Chiller maintenance. Chiller Maintenance Chiller Operation Manual

I. SAFETY.

Before you start operating the equipment, carefully read the chiller operating manual, which contains very important information about the placement, installation of the chiller, the conditions for using chillers and the care of the water-cooling unit.

Since the chiller operating manual is a source of information for the conscious and safe operation of the water cooling system, it should be retained without fail.

The manufacturer is not responsible if users of the installation do not comply with the information provided below:

1. When cleaning the chiller, never use cleaning devices that use steam, as steam on the electrical parts of the chiller may cause a short circuit or electric shock.
2. Do not use electrical appliances when working inside the chiller.
3. The electrical safety of the chiller is guaranteed if the plant's grounding system meets the required standards.
4. When cleaning or maintaining the chiller, you should disconnect it from the mains by turning off the main switch or removing the plug. When removing the plug, do not pull the cord.
5. Repairs to the device must only be carried out by qualified personnel. Carrying out repair work by unqualified persons is very dangerous.
6. Avoid damaging parts of the device through which the cooling gas circulates. Gas released when gas circulation tubes are bent, damaged or ruptured can cause skin irritation and eye damage.
7. Do not cover or obstruct the ventilation parts of the device with anything.
8. Never use the device as a support or stand.
9. During periods of inactivity of the installation, if the ambient temperature drops below 0 C, there is a possibility of freezing of the water in the installation. In this case, if the water cooler will not be used for a long time, antifreeze should be added to the water in the system or drained.
10. Possible damage resulting from maintenance and repair by incompetent personnel is not covered by the warranty.

II. GENERAL FORM

The operating instructions have been prepared in accordance with Directive 98/37/EC of the European Union and standard EN 60204-1, 1997 in order to use the installation, manufactured using the latest technology, with maximum safety and maximum performance.

The instruction manual has been prepared to ensure the safe and effective use of the device, which is manufactured using new technologies in accordance with the standards established in Turkey.

The service life of the device is set by the Ministry of Industry at 10 years.

The complete water cooling unit is used for machines for the production and forming of plastic, soles, metal products, for extruders, in the textile and chemical industries, dairies, any industrial and production complexes where cold water is required, as well as in air conditioning systems.

The devices are manufactured in different capacities - 18 different types, with a capacity starting from 3,000 kcal/h. up to 320,000 kcal/h.

All system units are installed on a durable and corrosion-resistant frame in compliance with the necessary safety measures. After installation, all pressure-bearing parts are tested for leaks.

During the production of the equipment, the necessary precautions were taken to protect the equipment from external influences (corrosion, shock, pressure).

III. TRANSPORTATION AND STORAGE OF EQUIPMENT

Lifting and transportation.

Due to the fact that the equipment has a large mass, it must be lifted and moved using a winch or hoist. There are no special notes regarding transporting equipment using a lift, just make sure that the equipment is well balanced on the lift pins.

When transporting equipment using a winch, you should tie a belt of appropriate strength around the bottom beam of the equipment, and then hook it to the center of gravity.

Storage

If the water cooler will be inoperative for a long time, some operations should be carried out before doing so.

The incoming electricity must be turned off and the power cable must be disconnected. The water in the cooling system must be drained through the valve.

To protect the equipment from dust and dirt, it should be covered.

Do not place any weight on the unit.

The equipment should not be stored tilted.

IV. PLACEMENT AND INSTALLATION

Selecting a location

The main consideration for the equipment is the location in which it will be placed. The place in which the equipment will be placed must be cool, well ventilated, away from heat sources, and not exposed to direct sunlight.

If the equipment is located in a hot, poorly ventilated place, then the excess hot air coming from the equipment must be disposed of using a special air duct. Otherwise, the equipment, as a result of greater load, will consume excess electricity. Therefore, carrying out this procedure will be useful for you.

If you are faced with the need to construct an air duct, it is recommended to place the equipment in a place closest to the external environment in order to minimize the distance for the release of hot air.

It is advisable to use a separate room for installing chillers. Select a site for installing the chiller, taking into account its dimensions and weight. It is not allowed to install the chiller in unheated rooms and rooms where the temperature can drop below + 5°C.
- The room should be easily accessible and well lit.
- To enable maintenance and repair, it is necessary to ensure a minimum distance between equipment of 1.5 meters and at least 1 meter to protruding parts of the walls.

Ventilation requirements

1. According to the operating temperature of the chiller, select a room in which the temperature will be maintained from + 5°C to +30°C. It is necessary to ensure the necessary ventilation of the room. Room temperatures below +5°C are unacceptable for operation and storage of the chiller.

2. In case of insufficient ventilation, it is necessary to install a casing to remove hot air outside. Do not allow cooling air to recirculate. To do this, it is preferable to make the air intake and outlet on different sides of the room

3. When making a casing that removes hot air, please note that its cross-section must be no less than the outlet cross-sectional area on the chiller. The length of such a casing should not exceed 4 meters and have no more than one turn. Longer lengths and more rotations of the shroud create greater resistance to air flow and will result in insufficient cooling.

4. If it is not possible to manufacture casings, an exhaust fan of the same capacity as the chiller condenser fan should be installed in close proximity to the hot air outlet from the chiller.

5. The cross-section for the passage of clean air must be 1.5-2 times larger than the inlet cross-section on the chiller.

6. Protect the premises from explosive and corrosive gases.

Electrical connection.

The equipment operates on alternating electric current, the voltage of which is 400 V, and the frequency of which is 50 Hz.

The input terminals located on the control panel must be connected to the type of electrical cable specified on the label located on the inside of the panel and the connection must be made in accordance with EN 60204-1. Before supplying power to the installation, it is necessary to protect the power line with a fuse with the capacity indicated on the panel plate.

Connection of the electrical cable and fuses must only be carried out by responsible personnel.

The installation must be provided with a grounding line and connected to the specified terminals.

Water connection

Depending on the type of equipment, water pipes of different diameters inside the equipment should be extended with pipes of the same diameters outside the equipment and connected to your system.

In order to ensure water supply to the equipment, a pipe of diameter should be brought to the place marked “power” on the back of the installation and equipped with a valve.

V. FUNCTIONS OF LAMPS, BUTTONS AND SWITCHES ON THE EQUIPMENT

Control Panel

a) Water pump switch.
Used to turn the water pump on and off. To operate the cooling system, the water pump must be running and circulate water through the system.

b) Compressor switch.
Used to activate and disable cooling system functions.

c) Thermostat switch.
Used to adjust the temperature of the cold water tank. Multifunctional sensor, shows the current temperature if no button is pressed and no alarm is given. In order to set the desired temperature, read the information about using the thermostat, which is given in the application.

Functions of warning lamps

1) Condenser fan in action.
Indicates that the fan motors are powered.

2) The thermal fuse of the condenser fan has blown.
This signal is used in cooling groups with high capacity. If the fans used in the cooling group operate at a voltage of 400 V, then they are protected from sudden voltage drops and loss of one of the phases by a thermal relay located on the electrical panel. If this light comes on, press the reset button for the fan thermal relay located on the electrical panel.

3) Crankcase heater in action.
When the compressor crankcase heats up, this signal comes on. This time is the compressor stop period.

4) Frost thermostat warning light.
Reduced water temperature is a period of interruption of work. If the water temperature drops below the adjusted one, this entails stopping the entire cooling system. Once the water temperature reaches the required level, the cooling system will come into operation automatically.

5) Water flow signal.
If there is no water flow in the heat exchanger or the flow has decreased, the cooling system turns off automatically. This means the system is clogged or the water pump is leaking air.

6) Thermal fault of the water pump.
Designed to prevent damage to the electric motor of the water pump, which can be caused by sudden voltage changes and the absence of one of the phases. If this signal comes on, press the water pump thermal relay reset button.

7) Water pump in action.
Once the water pump fuse is turned on, the water pump starts working. This signal means it is working.

8) The thermostat is set to automatic mode.
The cooling system turns off automatically after its temperature reaches the one that was set on the thermostat. Until the system comes into operation again, this signal remains on, which means that the system has reached the desired temperature.

9) Phase loss signal.
This equipment operates on electricity with a voltage of 380 V and a frequency of 50 Hz; in the event of sudden voltage changes (over 10%) or in the absence of one of the phases, the cooling system is turned off automatically using a phase loss relay located on the electrical panel. After the cause of the work stoppage is eliminated, the system starts working automatically.

10) High low pressure signal.
This means that the gas pipes or condensers are clogged, there is a refrigerant leak, the temperature of the system’s operating environment has risen above the permissible level and the system has automatically turned off.

11) Thermistor signal.
This signal lights up if the thermal thermistor in the engine compartment of the compressor has interrupted the operation of the motor. The thermal thermistor is designed to protect the motor winding from overheating in the event of prolonged operation of the motor. In this case, you should wait until the engine cools down.

12) Oil pressure switch signal.
This signal is used in cooling groups of type GRS 1505 and higher. If the compressor is not lubricated or the oil level drops below the permissible level, the system stops automatically. In this case, you should contact the manufacturer.

13) Compressor thermal fault.
In order to protect the compressor electric motor from voltage surges and phase loss, this thermal relay is installed on the electrical panel as additional protection. In the cases described above, this relay interrupts the electrical circuit. In order for the system to work, you must press the reset button located on the thermal relay.

14) Compressor in action.
Some time after the compressor fuse is turned on, the cooling system is activated and this signal means that the cooling system is working.

VI. EXPLOITATION

Before you start using

Check that the water container is filled to the correct level.
- Check the grounding of the equipment.
- Make sure that the fuse placed before installation on the power cable and the fuses on the electrical panel are turned on.
- Make sure that all three phases are connected to the terminals located on the electrical panel. Do not forget that when connecting electricity to the cooling group for the first time, or after the equipment has been idle for a long time, you must wait at least 8 hours.
- Check the thermostat settings.

Equipment operation

Turn on the circulation pump several times in short intervals. Make sure the motor rotates in the specified direction. Otherwise, swap the two power wires connected to the terminals on the electrical panel.

After the water pump begins to rotate in the required direction, it pumps water to the cooled body, which will result in a decrease in the water level in the tank. If the water level drops below half, turn off the motor and do not turn it on until the water is replenished. This procedure can be repeated 1-2 times.

If the pump does not pump water into the system, open the air bleed valve located on top of the pump and bleed air from the system.

Once you are sure that water is circulating normally in the system, turn the compressor switch to on. The equipment will begin cooling.

If any of the fuses shuts down the system, investigate the cause and only then operate the system. Under no circumstances continue to operate by pressing the reset button.

If the machine does not turn off for any reason, it can continue to work.

A digital thermometer-thermostat will automate the operation of your equipment.

VII. OPERATING MANUAL FOR WATER COOLING UNIT

If, after putting the equipment into operation, none of the alarms come on, and the equipment itself is operating smoothly, this means that all requirements have been met correctly.

Possible emergency situations and measures to eliminate them are given below.

1. Error: THE SYSTEM IS NOT WORKING.

Cause: The fuse is not turned on.
Remedy: Turn on the fuse.

Cause: The equipment is not receiving power.
Remedy: Check the ends of the power cable.

2. Error: COMPRESSOR DOES NOT WORK.

Cause: The motor contactor is not receiving power.
Remedy: Check the fuse.

Cause: The fuses are tripping.
Remedy: Possible jamming of the compressor due to internal damage. Contact the company service for control.

Cause: The low-high pressure pressure switch has opened a circuit.
Remedy: The system is clogged or there is a lack of gas. In this case, the condenser should be cleaned. One of the fans is not working.

Cause: The oil pressure switch has opened a circuit.
Remedy: Check the oil level in the compressor. If the level is sufficient, restart the compressor.

Cause: The thermostat has opened circuit.
Remedy: Check water temperature and thermostat settings.

Cause: The freeze thermostat has opened circuit.
Remedy: Check the heat exchanger for freezing. If there is no freezing, wait until the water warms up.

Cause: The compressor motor thermistor has opened circuit.
Remedy: Find and remove the cause of the motor overheating. Wait 5-6 hours until the engine cools down.

3. Error: COMPRESSOR OPERATES INTERMITTENTLY.

Cause: The low pressure setting is adjusted to a high level.
Remedy: Adjust the low pressure setting to normal level.

Cause: The solenoid valve on the fluid connection is leaking and there is frost around the valve.
Remedy: Call service to replace the solenoid valve.

Cause: The liquid pipe is too cool.
Remedy: The drying filter is clogged. Call service to replace the drying filter or solenoid valve bobbin.

Cause: The water in the heat exchanger is frozen.
Remedy: Wait for the ice to melt and investigate the cause of the freezing.

4. Error: COMPRESSOR RUNS CONSTANTLY.

Remedy: Set the thermostat to +10, 11°C.

Cause: Lack of gas in the system.
Remedy: Find out the reasons and call service to replenish the gas.

Cause: The contacts in the motor are stuck.
Remedy: Replace contacts.

5. Error: LACK OF OIL IN COMPRESSOR.

Cause: Oil level has dropped.
Remedy: Find out the cause. Call service to replenish the oil.

Cause: The system is operating at low pressure.
Remedy: There is a gas leak in the system. Locate the leak and call service to replenish the gas.

Cause: The crankcase plug is leaking oil.
Remedy: If the crankcase plug is loose, tighten it. If the leak does not stop, call service.

Cause: The expansion valve is loose.
Remedy: Attach with a metal strip.

6. Error: COMPRESSOR IS NOISY

Cause: Oil level has dropped.
Remedy: Find out the cause. Call service to replenish the oil.

Cause: Oil level too high.
Remedy: Check the oil level. If the level is too high, call service.

Cause: The internal parts of the compressor are damaged.
Remedy: Call service to remove and further repair the compressor.

Cause: The expansion valve remained in the open position.
Remedy: Call service to replace the valve.

Causes: Compressor mounting bolts are loose.
Remedy: Tighten the bolts.

7. Error: SUCTION PRESSURE TOO HIGH.

Causes: The liquid level in the heat exchanger is too high, the expansion valve does not control the liquid level.
Remedy: Call service to replace or adjust the expansion valve.

Cause: Suction valve is broken.
Remedy: Call service to replace or repair the valve.

8. Error: SUCTION PRESSURE TOO LOW.

Cause: The gas level has dropped and bubbles are visible in the sight glass.
Remedy: Call service to determine if there is a gas leak and top it up if necessary.

Cause: The expansion valve remained in the closed position.
Remedy: Call service to replace the expansion valve.

Cause: Thermostat is set low.
Remedy: Set the thermostat to +10, 11°C.

Cause: There is a large amount of oil in the system, the expansion valve needle is frozen.
Remedy: Call service to drain the oil and replace the drying filter.

9. Error: DISCHARGE PRESSURE TOO HIGH.

Cause: The condenser fan motor is faulty.
Elimination: Investigate the causes and call service for elimination.

Causes: The condenser fan rotates in the wrong direction.
Remedy: Valid only for 3-phase fans. Swap the two input pins.

Cause: There is too much gas in the system.
Remedy: Call the service for monitoring.

Cause: There is foreign gas in the system.
Remedy: Call service for gas release and control.

Cause: The capacitors are clogged.
Remedy: Clean the capacitors with compressed air.

10. Error: DISCHARGE PRESSURE TOO LOW.

Cause: A large amount of cold air enters the condenser (winter conditions).
Remedy: If the system has two fans, in winter conditions one of them should be turned off using a fuse.

Cause: The start relief or power control systems remain permanently switched on.
Remedy: Call service to determine the cause.

Cause: Gas leak.
Remedy: Call service to identify and repair the gas leak and test for leakage.

VIII. CARE OF THE WATER COOLING UNIT

Before carrying out maintenance work, the main fuse installed on your side must be turned off. The person authorized to carry out the repair must lock the electrical panel and remove the key for storage.

The most vulnerable point in refrigeration equipment is the compressor. The largest number of breakdowns in refrigeration compressors occurs for the following reasons: 1 - refrigerant entering the compressor in liquefied form, 2 - insufficient lubrication of the compressor with oil. Compressor wear and tear as a result of prolonged operation under normal conditions is practically impossible. Prevention of breakdowns is possible only with proper use of equipment and regular inspection.

1. Once a week.

Check the oil level. If the level is below the average mark on the glass eye, and during operation of the equipment, when checking every half hour, the level continues to rise and fall, call the service to top up the oil level. If the oil color is too dark and close to black, you should call a service to change the oil. It is recommended to use the same type of oil as before the change.
- The cracks in the condenser should be blown out with compressed air.
- If abnormal signs of operation (noise, vibration, icing, increase or decrease in operating pressure, heating) of the equipment appear, you should immediately contact the service center.
In addition, the system discharge pressure should be constantly monitored. If this pressure is too high, then there is a possibility of non-liquefiable gases appearing in the system.
The refrigerant amount should be checked regularly through the sight glass. If there are a large number of bubbles in the gas, the gas should be topped up. The lack of gas can be judged by insufficient cooling, as well as excessive heating of the compressor.

2. Once a month.

It is recommended to repeat all operations performed every week.
- All engines should be inspected and oil added if necessary.
- Check the strength of the motor mounts.
- If the system uses belts, their tension should be checked regularly. If the belt, when pressing on it with a finger, deviates by 20-25 mm, then the tension can be considered normal.

3. Once a year

The water chiller must repeat all weekly and monthly inspection procedures.
- Inspect the contacts on the electrical panel and check the functions. To control the operation of thermal relays, test them by lowering the settings below the established ones.
- Check the main fuse contacts.
- Clean the filters of the water supply system.
- Replace the drying filter in the cooling system by calling a service team.
- If there is an air channel, inspect it (dents, damage, sagging, etc.).

IMPORTANT NOTICE:
Interventions in freon systems should only be carried out by experienced personnel from your company.
If the ambient temperature in which the chiller operates is below 0 o C, there is a possibility of freezing of the water in the cooler. If the chiller will not be used for a long time, antifreeze should be added to the water or the water should be drained.

IX. GUARANTEE

The determination of the repair technique, as well as the parts to be repaired or replaced, is entirely carried out by our company.

Damage caused by shipping, handling and installation after the product has been shipped by our company is not covered by the warranty.

Damage caused by use of the equipment that is not in accordance with the above recommendations for use is not covered by the warranty.

The warranty period begins from the day the goods are shipped.

If the use of the equipment is consistent with the above-described recommendations for use, and repair procedures were carried out only by professional personnel of our company, the warranty period for servicing the equipment is 1 year.

To ensure normal and uninterrupted operation of the refrigeration unit, timely scheduled maintenance is required, in accordance with the operating instructions and following all the requirements set out in it.

Precautions for servicing and operating a refrigeration machine, chiller (water cooler)

Below is a list of measures and requirements that must be fulfilled by personnel service and operation of chillers and refrigeration machines.

Before installing, starting up and maintaining the refrigeration machine, be sure to read the operating instructions

Maintenance of central units and chillers (water coolers) should be performed only by qualified workers who have all the necessary permits.

All manipulations related to routine maintenance are allowed only when the machine is de-energized. The only exceptions are those works that are intended to be carried out while the cooler is running.

• Carry out routine inspections of the cooler at the periods specified in the instructions;
• Be careful not to touch the discharge line with unprotected parts of your body to avoid thermal burns. The coolant discharge line temperature can reach 120 degrees;
• If a coolant malfunction occurs, determine the cause of the malfunction. Do not run the installation in production mode until it is resolved;
• If a refrigerant or coolant leak occurs, turn off the power to the refrigeration unit using the main circuit breaker;
• Do not reconfigure elements of the cooler automatic protection system without obtaining approval from the manufacturer;
• Monitor the tightness of the electrical contacts inside the control panel, stretch the power contacts and contacts periodically, according to the instructions;
• If the surface of the heat exchanger is contaminated due to mineral deposits, only cleaning reagents specifically designed for this purpose should be used;
• If a refrigerant leak occurs due to damage to the pipeline and cannot be eliminated if there is freon in the system, proceed as follows:

1. Collect the maximum amount in the receiver by shutting off its supply from it;
2. Release the remaining refrigerant into an empty cylinder;
3. Vaccumate the system according to the power of the vacuum pump and the volume of the refrigeration circuit, but not less than two hours;
4. Solder the damaged area;
5. Pressurize the evacuated refrigeration circuit with an inert gas (!) - 25, kg/cm2, for example, nitrogen. Do not use oxygen, explosive (!);
6. Use a soapy solution to check the sealed area for leaks;
7. Blow off nitrogen, vaccum again;
8. By opening the solenoid, release freon into the refrigeration circuit, top up if necessary

• If the chiller (water cooler) has a plate evaporator, then the hydraulic module must include a water filter. It is necessary to find out the frequency and degree of its contamination and clean it. But at least once a month
• Before starting work, adjust the automatic bypass valve on the supply line, if equipped.
• Check the oil level in the compressor at the intervals specified in the operating instructions. If the oil level is below normal (usually half the sight glass is normal), then you should inspect the refrigeration circuit of the unit for oil leaks
• When operating the chiller (water cooler) at negative ambient temperatures, do not use water(!) as a coolant. The coolant circuit must be filled with the appropriate concentration based on the ambient temperature

When operating a refrigeration unit at sub-zero temperatures, the following measures must be taken:

1. Install a compressor crankcase heating element to avoid thickening of the lubricating oil when the refrigeration compressor is stopped
2. Install a heating element for the liquid freon receiver to maintain high pressure in it when the refrigeration unit is stopped
3. Install a differential valve on the discharge side of the condenser and receiver to raise the pressure to operating pressure
4. Install an automatic time relay to delay the low pressure alarm until the compressor raises the pressure in the refrigeration circuit
5. When the chiller (water cooler) is operating at a negative temperature, it is necessary to charge the system with the required concentration in accordance with the required final temperature of the coolant at the outlet of the cooler

• DO NOT set the response temperature on the control processor below +6°C when using a plate heat exchanger and water at the same time. This will lead to inevitable rupture of the heat exchanger plates and failure of the entire installation and, as a consequence, breakdown of the chiller (water cooler) and the need for its repair outside the warranty

• Before turning on the chiller (water cooler) for the first time, the shield must be grounded (!)

• A carbon dioxide fire extinguisher must be located near the installation, in accordance with fire safety regulations.

• Before starting the installation, make sure that there are no tools left in the installation used during installation and commissioning, as well as other foreign objects.

• Avoid exposure to mechanical loads on the freon circuit of the chiller (water cooler) under pressure

• If the condenser of the refrigeration machine is located indoors, it is necessary to provide exhaust ventilation or ventilation of the room for better heat removal, otherwise the refrigeration plant may stop due to a high pressure accident

• Checking the functionality of the pressure switch (PD) of emergency and responding condenser fans. It is performed by forcing the relay foot in the direction of emergency operation. The installation should stop and the indicator light corresponding to the alarm should light up. Resets with the alarm reset button. If it's the fan relay, the fan should start spinning.

• Checking the functionality of the fluid circulation control relay.

• This is checked by turning off the pump while the refrigeration circuit of the chiller (water cooler) is turned on. The cooler should turn off automatically. The indicator light corresponding to the fault should light up. Then turn on the pump. should automatically turn on again and the red light should go out

• To replace failed parts of the chiller (water cooler) and components that cannot be repaired, it is allowed to use only the same parts and components specified in the specification of the technical passport of the refrigeration unit. If exactly the same parts and components are not available, then replacement with equivalent analogues is possible only after consultation and permission from the technical service of the manufacturer.

If you follow all the above rules on service and operation of chillers and refrigeration machines, then you minimize the possibility of emergency and traumatic situations.

Chiller Maintenance

Chiller Maintenance

Refrigerator ( chiller), this is a technically complex device on which the entire operation of the air conditioning system depends, Requires proper operation and maintenance.

Timely and regular maintenance of the chiller is the key to long and uninterrupted operation of it and the entire air conditioning system. The cost of chiller maintenance cannot be high because... it belongs to a class of devices that do not require large expenses, but repairing refrigeration machines can cost you a pretty penny.

Service will help reduce wear on all components of the unit, as well as prevent premature breakdowns. Servicing chillers is economically preferable to repairing them.

Repair is a set of works carried out to restore the functionality of equipment lost as a result of failure, damage, wear or exhaustion.

In most cases, the reason for repair is, as a rule, premature failure of the unit due to non-compliance with operating rules and lack of regular technical and service maintenance. Correct installation, operation and timely Chiller service guarantees a longer service life of the unit.

Maintenance work must be carried out by authorized specialists in compliance with all safety measures provided for by the equipment manufacturer's instructions. If the instructions given in the documentation are not followed, the manufacturer is not responsible for the safe operation of the unit and disclaims warranty service obligations.

Chiller maintenance involves performing certain work, the duration of which is calculated in months or years that have passed since startup, as well as in operating hours of the unit. The earliest of the two service dates is selected., the number of hours worked by the unit can be found in the corresponding controller menu.

The list of routine maintenance is given in the maintenance instructions for the refrigeration machine. Also, authorized specialists must keep a log in which it is necessary to enter information about the work performed, including repair work and unscheduled maintenance.

Scheduled maintenance work on the chiller should be carried out regularly at the intervals specified in the documentation. If the instructions given in the documentation are not followed, the manufacturer is not responsible for the safe operation of the unit and disclaims obligations for warranty maintenance of the refrigeration machine.

Chiller maintenance involves performing certain work, the duration of which is calculated in months or years that have passed since startup, as well as in the working hours of the unit. The earlier of the two dates is selected; the number of hours worked by the unit can be found in the corresponding controller menu.

Chiller servicing includes the following work:

1. • Check for alarm messages in the corresponding controller menu.
   • Visually check the system for leaks
   • Checking and cleaning the outlets
   • Checking the condition of the water circuit filters
   • Removing air from the water circuit
   • Checking the condition and cleaning of air-cooled condensers
   • Inspection of pressure vessels
   • Checking the general condition of the unit
2. Qualified engineer at the beginning and end of the season:
   • Checking air flow
   • Checking water flow through the condenser
   • Checking the tightness of the refrigeration circuit
   • Checking the tightness of electrical connections
   • Checking the tightness of the refrigeration circuit connections
   • Checking the condition of fan and motor bearings
   • Checking the operating parameters of the refrigeration circuits
   • Checking the parameters of the power supply network, current consumption, grounding
   • Checking the oil level
   • Checking the condition of pipeline insulation
3. Qualified operator at the beginning and end of the season:
   • Oil change every 15,000 operating hours or every three years
   • Check the oil level (if there is an indicator) at the beginning of the season or once a year
   • Check vibration and noise levels at the beginning of the season or once a year
   • Check control and protection devices at the beginning of the season or once a year
   • Check the motor insulation at the beginning of the season or once a year

When carrying out maintenance work on the chiller it is very important to prevent rust from forming on the surface high-pressure vessels (evaporators, condensers, heat exchangers, liquid receivers) and deformation of their casing, for this it is necessary to paint the high-pressure vessels or apply an anti-corrosion coating to them when corrosion is detected.

Accumulation of dirt on pipes and fins of heat exchangers is unacceptable this leads to an increase in condensation pressure, which in turn leads to an increase in energy consumption and accelerates wear on the compressors, which can cause an unplanned shutdown of the unit. The fins and surface of the heat exchanger tubes should be thoroughly washed with a stream of water when carrying out maintenance work on the refrigeration machine, and cleaning should be carried out more often during leaf fall or the dispersion of fluff and pollen.

For chillers equipped with radial fans, it is necessary to check the tension of the belt drive and if the belt is loose, its tension should be increased to the proper value. If the belt tension is too low, it can cause slippage and damage to the drive. On the other hand, too much belt tension can cause premature bearing wear.

Remember that timely Scheduled chiller maintenance prevents premature failure, thereby saving you money on repairs, since repairing a chiller is a very expensive pleasure.

What to do if the chiller breaks down?

Malfunctions are caused by improper operation or mechanical damage. Other causes of failure may include temperature changes, power outages, and unauthorized changes to the device’s automatic settings.

Regardless of the cause of the breakdown, chiller repairs should only be trusted to professionals. Don't skimp on repairs by trying to fix it yourself or using a "jack of all trades"! Repairs after incompetent intervention can entail much higher costs than if you immediately turned to specialists.

Sometimes repairing chillers is very labor-intensive and requires more than one specialist to complete it. Ordering new components takes a lot of time. And setting up a controller of uncommon brands is a task for a real pro.

All-climate specialists provide a full range of services for service, maintenance and repair of chillers of any complexity. Our specialists have proven themselves well in the engineering services market. Many large companies trust us; the experience of our specialists allows us to carry out all work efficiently and quickly. The All-climate company provides a guarantee for all services provided, which is supported in our service center.