Troubleshooting and Solution Guide for Chiller Low Pressure Faults
Release time:
2025-06-20
Only by mastering scientific troubleshooting methods and combining them with equipment maintenance can the chiller's continuous and stable operation be ensured.
In industrial production, chillers, as core temperature control equipment, are widely used in various fields such as medicine, electronics, and food, playing a key role in ensuring process stability. However, low-pressure faults are one of the more common problems during equipment operation. When the compressor suction pressure is below 0.2 MPa, the low-pressure protection relay will automatically trigger, not only resulting in insufficient refrigeration capacity but also causing energy waste. The following are troubleshooting and solutions summarized by professional technicians.
I. Troubleshooting Abnormal Cooling Water Temperature
Problem Manifestation
- Starting the equipment when the ambient temperature is too low
- Insufficient refrigerant oil temperature, leading to incomplete refrigerant separation
Solutions
- If the cooling water temperature is low, the cooling tower can be turned off or the throttle valve can be adjusted to raise the water temperature to the normal range.
- For insufficient refrigerant oil temperature, extend the unit preheating time and wait for the oil temperature to rise before starting.
II. Expansion Valve Inspection and Repair
Causes of the Problem
- Sufficient refrigerant but the expansion valve opening is too small
- Valve blockage due to low-temperature operation or long-term shutdown
Handling Methods
- Such faults often occur after low-temperature operation or restarting after shutdown.
- No disassembly and repair is required; let the unit run for a while to restore normal operation.
III. Refrigerant Status Check
Abnormal Phenomena
- When a large amount of refrigerant leaks, the system equilibrium pressure drops sharply.
- The low-pressure alarm is triggered immediately after startup; it cannot start when the suction pressure is below 0.2 MPa.
Solution Steps
- Use an electronic leak detector to check the pipeline welds and valve connections.
- After welding the leaking parts, refill the refrigerant according to the standard.
IV. Evaporator Clogging Check
Fault Impact
- Reduced heat exchange efficiency; the refrigerant cannot evaporate normally.
- The inlet and outlet water temperature difference of the unit increases, and the refrigeration effect is significantly reduced.
Maintenance Measures
- Establish a regular backwashing system and use a special cleaning agent to remove impurities from the pipeline.
- It is recommended to perform chemical cleaning once per quarter to keep the heat transfer surface clean.
V. Low-Pressure Protection Device Inspection
Common Problems
- Relay dampness causing contact short circuit
- Poor line contact causing false alarms
Inspection Methods
- Use a multimeter to check the relay coil resistance; replace if the resistance is abnormal.
- Check the wiring terminals and clean or replace oxidized contacts.
VI. System Air and Water Circulation Problems
Fault Manifestation
- System air accumulation causing insufficient refrigerant water flow
- Water pump mismatch with the system, causing wet compression
- Frosting appears at the suction port, and the inlet and outlet water pressure difference decreases.
Solutions
VII. High-Precision Water-Cooled Chiller
- Core Differences: Compared with ordinary units, temperature control accuracy (±0.002℃ vs. ±0.1℃ or more), data monitoring (large-capacity storage, USB/Ethernet, MODBUS protocol), and application scenarios (semiconductors, lasers, medicine, etc., high-end fields).
- Application Scenarios: Semiconductor manufacturing (photolithography lens cooling, etching/deposition equipment), medical (MRI superconducting coils, cryo-electron microscopy), high-precision optics (lasers, astronomical telescopes), new energy (lithium battery coating machines, superconducting material testing), quantum computing (dilution refrigerator pre-cooling), food and pharmaceuticals (mRNA vaccine freeze-drying, fermenters).
- Core Technological Features: High-efficiency energy-saving design (international brand compressors, high-efficiency plate heat exchangers), precise temperature control (self-developed acquisition module, PID algorithm), low noise (≤65 decibels), intuitive operation (large-size touch screen, data export, safety protection).
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