, based on Hengde’s expert advice.   1. Pre-Startup Key Checks Water System Inspection Winter temperatures can cause water to freeze, so it’s crucial to thoroughly check both the cooling and chilled water systems. Ensure the water level is normal, and that the water is clear and free from impurities. If the water quality is poor, it should be treated or replaced. Additionally, inspect the water system's filters, clean or replace the filter elements to ensure smooth water flow and prevent ice blockages in the pipes.   Insulation measures inspection Check whether the insulation layer of each component of the industrial chiller is intact, especially the pipes and water tanks. If the insulation layer is damaged, the heat loss of the equipment will accelerate in a low temperature environment, energy consumption will increase, and the water system may also freeze. If damage is found, it is necessary to repair or replace the insulation material in time.   Electrical System Pre-Inspection Quickly check the electrical wiring for visible damage and ensure that terminal connections are secure. Verify that the power supply voltage is stable and within the chiller's rated voltage range. Hengde industrial chillers are equipped with an intelligent voltage monitoring system, but a manual inspection can help identify potential issues before they arise.   2. Operating Precautions Insulation measures inspection Check whether the insulation layer of each component of the chiller is intact, especially the pipes and water tanks. If the insulation layer is damaged, the heat loss of the equipment will accelerate in a low temperature environment, energy consumption will increase, and the water system may also freeze. If damage is found, it is necessary to repair or replace the insulation material in time.   Monitor Temperature Fluctuations In winter, the lower ambient temperature reduces the cooling load on the industrial chiller. It’s essential to closely monitor the temperatures of the evaporator, condenser, as well as the outlet temperatures of industrial chilled and cooling water. Based on these readings, adjust the operational parameters accordingly to prevent prolonged low-load operation, which can reduce compressor efficiency and increase energy consumption. Hengde industrial chillers feature an intelligent control system that automatically adjusts based on temperature fluctuations, ensuring efficient operation.   Insulation measures inspection Check whether the insulation layer of each component of the industrial chiller is intact, especially the pipes and water tanks. If the insulation layer is damaged, the heat loss of the equipment will accelerate in a low temperature environment, energy consumption will increase, and the water system may also freeze. If damage is found, it is necessary to repair or replace the insulation material in time.    Prevent Ice Formation In cold weather, the risk of water system freezing is higher. To prevent freezing, add an appropriate amount of antifreeze to the water, and ensure that the water system circulates properly. If any signs of freezing are detected, immediately shut down the system, thaw it, and restart it only after ensuring the water flow is restored.   Hengde not only offers high-performance industrial chillers but also provides comprehensive technical support and after-sales services. During winter operations, Hengde’s expert technical team is available to offer remote or on-site guidance, helping users solve any issues they may encounter. Hengde also conducts regular follow-up visits to check the equipment's operation, offering targeted maintenance suggestions to ensure the industrial water cooled chiller and air cooled chiller run efficiently and reliably throughout the winter.   Choose Hengde, Choose Perfect Industrial Chillers!