In modern industrial production, the workshop chiller unit, as the core equipment of air conditioning and process cooling systems, plays a critical role in production efficiency, product quality, and energy consumption. However, factors such as long-term high-load operation, environmental dust, and changes in water quality can easily lead to equipment performance degradation and even sudden malfunctions.
Here are systematic maintenance and repair recommendations, divided into three levels: daily maintenance, regular maintenance, and annual major repairs.
I. Routine Maintenance (Daily)/Weekly)
1. Operational Parameters Monitoring
Inspect Frozen WaterAre the incoming and outgoing cooling water temperatures and pressures normal?
Record electrical parameters such as current, voltage, and compressor current.
Monitor for any unusual noises, vibrations, or odors.
2. Cleanliness and Environmental Inspections
Clear debris around the aircraft engine and ensure good ventilation.
Inspect for blockages or dust accumulation around the condenser and evaporator.
Ensure the control cabinet is dry and free of water accumulation.
3. Leak Inspection
Inspect refrigerant pipelines, water pipe joints, and valves for leaks.
If using ethylene glycol solution, it is necessary to check the concentration and antifreeze properties.
Regular Maintenance (Monthly)/each quarter)
1. Water System Maintenance
Wash or ReplaceY-Type Filter
Inspect pump operation, sealing, and bearing lubrication.
Monitor Water QualitypH value, turbidity, and hardness; add corrosion inhibitors or biocides as necessary.
Air exhaust within the emission system to prevent airlock.
2. Electrical System Inspection
Secure wiring terminals inside the electrical control cabinet.
Inspect for burnishing on contactor and relay contacts.
Test the sensitivity of safety protection devices (high/low voltage switches, flow switches, oil pressure differential, etc.).
3. Lubrication and Transmission Components
Apply appropriate lubricant to the bearing of wind turbine motors and pump bearings.
Check belt tension (if belt-driven).
4. Condenser/Evaporator Cleaning (as per water quality conditions)
For shell-and-tube heat exchangers, chemical cleaning or physical flushing can be employed.
The air-cooled unit requires cleaning of the fin dust (using a soft brush or a high-pressure air gun, avoid damaging the aluminum fins).
Annual Major Maintenance (recommended to shut down for inspection once a year)
1. Deep Inspection of Refrigeration Systems
Check refrigerant charge levels, and recover, leak check, evacuate, and recharge as necessary.
Replace the desiccant filter.
Check the quality and level of the compressor oil, and replace the refrigerant oil if necessary.
Inspect the compressor winding insulation resistance.
2. Heat Exchanger Professional Cleaning
Hiring a professional company for chemical cleaning or mechanical descaling of condensers and evaporators.
Inspect copper tubes for corrosion and perforations.
Control System Calibration
Verify temperature and pressure sensor accuracy.
Upgrade or BackupPLC/Controller Programming (as applicable)
Simulate fault test for alarm and chain functions.
4. Energy Efficiency Assessment
RecordCompare the COP (Coefficient of Performance) or kW/RT values to historical data to determine if efficiency has decreased.
Propose energy-saving optimization suggestions (such as variable frequency transformation, intelligent control, etc.).
Four: Cautionary Notes
Safety First: Power Off and Tag OutPerform any maintenance only after LOTO.
Documenting Perfection: Establishing Equipment Maintenance Records for Efficient Fault Trend Tracking
Professional Operation: Certification Required for Refrigerant Handling；
Seasonal Preparedness: Winter – Antifreeze preparation (drain or add antifreeze), and a comprehensive check before summer.
