Troubleshooting Common Chiller Problems – A Comprehensive Guide

A properly maintained chiller system is essential for maximizing performance, reducing energy costs, and extending the lifespan of the equipment. However, even with regular servicing, chillers can still experience operational issues due to wear and tear, environmental factors, or improper usage. Understanding these common problems and how to troubleshoot them can prevent costly downtime and system failures.

In this guide, we’ll cover:

• Common chiller problems

• Causes of chiller issues

• Troubleshooting techniques

• Preventative maintenance best practices

• Steps to take if replacement parts are needed

Common Chiller Problems and Their Causes

Even well-maintained chillers can develop issues over time. Some of the most frequent chiller problems include:

• Insufficient cooling

• Chiller failing to start

• Low coolant levels

• Poor water or refrigerant flow

• Low or high-temperature alarms

• High or low-pressure alarms

These problems often arise due to factors such as poor operating conditions, lack of preventive maintenance, or incorrect system sizing. If a chiller is not operated or serviced correctly, it may consume excess energy and be more prone to breakdowns.

How to Troubleshoot Common Chiller Problems

1. Insufficient Cooling

If your chiller is not providing adequate cooling, check the following:

• Ensure the coolant temperature at the outlet is within the recommended range.

• Inspect the condenser and evaporator coils for dirt or debris that may be reducing heat exchange efficiency.

• Verify that refrigerant levels are adequate and there are no leaks.

• Check the compressor operation to confirm it is running efficiently.

2. Chiller Won’t Start

A non-starting chiller can be caused by electrical issues. Troubleshooting steps include:

• Checking for loose wiring or damaged electrical connections.

• Inspecting circuit breakers and fuses to ensure they are intact.

• Confirming that all power switches are in the correct position.

• If none of these resolve the issue, professional servicing may be required.

3. Low Coolant Level

A chiller with low coolant levels may trigger an alarm. To address this:

• Check for leaks in the coolant circuit and repair them promptly.

• If evaporation is the cause, refill the coolant to the recommended level.

• Ensure the system is sealed properly to prevent further loss.

4. Insufficient Pumping

Poor coolant circulation can result from various issues, such as:

• Partially closed valves restricting flow.

• Blockages in process lines reducing efficiency.

• A failed pump preventing proper coolant movement.

• Low coolant volume affecting the system’s performance.

5. Temperature Alarms (High or Low)

If the chiller is operating outside its temperature limits:

• Verify that the heat load is appropriate for the chiller’s capacity.

• Check if temperature setpoints are correctly configured.

• Inspect the glycol tank to ensure the mixture is at the correct concentration.

• If the issue persists, a deeper system inspection may be needed.

6. High or Low-Pressure Alarms

Pressure-related alarms can indicate potential system failures.

• High-pressure alarms may be due to a dirty condenser, poor airflow, or a faulty fan motor. Cleaning the condenser and ensuring proper ventilation can help resolve the issue.

• Low-pressure alarms might stem from refrigerant leaks, pump failures, or blockages. Checking for leaks and ensuring proper refrigerant flow is critical to troubleshooting.

Preventative Maintenance for Long-Term Reliability

Preventative maintenance is essential to keep chillers running efficiently and avoid unexpected failures. Regular maintenance tasks should include:

• Cleaning and inspecting evaporator and condenser coils.

• Monitoring refrigerant and oil levels.

• Checking pumps and circulation systems for optimal performance.

• Inspecting electrical connections and control panels.

• Ensuring proper system calibration for load and efficiency.

When to Seek Professional Support or Replacement Parts

If troubleshooting efforts do not resolve the issue, professional servicing may be necessary. In cases where chiller components are worn out or damaged, sourcing high-quality spare parts is essential for maintaining reliability.

At Kaydeli, we provide expert support, preventative maintenance solutions, and a comprehensive range of chiller spare parts. Whether you need a replacement compressor, fan motor, or filter drier, our team is here to ensure your chiller system operates at peak performance.

Contact Kaydeli for Reliable Chiller Solutions

If your chiller is experiencing persistent issues, don’t wait for a major breakdown. Contact Kaydeli today for expert troubleshooting, maintenance services, and high-quality spare parts to keep your system running smoothly and efficiently.