howHow to use industrial chillers well and how to maintain them properly are important issues,Reasonable maintenance of industrial chillers can enable them to fully utilize efficient refrigeration, save energy, extend the service life of industrial chillers, save funds, and greatly benefit the improvement of product quality and production efficiencyTherefore, when a factory buys a new industrial chiller, it is very necessary to develop a comprehensive maintenance manual for the industrial chiller.

1、 Standardization of Regular Maintenance for Industrial Chillers

1. Ice water machine maintenance: Keep the surface of the industrial ice water machine clean, regularly clean the ice water and cooling filter, and ensure that the industrial ice water machine is in use

2. If it has been more than six months, or if the high and low pressure engines frequently malfunction, or if the cooling capacity decreases, please check if the pressure on the high-pressure gauge is higher than 30 kilograms.

3. If the industrial chiller is stopped for a period of time, due to the solidification of water pollutants, the pump blades of the water pump may be solidified by the pollutants. When restarting, the pump rotor must be loosened first to avoid the pump blades not rotating and causing the fuse to burn out.

4. The air-cooled ice water machine requires observation and maintenance of the finned condenser.

5. Water cooled ice water machines are mainly used for observation and maintenance of cooling towers and water-cooled shell and tube condensers!

2、 Maintenance Manual for Industrial Chiller Unit

1. Purpose

Standardize the maintenance of industrial chillers to ensure their normal operation.

2. Scope of application

Maintenance of cooling ice water machines, central air conditioning ice water units, etc. for factories and projects in various industries.

3. Daily maintenance: maintenance teams for each project

3.1 Cycle: Half a month

3.2 Clean the dust on the surface of the unit, remove rust on the metal surface, and add rust proof oil.

3.3 Check whether the machine foot bolts are loose, whether the unit has abnormal vibration and noise, and immediately deal with them.

3.4 Use a Freon electronic leak detector to detect if there is any Freon leakage in the unit. If it indicates leakage, immediate repair, leak prevention, and supplementation should be carried out.

3.5 Check the filling amount of Freon, the liquid level should be in the middle of the Freon sight glass, and make appropriate adjustments if necessary.

3.6 Check if the oil pressure is normal. If the pressure difference of the oil filter is greater than 25PSIG, the oil filter should be replaced. And check the working condition of the return oil system, the return oil temperature (bearing temperature) should be within the allowable range.

3.7 Check if the oil level is in the middle of the upper mirror. If the oil level is low, immediately replenish the refrigeration oil.

3.8 Check the various operating parameters of the unit and the working procedures of the computer control center. 3.9 Check the heat exchange efficiency of the heat exchanger.

4. First level maintenance: maintenance teams for each project

4.1 Cycle: Six months

4.2 Check if the bolts of the unit are loose, if there are any abnormal vibrations or noises, and handle them immediately.

4.3 Ensure proper insulation of the unit and pipelines.

4.4 Check whether the unit leaks Freon, and deal with it immediately if there is any leakage.

4.5 Check if the oil level is appropriate, and if there is a low oil level, it should be replenished immediately.

4.6 Check whether the heat exchange effect of the evaporator and condenser is good.

4.7 Maintenance and start-up of the electric cabinet.

5. Secondary maintenance: maintenance teams for each project

5.1 Cycle: Year

5.2 Check the oil return system, replace the dryer, oil filter, and inspect the lubricating oil of the refrigeration unit to ensure that it meets the following specifications:

5.2.1 Viscosity at 100F (38 ℃) 300 ± 25ssu (59.2 to 70.1 square millimeters per second)

5.2.2 Viscosity at 210F (99 ℃) 50 to 55ssu (7.3 to 8.8 square millimeters per second)

5.2.3 * * Small viscosity index 955.2.4 Flow point -5F (-21 ℃) 5.2.5 * * Flash point 400F (204 ℃) 5.2.6 Acidity index cannot exceed 2.0mgKOH/mg

5.2.7 If the above indicators cannot be achieved in the test, the lubricating oil of the refrigeration unit should be replaced.

5.3 Check the operation parameters of the host and the unit, check the working program of the computer board, and make appropriate adjustments to relevant components.

5.4 Check the lubrication system. When the pressure difference of the oil filter is greater than 25PSIG, the oil filter, refrigerant filter element, and refrigerant filter screen should be replaced.

5.5 Check the wear of the bearings. If there is wear on the bearings, it can sometimes be detected by abnormal vibration and temperature rise of the bearings.

5.6 Check the compressor motor and measure the insulation resistance of the motor. For closed compressors, the insulation resistance should not be less than 50M Ω, and for open compressors, it should not be less than 0.5M Ω.

5.7 Check the filling amount of Freon, the liquid level should be in the middle of the Freon sight glass, and make appropriate adjustments if necessary.

5.8 Check the cooling effect of the refrigeration cycle.

5.9 Check and clean the evaporator and condenser heat exchange copper pipes. If the copper pipes are severely scaled, they should be cleaned;

3、 Common faults and troubleshooting methods of industrial chillers:

1. The reasons and solutions for the power indicator light of the industrial chiller not turning on when the power switch is turned on are:

1.1. No power supply, check the power supply line;

1.2. The power indicator light is damaged, replace the electronic board.

1.3. If the control circuit transformer is damaged, replace it.

1.4. The fuse is damaged and needs to be replaced;

2. Compressor high pressure faults and troubleshooting methods:

2.1. The condenser is dirty and blocked Clean the condenser

2.2 Cooling tower motor fan failure: Replace the cooling tower motor.

3. Reasons for compressor failure in industrial chillers:

3.1. The overload protector on the compressor AC contactor is activated.

3.2. Compressor capacitor burnt out (single-phase).

3.3. Check if the compressor coil winding is normal. Generally, the winding value should be greater than 7 ohms;

3.4. Simply press the RESET button in the overcurrent protector.

3.5. Replace the capacitors of the chiller and industrial chiller.

3.6. If it is confirmed to be a winding issue, please replace the compressor.

4. Power failure (shutdown temperature controller without display, etc.) Reason:

4.1. mains power disconnection, phase loss, and instability.

4.2 Check if the phase sequence protector is burnt out.

4.3. The fuse is burnt out.

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