Installation, Maintenance and Care Guide for Air-Cooled & Water-Cooled Industrial Chillers

Installation, Maintenance and Care Guide for Air-Cooled & Water-Cooled Industrial Chillers

Industrial chillers are essential cooling equipment for factories, workshops and other industrial venues. Proper installation and regular maintenance not only ensure stable operation of the chillers but also extend their service life. This guide provides simple and practical suggestions for the installation, maintenance and care of air-cooled and water-cooled industrial chillers, suitable for daily operation and management.

1. Installation Suggestions

The installation quality directly affects the operation efficiency and safety of chillers. Different types of chillers have specific requirements for installation environments and supporting facilities.

1.1 Air-Cooled Chillers

• Location Selection: Install in a well-ventilated open area, roof or outdoor platform. Ensure there is no obstruction within 1.5 meters around the chiller to avoid hot air circulation (which reduces cooling efficiency). Keep away from high-temperature heat sources (such as boiler exhaust ports) and corrosive gas areas.

• Foundation Requirements: The installation foundation should be flat, solid and able to bear the weight of the chiller. Use shock-absorbing pads between the chiller and the foundation to reduce vibration and noise during operation.

• Electrical Connection: Connect the power supply in accordance with the chiller’s rated voltage and current requirements. Ensure the wiring is firm, waterproof and anti-leakage. Equip with independent switches and protective devices to avoid electrical faults.

• Airflow Guarantee: Ensure the direction of the chiller’s air outlet and inlet is not blocked by walls, railings or other equipment. For roof installation, consider wind resistance and fix the chiller firmly to prevent displacement due to strong winds.

1.2 Water-Cooled Chillers

• Overall Layout: The chiller, cooling tower, water pump and pipe network should be arranged reasonably to minimize the length of water pipes and reduce energy loss. The cooling tower should be installed in a well-ventilated high place to avoid being affected by the chiller’s exhaust air.

• Pipe Installation: Use corrosion-resistant pipes (such as galvanized steel pipes or stainless steel pipes) and install filters at the water inlet of the chiller to prevent impurities from entering the internal system. Ensure the pipes are sealed tightly to avoid water leakage; the pipe network should have a slope to facilitate drainage during maintenance.

• Cooling Tower Matching: The cooling capacity of the cooling tower must match the chiller’s heat dissipation demand. Install a water level controller and overflow device in the cooling tower to maintain a stable water level and prevent dry operation of the water pump.

• Vibration and Noise Control: Same as air-cooled chillers, use shock-absorbing pads for the chiller and water pump. Add expansion joints to long water pipes to adapt to thermal expansion and contraction and reduce pipeline damage.

2. Daily Maintenance Suggestions

Daily maintenance focuses on inspection and cleaning, which can detect potential faults in time and ensure the chiller operates efficiently. The frequency of daily maintenance is recommended to be once a week.

2.1 Air-Cooled Chillers

• Fan and Heat Exchanger: Check if the fan operates smoothly without abnormal noise or jamming. Clean the dust, oil stains and debris on the surface of the heat exchanger fins with a high-pressure water gun (adjust the water pressure to avoid damaging the fins) to ensure good heat dissipation effect.

• Electrical System: Inspect the wiring terminals for looseness, oxidation or overheating. Check the operation status of the control panel, ensure the display data is normal and the alarm function is sensitive.

• Refrigerant Leakage: Observe the refrigerant pressure gauge. If the pressure is abnormal, check for refrigerant leakage. If leakage is found, repair the leak point in time and replenish the refrigerant according to the specified type.

2.2 Water-Cooled Chillers

• Water System Inspection: Check the water level of the cooling tower, replenish water in time if it is insufficient. Inspect the water pump for abnormal noise, vibration and water leakage, and check the lubricating oil level of the water pump (if applicable) to ensure normal operation.

• Filter Cleaning: Clean the filters of the chiller and cooling tower regularly to remove impurities such as sediment and algae, prevent pipe blockage and improve water circulation efficiency.

• Water Quality Management: Test the water quality of the circulating system regularly (once a month). Control the pH value of the water between 7.0-8.5 and add scale inhibitors and bactericides appropriately to prevent scaling, corrosion and algae growth in the pipes and chiller internal components.

3. Regular Maintenance and Care (Monthly/Quarterly/Annual)

In addition to daily maintenance, regular in-depth maintenance is required to ensure the long-term stable operation of the chiller. The maintenance cycle can be adjusted according to the frequency of use and operating environment.

3.1 Monthly Maintenance

• For air-cooled chillers: Check the tightness of the fan belt (if equipped), adjust or replace the belt if it is loose or worn. Inspect the condenser for fouling and clean it if necessary.

• For water-cooled chillers: Drain part of the circulating water and replenish new water to reduce the concentration of impurities in the water. Inspect the cooling tower fill for blockage and clean it with a brush or high-pressure water gun.

3.2 Quarterly Maintenance

• Inspect the chiller’s compressor: Check the operating temperature, noise and vibration of the compressor. Check the lubricating oil quality and oil level, replace the lubricating oil if it is deteriorated or insufficient.

• Check the expansion valve and dry filter: Clean or replace the dry filter to prevent clogging. Adjust the expansion valve to ensure the refrigerant flow is reasonable.

• For water-cooled chillers: Disassemble and clean the chiller’s evaporator and condenser to remove scale and dirt on the surface.

3.3 Annual Maintenance

• Comprehensive inspection of the electrical system: Test the insulation performance of the motor, check the operation of the frequency converter (if equipped) and calibrate the instruments and meters.

• Overhaul the cooling tower (for water-cooled chillers): Inspect the tower body for corrosion and leakage, repair or replace damaged parts (such as fill, drift eliminator). Grease the rotating parts of the cooling tower.

• Perform a full-system pressure test: Test the airtightness of the refrigerant system and water system to ensure there is no leakage. Conduct a trial operation after maintenance to adjust the operating parameters to the optimal state.

4. Key Notes for Maintenance

• Before any maintenance work, cut off the power supply of the chiller and hang a "maintenance in progress" sign to avoid electric shock accidents. For water-cooled chillers, drain the circulating water first.

• Use professional tools and accessories during maintenance, and follow the manufacturer’s operation manual. Do not modify the chiller’s structure or parameters without authorization.

• Record the maintenance content, time and parameters in detail to form a maintenance log, which is convenient for tracking the operation status of the chiller and troubleshooting.

• If complex faults are encountered (such as compressor failure, refrigerant system blockage), do not disassemble and repair them by yourself. Contact professional maintenance personnel in time.

• For chillers that are not used for a long time (such as during shutdown), drain the water in the water system of water-cooled chillers to prevent pipe freezing and cracking. Cover the chiller with a protective cover to prevent dust and debris from entering.

5. Summary

The installation, maintenance and care of industrial chillers should be carried out in accordance with their types and operating characteristics. Strictly following the above suggestions can effectively improve the operation efficiency of the chiller, reduce failure rates, extend its service life and further reduce operating costs for enterprises. Regular professional inspection and maintenance are also an important part of ensuring the stable operation of the chiller.