From Faults to Optimization: A Full-Process Troubleshooting and Solution Guide for Refrigeration Equipment

As summer arrives, the operational load of refrigeration equipment in industries such as chemicals, pharmaceuticals, and new materials increases significantly due to high ambient temperatures. With more frequent usage, issues such as compressor overload, rising condensing pressure, and reduced heat exchange efficiency are more likely to occur. If not handled properly, these faults can disrupt process stability and even pose safety risks. Therefore, understanding the common types of refrigeration equipment failures and their corresponding solutions is critical to ensuring production continuity and equipment reliability.

 

1. Potential Equipment Failures

 

Refrigeration System Issues

 

Refrigerant Deficiency: Insufficient refrigerant charge is a common problem. As the refrigerant plays a key role in transferring heat, its shortage prevents effective cooling. Causes include natural leakage over time, damaged components, or poor sealing at pipe joints, evaporators, or condensers.

 

Compressor Faults: As the core of the refrigeration system, compressor failures significantly reduce cooling capacity. Common issues include piston or cylinder wear that lowers compression ratios, or motor malfunctions preventing normal operation.

 

Condenser Problems: The condenser must cool high-pressure refrigerant gas into liquid. Poor heat dissipation due to dust accumulation or fan failures leads to reduced cooling performance.

 

Expansion Device Failures: Devices such as expansion valves regulate refrigerant flow and pressure. Blockages, sensor malfunctions, or valve defects can cause unstable flow and impaired cooling efficiency.

 

Electrical System Issues

 

Temperature Sensor Faults: Malfunctioning or aging sensors provide inaccurate signals, leading to improper control responses and abnormal operation.

 

Controller Failures: As the "brain" of the system, controller malfunctions—such as circuit board damage or program errors—can disrupt temperature regulation.

 

Power Supply Issues: Voltage fluctuations or low supply voltage can hinder compressor operation, causing startup failures or reduced cooling capacity.

 

Other Operational Problems

 

Insufficient Insulation: Aging or damaged insulation, or poor sealing of enclosures, allows excessive heat infiltration, increasing cooling loads.

 

Excessive Load: Overloading the equipment with too many or high-heat items exceeds design capacity, making it difficult to reach set temperatures.

 

Poor Air Circulation: Frost accumulation on evaporators or fan failures block airflow, causing uneven temperature distribution.

 

2. II. Solutions to Equipment Failures

 

After outlining the potential issues that may arise during the operation of refrigeration equipment, we will now draw on practical experience and technical insights to present feasible optimization and troubleshooting solutions for daily maintenance and operation.

 

• Check refrigerant pressure and charge; locate and repair leaks before recharging refrigerant.

 

• Inspect compressor performance, including motor condition and compression ratio; repair or replace faulty units.

 

• Clean condenser surfaces and verify proper fan operation.

 

• Inspect and service the expansion valve; clean blockages, adjust flow, or replace if necessary.

 

• Test temperature sensors and controllers; replace or repair defective components.

 

• Monitor power supply stability and ensure voltage remains within specified limits.

 

• Inspect and maintain insulation materials; repair or replace damaged insulation and improve sealing at doors and joints.

 

• Optimize load management inside refrigeration equipment; avoid overloading.

 

• Remove frost buildup on evaporators and confirm fans operate properly to ensure smooth air circulation.

 

Refrigeration equipment plays a pivotal role in industries such as chemicals, pharmaceuticals, and new materials. Even minor faults can trigger a chain reaction, leading to process instability and safety hazards. During high-temperature seasons and heavy-duty operation, adopting the principle of “early detection, prompt response, and proactive prevention” is essential to maintain stable and safe production. The analysis and solutions presented in this article aim to provide practical guidance for frontline maintenance teams and lay a solid foundation for the long-term development of enterprises.