To ensure optimal performance and longevity of air-cooled chillers, regular maintenance and inspections are essential. Below are key steps to follow:
1. Check Voltage and Current Stability
- Ensure that the power supply is stable and within the acceptable range.
- Monitor the current draw of the compressor to detect potential issues early.
2. Regular Compressor Inspection
- Conduct necessary acceptance tests, following these steps:
- Gas-tightness test (to check for refrigerant leaks).
- Vacuum test (to ensure the system is airtight).
- Component testing before a full-system inspection.
- Inspect for abnormal noises, vibrations, or excessive heat during operation.
3. Routine Cleaning
- Keep the unit’s exterior and surroundings clean to prevent dust accumulation.
- Every six months, clean the entire system, including:
- Pipelines & filters (to remove dirt or blockages).
- Condenser & fan (dust buildup reduces cooling efficiency).
- Dirty fans can obstruct airflow, reducing cooling performance.
4. Instrument & Sensor Checks
- Temperature controller failure → Replace the temperature control unit.
- High-pressure fault
- Possible cause: Poor heat dissipation
- Solution: Clean the heat exchanger and improve ventilation
- Cooling fan malfunction
- Check if the fan motor is damaged and repair or replace it.
- High-pressure switch failure → Replace if necessary.
5. Check Refrigerant Levels
- Use high- and low-pressure gauges to monitor refrigerant levels:
- Normal operating range:
- High pressure: 11-17 kg/cm²
- Low pressure: 3-5 kg/cm²
- Stopped chiller:
- Both high and low pressures should be around 0.6 kg/cm².
- A drop in refrigerant levels can reduce cooling efficiency and may indicate leaks.
Additional Maintenance Tasks
- Monitor compressor oil levels and oil temperature.
- Check main power voltage and current.
- Ensure the chilled water supply temperature is correctly set.
- If any irregularities occur, make adjustments or repairs immediately.
Regular inspection, cleaning, and maintenance ensure that your air-cooled chiller remains efficient, reliable, and long-lasting.
Maintenance and Inspection of Air-Cooled Chillers