How can I reduce the risk of chiller breakdowns?

The environment in which a chiller operates can have a significant effect on its performance and reliability.

ATC’s standard chillers are designed for indoor installation and should be operated within the environmental conditions specified for the particular model.

Make sure that:

• Ventilation openings remain unobstructed
• The chiller has sufficient space for airflow
• Hot discharge air cannot easily recirculate back into the chiller
• The local ambient temperature remains within the specified operating range
• The equipment is protected from excessive dust, contamination, and moisture
• There is sufficient access for inspection and maintenance

Remember that the temperature immediately around the chiller can be higher than the general room temperature, particularly where several pieces of heat-generating equipment are installed nearby.

For an air-cooled chiller, the condenser needs an unrestricted supply of air to reject heat effectively.

Dust, fluff, and other debris can accumulate on the condenser and restrict airflow, potentially affecting cooling performance and increasing the demands placed on the refrigeration system.

ATC recommends checking the condenser monthly for accumulated dust or debris.

Where cleaning is required, follow the instructions in the operating manual for your particular chiller. Always isolate the electrical power supply before cleaning.

A vacuum cleaner is recommended for routine condenser cleaning where appropriate. Do not use compressed air to blow out the condenser.

The condition of the process fluid can affect cooling performance and the long-term condition of components within the coolant circuit.

For standard ATC chillers, use the specified Hexid or CoolFlow inhibited glycol-based coolant at the appropriate concentration for the equipment and operating conditions.

Approved inhibited coolants help to provide corrosion protection, inhibit biological growth, and protect components including pumps, seals, and heat exchangers.

Check the fluid condition and level as part of routine maintenance and investigate significant changes in appearance, contamination, or unexplained fluid loss.

Do not introduce tap water, DI water, oil, or another alternative fluid into a standard chiller without first confirming its suitability with ATC.

You do not need to wait for an annual service to pay attention to the condition of your chiller.

Regular visual checks can help to identify developing problems such as:

• Fluid leaks
• Damaged or deteriorating hoses
• Unusual fluid condition
• Blocked ventilation areas
• Excessive condenser contamination
• Unexpected noises or vibration
• Repeated alarms or warnings
• Changes in operating temperature or cooling performance

If something has changed from the chiller’s normal operation, investigate it rather than waiting for the problem to become more severe.

Refer to the operating manual for your particular model for the routine end-user maintenance requirements applicable to your equipment.

A developing problem does not always result in an immediate breakdown.

Changes such as difficulty maintaining the required setpoint, repeated alarms, unusual noises, or changes in coolant flow can indicate that something requires attention.

If your chiller begins behaving differently, record the symptoms and contact ATC if the cause cannot be identified through the normal user checks in your operating manual.

See “What should I do if my chiller displays an alarm or fault?” and “What information do I need when requesting technical support?” for further guidance.

The chiller is only one part of the complete cooling circuit.

Problems elsewhere in the installation can affect chiller operation, so hoses, pipework, connections, and the equipment being cooled should also be inspected and maintained appropriately.

Make sure that the cooling circuit provides a continuous flow path and that hoses and pipework are correctly sized, routed, and free from visible restrictions.

If changes are made to the process or cooling circuit, consider whether they could alter the heat load, coolant flow, or other operating conditions experienced by the chiller.

ATC recommends preventative maintenance at least once a year.

A preventative maintenance visit provides an opportunity to assess the overall condition and operation of the chiller, including the refrigeration system, fluid circuit, condenser and airflow, electrical and control systems, operating performance, and condition of key components.

The aim is to identify developing issues before they result in more significant problems or unexpected downtime.

Following the visit, ATC provides a service report with recommendations so that further maintenance or repairs can be planned where necessary.

Contact ATC if you notice:

• Repeated alarms or faults
• Difficult maintaining the required temperature
• Unexpected changes in coolant flow
• Fluid leaks
• Unusual noises or vibration
• Visible damage or deterioration
• A significant change in the condition of the process fluid
• Any other unexplained change in chiller performance

Providing the model, serial number, fault details, operating temperatures, and relevant photographs can help our team assess the issues more efficiently.

Regular checks, correct operating conditions, and preventative maintenance cannot eliminate every potential fault, but together they can help to maintain performance, identify developing problems earlier, and reduce the risk of avoidable downtime.