AHU common Issue and solution:

Any forced air system that’s used to heat or cool a home or business needs a large fan, known as a blower, to push
the air through the indoor air delivery network. But, the blower doesn’t work in isolation; it’s part of a number of
components, which is called the blower assembly. If any component in the blower assembly fails, the blower will be
less effective or stop working altogether. The air handler manages the delivery of your treated air, and problems in
this area can have a dramatic effect on your home. Let’s take a look at seven common air handler problems that will
affect the delivery of treated air throughout your home.

1. Fan Blade Issues

Because they are attached to a moving part, fan blades can be susceptible to bending, breaking, or becoming loose
during operation. When a blade is damaged in this way, it will have a major impact on the air flow, and it could
damage other components. A fan blade issue can usually be detected with weird sounding noises from your HVAC
system. As the fan rotates, you may hear loud banging or rattling sounds, and it’s a good idea to shut it down until it
can be repaired. Contact a local HVAC specialist, and they can check your air handler system and repair or replace the
fan blades for you.

2. Electrical Problems
The blower assembly contains a significant amount of electrical wiring, and over time, they can become frayed or
corroded. The motor itself can also develop an electrical issue related to the capacitors that can wear out and the
wiring itself. If you’re not trained to work on HVAC equipment, it’s a good idea to hire a local expert to work on your
system. The air handler contains a number of sensitive components that are easily damaged, and you can hurt
yourself if you’re not sure what you’re doing.

3. A Malfunctioning Limit Switch

The blower has a switch the protects the heating system, and it ensures that cool air cannot blow into your home
during the colder winter months. This component is known as the “limit switch” and if it fails, the blower will act
erratically. In some cases, the blower may run intermittently, it may run constantly, or it could stop working entirely.
A trained HVAC specialist can quickly fix this problem and restore your cooling or heating in next to no time.

4. Airflow Obstructions
The main purpose of the air handler is to promote the airflow throughout your home. So, any obstructions that limit
the airflow will work against the air handler and make it less efficient. A typical cause for the obstruction is an air filter
that has become dirty and clogged. This is an easy problem to avoid if you change or clean your air filter on a regular
basis. Try to clean your air filter each month on the same day, and if you have pets, you may want to clean it every
other week. This will keep the components in your air handler clean and clear, and the airflow will be optimized. If you
invest in an advanced digital or smart thermostat, you may get a warning when the air filter needs to be cleaned.

5. Condensation Leaks
A condensation leak usually causes a build-up of moisture or some water leakage under the unit. When the air
conditioner works harder during the hotter summer months, a great deal of extra condensation is caused. This is
collected in a drain pan that’s located under the air handler unit. The drain pan has a line that connects the unit to the
drainage system, and this can be prone to blockages. Any dirt or dust that’s collected from the indoor air makes its
way to the drain pan, where it becomes wet. This sticky material then enters the drain, where it clogs the drain line.
Another common issue is the formation of algae and mold inside the drain line. If bugs, mice, and other vermin make
their homes in the air conditioner unit, this can also lead to blockages. When the drain line becomes clogged, it can
lead to an overflow and water damage.

6. Dirty Evaporator Coils

When the evaporator coils in your system are dirty, they can freeze over and cause serious problems for your entire
cooling system. When the coils are frozen, they damage your compressor unit, which can be an expensive part to fix
or replace. In extreme cases, you may even have to replace your entire air conditioner system. A local HVAC specialist
can check your evaporator coils and compressor as part of a regular service.

7. Blower Compartment Issues

The blower compartment houses a number of sensitive components that keep your HVAC system working efficiently.
If the compartment is contaminated with dirt, dust, and other materials, it can affect your indoor air quality (IAQ).
This is also true of any leaks that may be lurking in the HVAC system where dirt and dust can enter the airflow. The
first people to notice these types of issues are those suffering from allergies and pre-existing respiratory conditions.
Locating air leaks and fixing them can be a tricky proposition if you don’t have experience and specialist equipment.
An annual HVAC service will identify these problems, and the technician can then fix them for you.

Adopting a DIY ethos to develop skills and save money on projects in your home is admirable. But, developing skills to
work on HVAC equipment can take time, and it is a very specialized field. HVAC equipment represents a significant
investment. So, it makes sense to protect it by using qualified technicians and approved parts in your system. Working
on HVAC equipment can cause damage if you’re not sure about what you’re doing, and some components can be
expensive to replace. It’s a better idea to hire a local HVAC specialist with a good track record for service. Ask about
deals on servicing and maintenance because it will save you money in the medium to long term. Well serviced HVAC
equipment is more efficient and less likely to fail when you need it most.

Here Are Top 11 Common Split Ac Problems And Their Possible Solutions
Nobody can refute that Air conditioner is a vital appliance for all homes and workplaces. It works explicitly like an
angel in the humid and hot season.

Since we understand that metropolitan cities have been going through pollution ambiance, therefore having an air
conditioner is always an accurate decision. Moreover, preserving your AC health frequently is the key to making it
work efficiently. Air-con is also similar to other electronics, and it will always need maintenance to upkeep the
essential performance.

Over the period, AC may encounter smash-up, damage, faults, and breakdowns, and there is no way to leave it.
Homeowners must converse with air-cooling reparation consultants and describe them possible defects. In case you
don’t know what to carry out, air conditioner professionals take care of it excellently. Allow us to discuss11 Common
Split AC Problems And Their Possible Solutions.

1. Indoor Unit is Creating Excessive Sound

Occasionally the split air conditioner’s indoor unit begins creating excessive clatter while functioning at the time of
turning on. However, the defect is minor, and there are no serious things to panic about. In that case, it is probably
the defective fan internally set in the indoor unit.

The fan may be dislocated from its correct spot; the air cooling expert will disassemble the indoor unit and fit the fan
in its right location. In a few conditions, the noise occurs because of dirt, dust, and buildup on the fan that can lead to
shuddering in the fan. Disassembling and cleaning the fan will solve noise issues.

2. AC is Continuously Switching On And Off

When you detect that split air-con starts switching on and off automatically, again and again, it is ideal for turning it
off until you call an AC service expert. The probable reason for such recurrent switching on and off is AC’s condenser,
and the evaporator is polluted or obstructed.

The grimy air filter blocks airflow, resulting in more issues comprising an ice-covered evaporator coil. It is vital to
wash, clean up and replace the air filter for improved cooling and efficiency. Other causes can be incorrect air
conditioner temperature and timer configurations.
Often set incorrect AC temperature or enable the sleep timer operation that automatically causes the AC to switch
off. You need to change the setting into default form, switch off the sleep mode, and check the rectified issue.

3. Insufficient Cooling and Warm Air Blowing

Split air exchanger appliances are pretty effective, and they can make cool the entire place according to the set
temperature. However, in case, split air circulator appliance is not blowing cold air as it generally previously regardless
making it switch on for long hours, then it indeed has some fault. The leading causes at the back of insufficient cooling
air may be contaminated air filters, ice upsurge on the evaporator coils obstruction in the condenser drainage
system.

Additionally, if the Climate control appliance is flowing warm air at the time of fan functioning, it may decline the
cooling system. The possible reasons are inadequate airflow, wrong thermostat settings, refrigerant leakage, and
electrical current failures. Instant AC repair and tune-up are ideal for solving that problem quickly.

4. Split AC Not Turning On

In that situation, the PCB most expected failed because there’s no exact basis behind that. A variety of things can
destroy current protection: overcrowding, a voltage spike, recurrent ON/OFF sequences, or physical scratch. It can
also happen because the copper wire gets too close to the solder point.

In some conditions, the capacitors and ICs have combusted; the PCB is not a component that can get repaired. The
sole alternative is to buy the new one and change it with the old defective PCB. A new PCB is standard and costly; it
has nothing to do with AC technicians because they come from AC part manufacturing companies.

5. AC is Spreading Bad Odor When Turning On

Often when you start the split air cooling system, it releases an unbearable bad odor. You need not take stress
because there may be a fault in the drainage mechanism. The drain faucet and hose may collect dirt, mud, and
wreckage over the period and gradually begins stinking foul. Only consulting and inviting an air cooling system
machinist is the way to get rid of such a stinking ambient.

6. Dirty Air Filter

Air filters in AC are responsible for sieving pure air from the outdoor unit and preventing it from dirt, pollutants, and
dust substance. These air filters need cleaning at least twice a year. The clogged filters can impure air quality and AC’s
cooling efficacy. A dirty filter compels air-chilling appliances to function rigorously and eat excessive electricity to cool
down the entire room.

It will finally lead to elevated energy charges and insufficient cooling. You need to dismantle the air filter from the
split air circulator to clean them (do as per AC’s manual and instructions given by the AC manufacturer). Sanitize and
wash air filters with a running lukewarm water vacuum cleaner if they are washable. You can also change them with a
new one if they don’t get clean or they are not washable.

We suggest making your air circulation system serviced a minimum of two times annually for improved efficiency and
preventing air filters from getting dirty.

7. Clogged Split AC Outdoor Unit

The Split air circulator appliance efficiency may also decline when the exterior unit compressor is filthy or obstructed
by dust, wreckages, and fallen leaves. The obstructed compressor prevents air from circulating in the indoor unit. The
ideal method is to clean the compressor by sprinkling water with elevated force. But we suggest that it will be
fantastic to avail air conditioner technologist assistance. Either professional will repair the compressor or replace it
with a new one.

8. Gas Leakage or Shortage in Refrigerant Level

The lower levels of refrigerant or gas leakage are one of the causes of insufficient cooling. Refrigerant is a gaseous or
liquid element that soaks heat from the atmosphere and delivers cool air when blended with an AC evaporator and
compressor. The air cooling appliance is with low refrigerant level, and gas leakage can decline cooling efficiency.

The gas leakage and shortage in refrigerate level is generally happens in regions positioned nearby shoreline areas or
anywhere near sewage where dampness and air pollutants are elevated. You must inspect the AC external and
internal unit and their connection.

The professional will detect link failure between both the units. When you find potential leakage, you need to top up
the refrigerant gas to a high level as recommended in AC maintenance guidelines. But it is not effortless to perform
guidelines precisely, and we suggest consulting an AC repairer to rectify this issue.

9. Swing System Is Not Functioning

When the swing system in the split air conditioner fails to perform, there may be two causes of such failure—the
swing is regulated by distinct swings machinery. The motor is defective, or PCB is not circulating current flow to the
swing motor.

A split air circulation system demands daily maintenance to stay running effectively with the help of AC annual
maintenance contract packages. But it may be hard for every homeowner to have sufficient time and skills for AC
servicing. Therefore it is always the correct step to pick the inclusive air conditioner AMC package in which your air
cooling machine can get one, two, and three years of maintenance and repair assistance.

10. Defective Compressor (Compressor Turning Off Too Often)

The compressor is the essential part of the air conditioner, and it is set in the outside unit. It is responsible for gas
circulation linking condense and the evaporator. If the compressor doesn’t work correctly, then the air conditioner
will not run efficiently to its complete capacity, or often it doesn’t perform at all. Moreover, a faulty capacitor burned
electric cable, and damaged compressor are also some of the reasons AC is not operating.

You can take many considerations to make a defect compressor work in a split air conditioner, including capacitor
replacement, condenser coil cleaning, and outdoor unit fan cleaning. However, if these tricks don’t work, the last
alternative is to buy a new compressor, and the compressor price lies between Rs 6,000 and 10,000, based on the air
conditioner brand. It is a pricey part of AC, and if you prevent your AC from collapsing, it is always vital to obtain AC
service and maintenance.

11. Ice Build-up on Evaporator Coils Surrounding

The low cooling of an air conditioner also happens because of ice buildup in the surrounding evaporator coils. Ice can
make a thick layer in the surrounding AC’s evaporator coils when you don’t pay attention to routine AC maintenance
and overhauling. The ice accumulation around the split AC’s evaporator coils can also happen because of lower
refrigerant levels and gas leakage. Ice upsurge can attract dirt/bacteria/debris accumulation on the air filter and other
AC components. It is advised to cleanse the air filter frequently to maintain air conditioner performance. If the
problem doesn’t fade away, consulting an expert AC service technician can bring a productive way out.
Concluding Considerations for Pro Tip

Safeguard and Preserve Split AC through our AMC (Annual Maintenance Contract) Package. What’s more, Key
vendors AC Maintenance Plan comes with two precautionary maintenance appointments yearly. Receiving reminders
from professional professionals is a great idea, and you can rest assured that you will do it correctly with AC service
being valid.

The AMC Plan for ACs is designed to give you harmony of the brain and allow you to pay attention to the other vital
aspects of your business. The AC AMC Package company provides unlimited repairs of all kinds, free gas charges for
any required maintenance, and the cost of spare parts at a significantly reduced rate.

Which are the common errors in air-cooled chillers?

1. Compressor suction pipe frosting: the system may not be drained well or the chilled water flow is
too large, the system pipeline is blocked, and the flow is too small. The pipeline should be cleared
and the air should be discharged.

2. Too high condensation pressure: when there is too much refrigerant; the outside air temperature
is too high, the ventilation of the unit is not good; when there is air or non condensable gas in the
refrigerant system, the condensation pressure will be too high.

Treatment method: discharge excess refrigerant; adjust and improve the ventilation environment
around the unit (such as setting up sun proof shed); open the exhaust eye for exhaust.

3. Too low condensation pressure: the refrigerant may be insufficient or the compressor is
damaged. Check whether there is leakage during treatment. After repairing, make up the refrigerant
and check the compressor. If damaged, replace it.

4. Excessive suction, excessive heat pressure. Improper adjustment of expansion valve may cause
high suction pressure.

Treatment method: discharge the excess refrigerant, reduce the cooling water volume, reduce the
heat load, and readjust the opening degree of the expansion valve.

5. If the suction pressure is too low: the refrigerant may be insufficient; the opening of the
expansion valve is too small; the pipeline of the equipment in the water system is blocked. Check
whether there is any leakage. After repairing, replenish the refrigerant and adjust or replace the
expansion valve.

How to solve issues related to inefficient operation of chiller?

Chillers or also known as refrigeration machines are widely used in many industries. Their main function is to
remove heat in order to maintain comfortable temperature within the rooms. Nowadays, there are many types of
chillers used for various purposes. Costs for installation of such system and its further operation are pretty high. It
is also obvious that the customer is interested in its stable and uninterruptible work. What are the common issues
owners of buildings with chillers installed face and how can they be avoided?

Issue: Unstable operation of chiller

Cause: Partial load
Power calculation for determining cooling capacity is normally carried out taking into account the highest air
temperature in the summer. Such high temperatures are irrelevant during the day as the air temperature drops at
nights and on cooler days. Therefore, generation of the cold for a building in relation to temperature fluctuations at
different times of the day and under various weather conditions is generally higher than it is necessary. In this case we
can see partial loading of the chiller. It further results in its decreased efficiency in general. It should also be noted
that type of compressor used and the type of capacity regulation are important for efficiency.

There might be another problem when loading on cooling system at a certain time is below the minimum values of
cooling capacity of chiller itself. In this case, we may see cyclic switching off and on and it also affects efficiency of the
system. This often becomes the main reason of failure of automatic control system because it wears it out. As a result,
you will face increased operating and maintenance costs of the chiller. It is extremely expensive for the owner of
facilities.

Resolution of the issue

In this case, it is advisable to install two chillers with different or identical capacities. At the same time, it is necessary
to select equipment according to its capacity and considering the needs of the building in cooling throughout the year.

At this point, the first chiller will have high efficiency refrigeration with most typical loads over a long period of time.
The second chiller will generate additional cold during peak loads.

Efficient operation of the cooling system under this approach will require correct calculation of building’s need in cold
throughout the year. When calculating, it is necessary to take into account the following factors: heat generation
variables within the building, changes in the air temperature outside, temperature of cooling water that circulates in
the system, load of building, etc.

Issue: Defrosting and damage to heat exchanger of the chiller

Cause: Not appropriate maintenance of equipment

Heat exchanger is one of the key components of the chiller. Working fluids of the system constantly run through its
channels. Leakage between circuits of heat exchanger is one of the most common failures. Untimely or incompetent
maintenance of the chiller may cause defrosting and damage to heat exchanger and chiller.

When micro leakage occurs, water enters refrigeration circuit that results in irreparable damage for the compressor.
After a while, refrigeration compressor will be completely flooded, and the chiller fails to operate.

Resolution of the issue

It is important to take preventive measures for safety of the equipment and mechanisms of the chiller. Professional
preservation of the system for winter period will be needed in this case. To do this, it is necessary to stop the chiller. If
it is water-based coolant, drain it completely from the heat exchanger and pipelines. After draining water from heat
exchanger (especially true for plate type), pour antifreeze into it for the winter storage period as remains of even a
small amount of water would expanding during crystallization may damage evaporator and refrigeration machine. As
we can see, “pennyworth” but timely measure will allow you maintain your equipment in good condition and avoid
unnecessary high costs.

Most of malfunctions that result in the failure of the heat exchanger and compressor, shutdown of the chiller and
costly repairs, may be identified and solved at the very initial stages. ARTS specialists perform both installation/repair
of chiller equipment and carry out complex diagnostics of systems. Scheduled diagnostics is recommended at intervals
of at least once a year for efficient operation of the chiller.

TOP mistakes when choosing your chiller

Specialists of companies that perform servicing HVAC equipment very often have to correct errors that customers
made themselves when choosing and installing their chillers. We have collected the most common ones. Following
the simple rules will help you to avoid unpleasant situations related to equipment failure, unnecessary energy costs
and additional expenses for repairs and maintenance.

Purchase of ready chiller without professional calculations

Nowadays you may find a wide range of ready-made chillers at the market. At first glance, such offers seem to be
more attractive than searching for equipment that fits your individual needs.

Conveyor chiller is unlikely to provide uninterrupted maintenance of comfortable room temperature. When selecting
a chiller for efficient cooling, some nuances should be considered as follows: features of production and technical
processes within the facilities, boiling temperature, temperature on evaporator, coolant consumption, condensation
temperature and some other parameters. It is very unlikely that a random chiller fits such features.

Professional companies that work with refrigeration equipment may be a perfect choice when selecting features of a
chiller for your specific needs. ARTS specialists have 20 years of experience in this field and therefore perform precise
calculations and selection of equipment based on specific parameters of buildings and your specific needs.

Purchase of used equipment

Some owners of buildings decide to buy a used chiller in order to save money instead of purchasing the brand new.
Common problems they may face during operation of cooling equipment are leaking oil, noise in compressor, failure
of fans or heat exchangers. Repair of such equipment is expensive. BY comparison, new high-quality equipment that is
selected by specialists operates smoothly and does not caus such problems.

The higher the pumping pressure, the better

“The higher pressure is, the greater is cooling capacity” is wrong statement. When installing large pump to increase
the pressure, it is necessary to clamp it to reduce pressure. This will result in increased energy consumption of the
pump.

In order to prevent such mistake, contact professionals that will design the system. This is when the equipment is
selected in accordance with existing parameters. We also recommend using “smart” pumps that have frequency
converters as they save energy and have longer service life.

Each owner of a facility willing to purchase and install of a chiller should realize that any minor mistake in its choice,
its unprofessional design of the system may result in serious consequences. Do not play with your nerves and do not
waste your money on excessive consumption of electricity, costly repairs of the expensive equipment. Just trust
professionals!

In the next issue we will talk about some details for design of chiller systems.

What are the troubleshooting tools of a water-cooled chiller?

Common fault 1: whether high and low voltage are normal

When the compressor is in operation, the difference between high pressure and low pressure is little
or equal, so we should check whether the valve plate of the compressor itself is damaged or broken,
and immediately stop the operation and inform the supplier to send someone to deal with it.
Common fault 2: insufficient refrigerant indicator light on

When the water temperature of the water-cooled refrigerator is above 5 ℃ and the pressure on the
low-pressure gauge is lower than 2kg / cm2, it is indicated that the refrigerant is insufficient. At this
time, we must carry out leak detection. If there is any leakage point, we should make up for the
leakage, then replace the drying filter and vacuum again, and fill the refrigerator with appropriate
refrigerant.

Common fault 3: reverse phase

When the water-cooled chiller has this fault, it will protect the phase in time. The reason of reverse
phase is that the water pump and compressor are reversed. At this time, we can exchange any two
phases in the power phase line. If the phase is missing, we only need to use a multimeter to measure
whether the three-phase power supply is normal and check whether the power line is broken.

Troubleshooting of water cooled chiller

Common fault 4: poor cooling results in slow or unable cooling

If the condenser of the water-cooled refrigerator has poor heat dissipation, the efficiency of the
compressor will be low, the operating current will be increased, and the high-pressure pressure will
rise to 20kg / cm2. At this time, the compressor will be tripped and stopped. At this time, it is
necessary to check whether the circulating water of the cooling water tower is normal, whether the
cooling water temperature is too high, whether the cooling water valve is fully opened, whether the
condenser is dirty, etc After normal operation, press the reset key to operate normally.

What are the safety devices in a water cool chiller?

According to Cet-Enviro, there are 10 safety devices in a water-cooled chiller for which you must have the knowledge.
However, with these 10 devices, you can prevent your chiller from being spoiled at the right time. The devices are
mentioned below with an explanation, however, these devices will save you from masseur breakdown.

• HP Switch: stands for High-Pressure Switch that comes in both small and big chillers. If this pressure goes
up from 300 to 350 it means there is something wrong, so seeing this device trip down immediately.
However, you have to reset it all the time as it trips down.
• LP Switch: Low-Pressure Switch; when a chiller suffers from low pressure this will continuously run and
will not cool the air because there is no pressure at all. So, the LP switch will be tripped down, the biggest
thing is that you do not have to reset it, this will start automatically.
• AntiFreeze: with this, you can detect why the flow of water has stopped in the evaporator? If the flow of
the water stops, the water will be converted into ice and ice will extend its space compared to water, so
heat exchange is so important in a water chiller. Seeing all this antifreeze is used. As the temperature goes
down antifreeze will be active immediately and stop the water chiller.
• Water Flow Switch: If both evaporator or condenser will face the problem related to water flow or
pressure this will tripped down the whole system.
• Phase Reversal or Phase Sequence: The fan of the water cooler condenser has to work in the right
direction, not in the left direction. As we are able to change the direction of the fan with three phases.
However, you can not use a water cooler chiller fan in another direction, this will not work. In this case
your fan will not cool and this will cause you damage to the system, even if you change the phase. So, the
system does not damage phase reversal or phase sequence is used.
• SPP Switch: This is known as “Single Phase Preventer”. In any of the cases if your water cooling condenser
is not cooling, even in three phases as well. In such a case there could be problems either with write break
down or any other problem. SPP will switch off the system and prevent it from any miss happening to your
condenser.
 • Oil Pressure Switch/ Oil safety Switch: Oil has its own role in the whole system of water chillers. Having
pressure of oil is really so important. In many of the cases oil pressure stopped if this happened the
chances of being ceased will be increased. To save the machine from this problem Oil pressure switch or
oil safety switch is used for a water cooler condenser.
• Compressor Motor High Temperature Protection: If a compressor’s motor temperature goes above this
will damage the motor or affect the wiring to be opened. This device will save the motor from
overheating.
• Oil Level Switch: The oil goes into the oil separator and starts gathering there and this comes back to the
compressor. If in any of the cases the level of oil goes down thai may damage the system. To prevent this
problem the oil level switch is used.
• Relief Valve: This is a mechanical device, if in any of the cases the pressure on the flow goes down or up,
in that case this may cause you to blast the system water cooling cool condenser use. In any of the cases if
these devices even all of them do not work. Relieve Value will open immediately to law the pressure in the
open air and prevent the whole system from being blasted

What are the three common cooling tower problems?

According to Cet-Enviro as they have experienced there are four types of problems that occur in
cooling towers commonly. These four problems are the most popular problems that every cooling
tower faces.

Scaling: This builds up the layers in the water which rob efficiency. In water, there are different
types of minerals found like calcium, which is part of the high heat system breakdown and are
deposited on the cooling tower heat exchange surfaces.

Biological Contamination: Cooling towers by nature are places that are hot. Along with the
common and plentiful nutrients that most water sources contain it is an ideal place for the growth of
unwanted biological growth in the water like bacteria. However, these contaminants are not good
for your cooling tower because every layer can reduce thermal conductivity.

Fouling: The falling can be seen in different areas of the chiller. So, this is the main location where
this starts fouling. This is caused by debris, dirt, and dust all the time and they are common in
water. This will consume more and more energy.

Corrosion: Most of the time we ignore the leakage this can be especially prevalent in cooling
towers that use closed-loop systems. When the air, sodium, and other chemicals that are found in
our water supplies are left unchecked to run by the chiller tower system. The outside of the surface
starts leaking and causing the line to eat.

So, these are the common problems that will stop your cooling towers
Common Chiller Issues & Solutions
Chillers are crucial for achieving the necessary temperatures for a variety of industrial operations, which results in

high energy consumption in these facilities. In order to enhance system performance, guarantee a long lifespan, and

reduce energy costs, operators must prioritize the proper operation and maintenance approach. This article lists

typical chiller issues, offers fixes, and emphasizes useful troubleshooting advice.

Three common causes of chiller issues include improper chiller sizing, improper operating procedures, and careless

maintenance. Operators must therefore carefully take these aspects into account to reduce any potential risks to the

cooling system.

The following are some typical chiller issues and possible solutions that can be managed more efficiently using

maintenance software:

Maintenance Neglect

Operators may fail to follow recommended maintenance procedures, which harms chillers’ overall performance and

results in excessive energy use. Operators are responsible for ensuring efficient maintenance, which includes

appropriate equipment diagnostics utilizing operating records. In order to determine their state and plan

for preventative and corrective maintenance, chiller units also need to undergo routine inspections.

Improper Operation

The manufacturer’s instructions for correctly operating industrial chillers are included in the manuals that come with

them. Operators must abide by these rules since bad operating procedures reduce the effectiveness and lifespan of

the equipment. Even if incorrect practices may not stop these cooling systems from functioning, it is noteworthy that

the systems grow more prone to expensive and serious problems. Implementing training programs on proper chiller

operation and maintenance as well as effective chiller maintenance programs is necessary to mitigate this threat.

Incorrect Sizing

The sizing of chillers is crucial when establishing cooling systems in industrial buildings. Inadequate airflow and

inefficient cooling may result from undersized equipment. On the other hand, oversizing severely limits low-load

operations and raises operating expenses. To determine whether existing chillers are appropriate for the common

cooling loads, operators must evaluate their cooling capability.

Some Common Issues

Despite appropriate operation and routine maintenance, chillers are nonetheless susceptible to damage because of

aging or deterioration. Operators can detect the likely problem prior to chiller repairs by understanding common

initial troubleshooting techniques.

Chiller Won’t Start

There are several possible reasons why a chiller may not start. Some common causes include:

• Electrical problems: If there is an issue with the electrical supply, such as a loose wire, blown fuse, or tripped
circuit breaker, the chiller may not turn on.
• Control system problems, such as a broken control panel or thermostat, could prevent the chiller from
starting.
• Problems with the refrigerant system, such as low refrigerant levels or a leak, could prevent the chiller from
starting.
• Problems with the compressor, such as a failing motor or a seized compressor, may prevent the chiller from
starting.
• Mechanical problems: If there is a mechanical problem, such as a broken part or damaged belt, the chiller
might not start.

To stop further damage and make sure the chiller is running properly, it’s critical to find and fix the root cause of the

problem if the chiller won’t start. It could be required to call a professional for repair in some circumstances.

Inadequate Pumping

Inadequate pumping can cause a chiller to not work properly. These elements can greatly hinder the refrigeration

cycle’s ability to flow coolant adequately. Here are some possible causes of inadequate pumping and how to address

them:

• Low flow rate: A pump’s flow rate may not be sufficient to circulate enough refrigerant to adequately cool
the chiller. Check the pump for any obstructions or constraints and make sure it is the right size for the chiller
to solve this issue.
• Pump failure: If the pump has failed, the chiller won’t operate correctly since it can’t circulate refrigerant.
The pump will need to be fixed or replaced to solve this issue.
• Pump seals that are worn or damaged may allow refrigerant to leak and prevent the pump from circulating
enough refrigerant to effectively cool the chiller. The pump seals will need to be fixed or changed to solve
this issue.
• Insufficient refrigerant circulation: If the pump speed is not set correctly, it may not be able to adequately
cool the chiller. If necessary, change the pump’s speed to resolve this issue.

Inadequate pumping can make the chiller malfunction, so it’s crucial to find and fix the root problem as soon as

possible to save further damage and make sure the system is functioning effectively. It could be required to contact a

professional for repair if you are unable to resolve the issue.

Inadequate Cooling

By measuring the coolant’s temperature at the chiller outlet, operators can troubleshoot this issue. A temperature

that deviates from the norm for the process points to an iced-up evaporator or deteriorating coolant fluid. There are

several possible causes of inadequate cooling in a chiller. Here are some potential causes and how to address them:
 • Low refrigerant levels: The chiller won’t be able to cool efficiently if the refrigerant levels are too low. Check
the refrigerant levels and replace them as necessary to solve this issue.
• Compressor failure: If the compressor has failed, the chiller won’t be able to cool efficiently since it won’t be
able to circulate refrigerant. The compressor will need to be fixed or replaced in order to solve this issue.
• Condenser coils that are unclean or clogged can make it harder for the chiller to effectively dissipate heat,
which could result in improper cooling. Condenser coils must be cleaned or changed to resolve this issue.
• Incorrect thermostat setting: The chiller may not be able to maintain the desired temperature if the
thermostat is not set to the proper temperature. Adjust the thermostat setting as necessary to solve this
issue.
• Airflow problems: The chiller may not be able to circulate cool air adequately if there are airflow problems,
such as blocked air filters or damaged ducting. Clean or replace the air filters, and address any broken
ductwork, to solve this issue.

Numerous problems can result in inadequate cooling, so it’s crucial to find and fix the root of the issue as soon as you

can to stop further damage and make sure the appliance is working properly. It could be required to contact a

professional for repair if you are unable to resolve the issue.

Environmental Conditions

Due to modifications to the process or changes in the surrounding temperature, the chiller may be under too much

load. Similarly, a change in the chiller’s position (near other heat-generating equipment or farther from the process

equipment); loose, damaged, or missing insulation on the pipes between the chiller and the process; or even changes

in line voltage may be impairing the chiller’s ability to remove heat.

Other Common Chiller Faults

The majority of modern chillers show a fault or error code when performance-impairing situations are found. such

codes are typically very specific and will speed up the process of problem diagnosis. These are a few of the more

typical alarms and faults:

• Warning of Low Temperature: The process temperature has dropped below the temperature value that the
user established. This can be caused by an inadequate heat load or a low-temperature alarm set too high.
• Warning of High Temperature: The process temperature has exceeded the temperature limit that the user
selected. This can be a result of a high heat load or a low high-temperature alarm setting.
• Safety Alarm for Over-Temperature: Indicates that the process temperature has surpassed a safety cutoff
that has been specified by the manufacturer or the user. A refrigeration system issue or a safety setting that
is too low in temperature could be to blame for this.
• Warning for Low Liquid Level: The reservoir no longer contains an adequate amount of coolant. Leaks in the
circulation system or evaporation could be to blame for this.

Types of Chillers

Some of the most common chillers include:

Air-cooled chillers: Air is used by these chillers to remove heat from a system or process. They are frequently utilized

in circumstances where there is not enough room or where water is not easily accessible for cooling.
Water-cooled chillers: These chillers use water to cool a system or process. They need a water source and a way to get

rid of the heated water, but they are more efficient than air-cooled chillers.

Evaporative chillers: These chillers remove heat from a procedure or system by causing a liquid (like water) to

evaporate. They are frequently utilized in arid or dry regions when the surrounding air is generally chilly and dry.

Absorption chillers: To remove heat from a system or process, these chillers employ a chemical absorption

mechanism. As they may be fueled by a number of energy sources, they are frequently employed in applications

where electricity is not easily accessible (such as natural gas or solar energy).

Screw chillers: These chillers remove heat from a system or process by compressing and expanding a refrigerant using

a screw-type compressor. They are renowned for being highly effective and dependable.

Vapor Compressor chillers: Vapor compressor chillers use a compressor to pump refrigerant which extracts unwanted

heat from a process. The components of the system are the same as in the absorption type – we have an evaporator,

a condenser, and an expansion unit. However, there is no absorbent medium in the unit.

The Solution – Preventive Maintenance

A software tool that can be used to organize maintenance duties and operations for chillers and other equipment is

called a computerized maintenance management system (CMMS). A CMMS can assist in managing chiller issues in a

number of ways, including:

Routine inspections, cleaning, and other preventative maintenance operations for chillers can be scheduled using a

CMMS, and they can be tracked. This can assist in spotting and resolving possible issues before they arise.

Used to record maintenance operations, including the type of work done, the components and materials used, and

the outcomes of any diagnostic tests. Maintenance activities can then be analysed. With the use of this data, trends

can be analysed and recurrent problems that may require attention can be found.

Create work orders for maintenance jobs and send warnings to the proper staff when they are approaching their due

dates or when problems are found. This can make sure that maintenance jobs are finished on time and that any

problems are fixed right away.

Providing real-time visibility into maintenance activities: A CMMS can provide real-time visibility into the status of

maintenance tasks and equipment, allowing maintenance staff to quickly identify and address any issues that arise.

Giving maintenance staff real-time visibility into maintenance activities: A CMMS can give maintenance workers real-

time visibility into the status of maintenance jobs and equipment, enabling them to see and resolve any problems as

they develop.