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.

After the industrial chiller system has passed the vacuum test, the vacuum state in the system can be used to charge the refrigerant.

1. Refrigerant charging

For newly installed systems, refrigerant can be added to the high-pressure end, and the operation method is as follows:

1) Turn on the cooling water system for the condenser, and keep the valve in the system as it was during the vacuum test

2) Connect the steel cylinder containing the refrigerant with the West 14mm×2mm seamless steel pipe (use a red copper pipe when filling with Freon). The mouth of the bottle is inclined downward, and the cylinder is at an angle of 30° with the ground, or the end of the cylinder is raised about 200-300mm.

3) Open the filling valve. When the system reaches a certain pressure (0.1～0.2 MPa for ammonia system; 0.2～0.3 MPa for Freon system), stop charging the refrigerant, and then check the sealing condition of the system at each connection and welding place. If there is no leakage, Can continue to charge refrigerant.

4) Close the outlet valve on the liquid reservoir and continue to charge the refrigerant. When the cylinder pressure and the pressure in the liquid reservoir reach equilibrium, the outlet valve on the liquid reservoir should be opened.

5) Start the refrigerating machine, make the refrigerating device enter the running state, and continue to charge the refrigerant at the same time. When white frost appears on the lower part of the cylinder, it means that the liquid refrigerant in the cylinder is almost completely filled. At this time, the cylinder valve and charging valve can be closed, and the bottle can be changed to continue charging.

6) Unless the outside temperature is very low, it is generally not necessary to pour hot water on the cylinder to increase the pressure in the cylinder when charging the refrigerant, because it is not safe to do so. If you need to speed up the filling speed, the hot water temperature must not exceed 50°C and other methods to heat the cylinder are strictly prohibited.

7) When filling freon, a filter drier must be installed on the special nozzle to reduce the possibility of water entering the system. When charging with high pressure section, never start the compressor, and pay attention to the exhaust valve not to leak, otherwise liquid hammer will occur.

8) When the refrigerant is charged up to 90% of the charging amount, the charging can be temporarily stopped, and the system can be tested to check whether the system dosage has met the operation requirements and avoid unnecessary trouble caused by excessive charging. For the old refrigeration system, when the refrigerant needs to be supplemented, it should be charged from the low pressure side.

2. Leak detection after filling

(1) Leak detection method with test paper Generally, phenolphthalein test paper is used to test the system's welds, flanges, and threaded connections for leaks. Wet the test paper and approach the inspected place. If it turns red, it means that there is ammonia leakage (note that the test paper should not be in contact with the soapy water on the pipe to create an illusion). Litmus paper that turns blue when exposed to ammonia can also be used.

(2) Halogen blowtorch leak detection method Halogen blowtorch is a common tool for leak detection in Freon refrigeration systems. The domestic halogen blowtorch is shown in the figure below, and the method of use is as follows:

1. Add alcohol: first unscrew the base 1 and add anhydrous alcohol with a purity of not less than 99.5% to the inside of the barrel, but the amount of injection should not be too much, just fill 1/2 to 3/4 of the volume of the lamp tube That's it, then the base should be fastened tightly.

2. Light a fire: turn the hand wheel 2 to the right, close the valve core, fill the wine glass, and then light it to heat the lamp tube and the upper part of the blowtorch. After heating a little, check whether the blowtorch is leaking.

3. Fire: When the alcohol in the beaker is nearly finished, turn the hand wheel 2 to the left and ignite the volatilized alcohol in the nozzle in the flame ring 4. At this time, the suction hose 6 of the halogen lamp emits With the sound of gas inhalation, you can start leak detection with a lamp.

4. Use: When testing, move the nozzle of the suction hose 6 close to the inspected place, and move slowly. If there is Freon gas leakage, it will decompose when it meets the flame. At this time, the orange-red flame will turn into green and the color of the flame. The change varies with the amount of Freon leakage, and the darker the color, the more serious the leakage of Freon.