Causes of Chiller Malfunctions, Troubleshooting Measures, and Operational Precautions

In everyday use, chillers can be classified by temperature into low‑temperature chillers and ambient‑temperature chillers. However, no mechanical equipment operates indefinitely without maintenance. If a chiller malfunctions, will you identify the cause and resolve the issue? Let’s take a look. Below is a detailed overview compiled by our editor, covering the common causes of chiller failures, corresponding troubleshooting measures, and proper operating procedures—information we hope will prove helpful to you.

I. Causes of Chiller Malfunctions and Corresponding Solutions

1. The cooling water temperature is too high, resulting in poor condensation performance. Chiller units are designed to operate under a rated cooling‑water temperature of 30–35°C; when the water temperature exceeds this range, heat dissipation deteriorates, inevitably leading to elevated condensing pressures. This issue typically occurs during periods of high ambient temperatures. Possible causes include malfunctions in the cooling tower—such as the fan failing to start or even reversing, or the water distributor not rotating—which manifest as very high and rapidly rising cooling‑water temperatures. Alternatively, high outdoor air temperatures combined with short water‑circulation paths and limited circulating water volume can also drive cooling‑water temperatures upward. In such cases, the cooling‑water temperature generally remains at a relatively high level; one effective solution is to increase the capacity of the cooling‑water storage tank.

2. Insufficient cooling water flow, failing to meet the rated flow rate. The primary symptoms are a reduced pressure differential between the unit’s inlet and outlet (compared with the initial differential when the system was first commissioned) and an increased temperature difference. Causes of inadequate flow include insufficient water supply or air entrainment in the system; the solution is to install air vents at high points in the piping to vent air. Other causes may be clogged pipe filters or the use of filters that are too fine, limiting water permeability—appropriate filters should be selected and their screens cleaned regularly. Additionally, the pump may be undersized and mismatched with the system.

3. Scaling or blockage in the condenser. Condensate water is typically supplied by tap water, which readily forms scale at temperatures above 30°C. Moreover, since cooling towers are open‑type and directly exposed to the atmosphere, dust and foreign particles can easily enter the cooling‑water system, leading to fouling and blockage of the condenser. This reduces the heat‑transfer surface area, lowers efficiency, and also impairs water flow. Symptoms include an increased pressure differential between the unit’s inlet and outlet, a larger temperature difference, and noticeably high temperatures on both the upper and lower sections of the condenser when touched; the condenser’s liquid‑side copper tubing may even feel scalding. Regular backwashing of the unit is recommended, and chemical cleaning to remove scale should be performed when necessary.

II. Proper Operating Procedures for Chillers

In fact, there are many types of chillers available on the market, which can be classified in various ways. By compressor type, the main categories are centrifugal chillers, reciprocating chillers, and screw chillers. Classified according to fuel type, they fall into oil‑fired and gas‑fired models. And based on their sealing configuration, chillers can be further divided into open‑type, semi‑closed, and fully closed units. So, what key considerations should operators keep in mind during actual use? Next, let our editor at Boer walk you through the proper operating procedures for chillers:

1. Check security settings

When operating chillers in industrial settings, several precautions must be observed to ensure safety. To prevent operational errors, always verify that the equipment’s safety devices are functioning properly before each start-up. These safety features primarily include confirming that the safety plunger is secure and that the safety door is within its proper operating range.

2. Pay attention to hand safety.

A particularly important point to note is that, during machine operation, you must never reach into the mold‑clamping mechanism. When removing the molded part, for safety, always open the safety guard first; only after confirming that everything is in proper working order should you close it. Failure to perform a thorough check can lead to workplace accidents, and if foreign objects are present in the mold, the chiller may not operate effectively.

In addition to the points mentioned above, it is also important to note that during machine operation, hands must never be inserted between the mold and the nozzle gate. Since the machine is still running, the high-speed motor can be extremely sharp and pose a serious risk of injury. Furthermore, when performing mold maintenance, always remember to shut off the oil pump motor first.

The above is a compilation by the editor of information on the causes of chiller malfunctions, corresponding troubleshooting measures, and operational precautions. We hope this will be helpful to you; if you’re interested, please save and follow for future reference.