The rated working condition of the cooling water required by the chiller is 30~35°C. The high water temperature and poor heat dissipation will inevitably lead to high condensation pressure. This phenomenon often occurs in high temperature seasons. The reason for the high water temperature may be: cooling tower failure, such as the fan is not turned on or even reversed, and the water distributor does not turn, which means that the temperature of the cooling water is high and rises rapidly; the external temperature is high, the waterway is short, and the amount of circulating water In this case, the cooling water temperature is generally maintained at a relatively high level, which can be solved by increasing the water storage tank.

2. The cooling water flow is insufficient and cannot reach the rated water flow:

The main performance is that the pressure difference between the inlet and outlet of the unit becomes smaller (compared with the pressure difference at the beginning of the system's operation), and the temperature difference becomes larger. The cause of insufficient water flow is the lack of water or air in the system. The solution is to install an exhaust valve at a high place in the pipeline to exhaust; the pipeline filter is clogged or too fine, and the water permeability is limited. Regularly clean the filter screen; the water pump is selected to be small and does not match the system.

3. Condenser scaling or blockage:

Condensed water is generally tap water, which is easy to scale when the temperature is above 30°C, and because the cooling tower is open and directly exposed to the air, dust and foreign matter can easily enter the cooling water system, causing the condenser to be dirty and blocked, and the heat exchange area is small , the efficiency is low, and it also affects the water flow. The performance is that the water pressure difference between the inlet and outlet of the unit and the temperature difference become larger, the temperature of the upper and lower parts of the condenser is very high when touched by hand, and the copper tube of the condenser liquid outlet is hot. The unit should be backwashed regularly, and if necessary, chemical cleaning and descaling should be carried out.

4. Too much refrigerant charge:

This kind of situation generally occurs after maintenance, and the performance is that the suction and discharge pressure and the balance pressure are high, and the operating current of the compressor is also high. Under the rated working condition, the air should be released according to the suction and exhaust pressure, balance pressure and operating current until it is normal.

5. The refrigerant is mixed with air, nitrogen and other non-condensable gases:

This kind of situation usually occurs after maintenance and the vacuuming is not complete. It can only be drained, re-evacuated, and re-charged with refrigerant.

6. False alarms caused by electrical failures:

Because the high-voltage protection relay is damp, poor contact or damaged, the electronic board of the unit is damp or damaged, and the communication failure causes false alarms. For this kind of false fault, the high-voltage fault indicator light on the electronic board is often off or dimly lit, the manual reset of the high-voltage protection relay is invalid, and the operating current of the measured compressor is normal, and the suction and discharge pressure are also normal.

7. The evaporation pressure is too low:

It may be that the evaporation pressure of the water-cooled chiller is too low due to insufficient refrigerant. Common reasons: Insufficient cooling water; less cooling load; throttle orifice failure (only makes the evaporation pressure low); the heat transfer tube of the evaporator is deteriorated due to scale and other pollution (only makes the evaporation pressure too low); Insufficient (only makes the evaporating pressure too low).

8. The oil pressure difference is too low:

If the compressor oil pressure is too low, the compressor will stop running. The common reasons are: the oil filter is clogged; too much refrigerant is mixed in the lubricating oil.

9. Oil temperature is too high:

If the oil temperature of the refrigeration compressor is too high, long-term operation will reduce the quality of the refrigeration oil and even carbonize the refrigeration oil. Common causes: the cooling capacity of the oil cooler is reduced; the supply of refrigerant for cooling the oil cooler is insufficient due to the blockage of the refrigerant filter.

10. Main motor overload:

Unbalanced power supply phase voltage; large power line voltage drop;

The introduction of various industrial chillers and common fault handling are relatively complicated. Generally, specific analysis is made according to the specific problems of the situation. It is recommended to judge according to the actual situation or contact the industrial chiller manufacturer to solve the problem.

The compressor is the core component of the industrial chiller. Although the brand compressor we use has a long life, in actual use, if the user does not carefully maintain and maintain the compressor of the industrial chiller, it will also cause problems. Failures of varying degrees will seriously affect the performance of the entire industrial chiller. Preventing compressor failure in industrial chillers is therefore critical to maintaining reliable operation and minimizing downtime. Here are some effective measures to prevent compressor failure:
1. Routine inspections: During the use of industrial chillers, you need to always pay attention to the problem of compressor operating noise. If the noise increases significantly, according to the experience introduced by the factory cooler factory, shutdown inspections need to be completed in a timely and effective manner. , on the basis of ensuring normal operation, complete the maintenance work of industrial cooler compressors. Note: Once the compressor makes noise, you need to be more vigilant. Often small problems can cause complex and serious faults in the later period, such as compressor fluid shock.

2. Regular maintenance: Implement a comprehensive maintenance plan for the chiller system, including routine inspections, cleaning, lubrication and component inspections. Follow the manufacturer's recommendations for maintenance intervals and procedures.

3. Monitor the refrigerant level: Make sure the chiller has the correct refrigerant charge. Low refrigerant levels can cause the compressor to work harder, leading to overheating and potential failure. Regularly check and maintain proper refrigerant levels according to system specifications. During use, the specific values of the pressure gauge of the industrial chiller need to be paid attention to at any time. If there is a large-scale abnormality, careful inspection is required at this time. The specific inspection method can be completed according to the relevant methods introduced by the domestic industrial chiller manufacturer. Check the process to avoid pressure problems that affect the specific working efficiency of the compressor of the industrial chiller, causing an increase in electricity consumption and increasing the energy consumption of the industrial chiller. Note: Chiller pressure gauge, including high pressure pressure gauge, low pressure pressure gauge, etc.
4. Clean condenser and evaporator coils: Dirty coils will reduce heat transfer efficiency, resulting in increased compressor workload and higher operating temperatures. Clean your condenser and evaporator coils regularly to remove dirt, dust and debris that has accumulated on their surfaces.

5. Maintain proper oil level and quality: Compressor oil lubricates and cools the compressor’s internal components. Monitor oil levels regularly and refill or replace oil as needed. Make sure the oil used is of the type and quality recommended for the cooling system.

6. Check the electrical connections: Loose or faulty electrical connections may cause excessive current, causing the compressor to overheat and malfunction. Regularly check and tighten electrical connections to ensure electrical components are intact.

7. Monitor operating parameters: Install a monitoring system to continuously monitor key parameters such as compressor discharge temperature, suction pressure, and motor current intensity. Set alerts or alarms to notify operators of any abnormal conditions so timely intervention and corrective measures can be taken.

8. Adequate airflow and ventilation: Make sure there is proper airflow and ventilation around the chiller. Poor airflow can cause the compressor to overheat. Remove any obstructions and regularly check and clean the air filter to maintain optimal airflow.

9. Avoid frequent cycles: Try to reduce the frequency of starting and shutting down the chiller, as frequent cycles will put extra pressure on the compressor. Maintain as stable operating conditions as possible to reduce compressor workload.

10. Train personnel: Provide appropriate training to chiller operators and maintenance personnel on chiller operation, maintenance procedures and troubleshooting techniques. Well-trained personnel can detect potential problems early and take appropriate measures to prevent compressor failure.

By implementing these measures, you can significantly reduce the risk of compressor failure and extend the life of your industrial chiller system. Additionally, it is recommended to consult the industrial chiller manufacturer’s guidelines and recommendations for specific maintenance procedures and precautions.

Although most of the various industrial chillers produced in my country are imported compressors, which have a long service life, but in actual use, if the user does not carefully maintain and maintain the compressors of the industrial chillers, Different degrees of failures will also occur, seriously affecting the performance of the entire industrial chiller. There are several effective measures to prevent industrial chiller compressors from malfunctioning, including:

Regular maintenance: Regular maintenance of the compressor, including cleaning and replacing parts, can prevent malfunctioning due to wear and tear.During the use of industrial chillers, it is necessary to pay attention to the noise of the compressor at all times. If the noise increases significantly, according to the experience introduced by the industrial cooler factory, it is necessary to complete the shutdown inspection in a timely and effective manner at this time to ensure normal operation. On the basis of this, complete the maintenance work of industrial cooler compressors. Note: Once the compressor makes noise, you must be more vigilant, often small problems will cause complex and serious failures in the later stage, such as compressor liquid shock.

Measure the operating temperature: During the operation of the industrial chiller, it is necessary to measure the specific operating temperature of the compressor of the industrial chiller by hand or equipment at any time. If the temperature is too high, it means that the industrial chiller is in an overloaded state. At this time, it is necessary to measure the current and voltage. In order to achieve the purpose of fault detection, so as to ensure that the industrial chiller compressor is in an absolutely safe operating state, reach a suitable operating temperature, and complete the entire operating process. Note: If the temperature of the compressor is too high, it may also be caused by too little fluorine, too small compressor power, too long capillary, poor condensation effect, temperature control failure, and lack of oil in the compressor. The damage is very serious, so special attention must be paid.

Clean condenser coils: The condenser coils of the chiller should be kept clean to ensure that the compressor is not overworked due to reduced heat transfer.Pay attention to the pressure gauge,if the high pressure gauge is very high, please check the condenser coil and clean it when necessary.

Proper refrigerant charge: The compressor should have the correct refrigerant charge to ensure that it is not working harder than necessary, which can cause it to malfunction.

Monitoring of operating conditions: The operating conditions of the compressor, including temperature and pressure, should be monitored to ensure that it is not overworked or subjected to conditions that can cause malfunctioning.

Training of personnel: Proper training of personnel in charge of operating and maintaining the compressor can prevent mistakes that can cause the compressor to damage.

An industrial water chiller is a device designed to remove heat from a process or equipment and transfer it to a separate water source. It is commonly used in various industrial applications, such as cooling machinery, lasers, plastic molding machines, and other processes that generate heat. The basic working principle involves the circulation of a coolant, typically water or a water-glycol mixture, through a closed loop.

Here is a general overview of how an industrial water chiller works:

Evaporator:
The process begins in the evaporator, where the chiller absorbs heat from the process or equipment that needs to be cooled.

The coolant (water or water-glycol mixture) flows through a coil or heat exchanger in the evaporator. As it circulates, it absorbs the heat from the process, causing the coolant to evaporate.

The vaporized coolant is then drawn into the compressor, which increases its pressure and temperature. This compression process is a key step in the refrigeration cycle.

The high-pressure, high-temperature vapor is then routed to the condenser.

In the condenser, the hot refrigerant vapor releases heat to a separate water circuit or air.

As the refrigerant gives up heat, it undergoes a phase change from vapor to liquid.

The high-pressure liquid refrigerant then passes through an expansion valve, where its pressure is rapidly reduced.

This reduction in pressure causes the refrigerant to expand, resulting in a decrease in temperature.

The now-cool refrigerant returns to the evaporator to absorb more heat from the process, and the cycle repeats.

Simultaneously, a separate water circuit, known as the cooling water circuit, is responsible for carrying away the heat absorbed by the chiller.

This cooling water is circulated through the condenser to remove the heat from the refrigerant.

A control system regulates the chiller's operation based on the temperature requirements of the process or equipment being cooled.
The system may include sensors, a thermostat, and a controller to maintain the desired temperature.

By continuously circulating the coolant through this refrigeration cycle, an industrial water chiller efficiently removes heat from the target process or equipment, ensuring that it operates within optimal temperature ranges.

OUMAL as a professional manufacturer and supplier of industrial chillers. Provides various types of cooling water chillers. Including air-cooled chillers and water-cooled chillers. Welcome to consult! oumal@oumal.com

In this era of advocating energy saving and environmental protection, it is very necessary to reduce the operating cost of the screw chiller. We can start from the product itself, and pay attention to various details in daily use, so as to reduce energy consumption and reduce the operating cost of the screw chiller. To reduce the operating cost of the screw chiller, we must start from its energy consumption. The energy consumption of the screw chiller mainly depends on whether the unit is faulty, and the other is the operating power of the unit. Next, let's talk about how to reduce the operating cost of the screw machine from several aspects.

1) Regular maintenance: Regular maintenance of the screw chiller is essential to ensure efficient operation. This includes cleaning the evaporator and condenser coils, checking and maintaining refrigerant levels, lubricating the compressor, and replacing worn out components.

2) Optimize water flows: Adjusting the flow rates of the chilled and condenser water can significantly impact the energy consumed. By minimizing the flow rates, the chiller consumes less energy.

3) Control temperature set points: Ensure optimal set points for both condensing and evaporator temperatures to prevent unnecessary operation of the chiller.

4) Use economizer mode: Many screw chillers have an economizer mode that utilizes free cooling when the outside temperature is cooler. This mode helps save energy and reduces running costs.

5) Upgrade to an energy-efficient system: Consider upgrading to a more efficient screw chiller model to reduce running costs. The initial investment may be higher, but it will pay off in terms of reduced energy consumption and lower operating costs.

6) Utilize VFDs: Variable Frequency Drives (VFDs) allow the chiller to operate at varying speeds, depending on the cooling requirement. This results in less energy consumed, along with reduced wear and tear on the equipment.

7) Use high-efficiency motors: The installation of high efficiency motors can significantly reduce energy consumption. These motors have high power factors, which means they consume less energy while operating at the same load.

8) Monitor energy usage: Regular energy monitoring helps identify inefficiencies and areas for improvement. By tracking energy usage, property owners can determine the best practices for reducing operating costs.

Pump Type: Select the appropriate pump type for your application. Common pump types used in chiller systems include centrifugal pumps and positive displacement pumps. Centrifugal pumps are generally more suitable for high flow rates, while positive displacement pumps are better for applications with variable or lower flow rates.

Steps for pump selection

1. Determine the working parameters of the chiller

Before selecting the type of water pump, it is first necessary to clarify the working parameters of the chiller, including cooling capacity, external ambient temperature, cooling water diameter, etc.

2. Choose the right pump type

When selecting models, it is necessary to choose popular pump types, such as centrifugal pumps, axial flow pumps, mixed flow pumps, etc. At the same time, full consideration should be given to indicators such as flow, lift, and efficiency, which can usually be calculated by professional selection software on the market or Refer to the selection manual of the large water pump manufacturer.

3. Determine the pump shaft power and motor power

After the selection, it is necessary to calculate the shaft power of the pump and the corresponding motor power based on the flow rate and head. In general, it is necessary to refer to the parameter manual of the pump manufacturer, or use professional software for calculation.

4. Check whether the matching of water pump and chiller is suitable

After determining the shaft power of the water pump and motor, it is necessary to check the data to ensure that the working range of the selected water pump can match the flow rate, head and other parameters required by the chiller, so as to ensure the normal operation of the chiller.

Industrial chillers can realize mutual switching, speed up production progress, reduce energy consumption, improve product molding efficiency, suppress product defects, and reduce the occurrence of defective products. Screw chillers are widely used in many fields such as electronics, rubber, plastics, papermaking, petroleum, chemical industry, food, machinery, brewing, vacuum coating, pharmaceuticals, etc., and are also widely used in places with centralized cooling to facilitate centralized management.

In industrial manufacturing, chillers are crucial to the transfer of heat. However, many chiller ma chines are prone to poor heat dissipation after a period of actual operation. At this time, product maintenance should be carried out in a timely manner.

First of all, let's clarify the signs of poor heat dissipation of the chiller. When the condenser of the chiller has poor heat dissipation, the efficiency of the compressor will decrease, and the operating current will increase, which will eventually lead to the air-cooled chiller high pressure. When the air-cooled high pressure rises to 24kg/cm2, the water-cooled chiller high pressure will rise to 20kg/cm2 is a sign of poor heat dissipation of the chiller. At this time, maintenance should be carried out in time.

Poor heat dissipation and treatment methods of water-cooled screw chiller:

When the heat dissipation of the condenser is poor, the efficiency of the compressor will be low, and the operating current will increase. The compressor will trip due to the protection of the high-voltage switch, causing the compressor to stop running. Whether the circulating water of the cooling tower is normal, whether the temperature of the cooling water is too high, whether the cooling tower fan pump is running, and whether the cooling water valve is open. After the above things are normal, you need to press the reset button again, or shut down and restart to operate normally. If high pressure overload occurs frequently, the condenser needs to be cleaned.

Treatment method for poor heat dissipation of air-cooled screw chiller:

1. Check whether thefin condenser of the chiller isdirty, if so, clean it with a small brush.

2. Check whether the fan of the chiller is working normally. If not, you can blow it with air or wipe it clean with a soft cloth dipped in some detergent.

3. Move the chiller to a well-ventilated place to avoid blocking the radiator.

4. If the heat dissipation performance of the chiller is still not good, you can consider upgrading the accessories of the chiller, such as fans, heat sinks or other components.

The above is Oumal's solution to the poor heat dissipation of the chiller. For more detailed information, please contact our Oumal manufacturer or Oumal sales: oumal@oumal.com.

Refrigerant leakage is a common failure of air-cooled chillers. To deal with refrigerant leakage of chillers, we must first understand the cause of refrigerant leakage and find out the cause of the failure to reduce losses caused by refrigerant leakage. If you have a refrigerant leak in an air-cooled chiller, it is important to address it promptly to prevent further damage and ensure the efficient operation of the system. Here are some steps to deal with a refrigerant leak:

Identify the Leak: Use a refrigerant leak detector or bubble solution to locate the source of the leak. Common areas where leaks occur include connections, fittings, valves, and joints.

Ensure Safety: Make sure to follow proper safety procedures when dealing with refrigerants. Wear protective gear such as gloves and goggles, and work in a well-ventilated area.

Repair the Leak: Depending on the size and location of the leak, you may be able to repair it yourself or contact a professional HVAC technician. Common repair methods for air-cooled chillers include tightening fittings, replacing faulty valves or gaskets, or soldering joints.

Evacuate and Recharge Refrigerant: If the refrigerant has leaked significantly, it may be necessary to evacuate the remaining refrigerant from the system using a recovery machine. Once the leak is repaired, vacuum the system to remove any moisture or air, and recharge it with the appropriate amount of refrigerant as specified by the manufacturer.

Test for Leaks: After the repair and recharge, test the system for any remaining leaks. Use a refrigerant leak detector or soap bubbles to carefully check all connections and areas that were repaired.

Monitor and Maintain: Regularly monitor the chiller system for any signs of leakage, such as reduced cooling capacity or unusual noises. Perform routine maintenance, including checking and tightening fittings, cleaning coils, and replacing worn-out parts, to prevent future leaks.

Remember, handling refrigerants can be hazardous and may require proper certification or training. If you're unsure or uncomfortable with dealing with refrigerant leaks, it's best to engage a licensed professional HVAC technician to assess and repair the leak.

Industrial chillers consume a lot of energy, especially in hot weather, and they have to work harder to maintain the desired temperature. In order to achieve the purpose of energy saving, users of various industrial chillers in the enterprise can combine their own actual operating environment to choose a suitable energy-saving solution for industrial chillers to improve the overall operating efficiency. Help enterprises complete all production processes with higher capital. Here are some ways to reduce your industrial chiller’s energy consumption during hot weather:

Optimizing Chiller Operating Conditions: Make sure your chiller is running at peak performance by regularly checking set points, temperature differentials, and water flow. Also, make sure the chiller is serviced and maintained regularly to avoid any inefficiencies.

Install a Variable Speed Drive (VSD): A VSD can be installed on the chiller's compressor to ensure the chiller is only running at its required capacity. This helps to significantly reduce energy consumption, since the chiller does not have to work at full capacity all the time. Equipped with a frequency conversion processing device, the high-quality frequency conversion device can achieve the effect of adjusting the speed of the compressor. If the low-pressure refrigerant can increase the pressure when it passes through the compressor, the speed of the centrifuge will cause a large-scale increase. The higher the pressure, the greater the load capacity it can provide. Use the frequency conversion processing device to work at an appropriate frequency according to the specific use environment, which can reduce the energy consumption level.

Rationally increasing the temperature of the evaporator and effectively increasing the temperature of the evaporator can improve the overall working efficiency. It provides higher evaporation in a shorter time, ensures the rapid condensation effect of the condenser, and has a great effect on quickly reducing the ambient temperature.

Recirculate with an economizer: An economizer recycles outside air to cool the water in the chiller. This is a very effective way to reduce energy consumption in hot weather, especially if the outside air temperature is lower than the return water temperature.

Improve insulation: Make sure the chiller and its components are well insulated to prevent heat loss. This helps reduce energy consumption because the chiller doesn't have to work as hard to maintain the desired temperature. Reasonably reduce the temperature of the condenser and reduce the temperature range of the condenser to adjust the entire low temperature to a lower level. The lower the temperature of the condenser, the faster the ambient temperature will drop, thus increasing the working power of the whole device.

Implement a maintenance program: A regular maintenance program helps to spot any inefficiencies in the chiller system and resolve them in a timely manner. This helps reduce energy consumption and extend the life of the chiller. Of course, this kind of maintenance is purpose maintenance. For example, you can start with the system. Only by doing a good job of maintenance can the equipment be used better and the efficiency will be greatly improved.

Consider Alternative Cooling Solutions: Depending on the application, alternative cooling solutions such as evaporative cooling or geothermal cooling may be used. In some applications, they are more energy efficient than traditional chillers.

Overall, reducing energy consumption of industrial chillers during hot weather requires a combination of regular maintenance, optimizing operating conditions and considering alternative cooling solutions.