Chillers need to operate continuously for extended periods after startup, so some components are susceptible to natural wear and tear and accidental damage. Waiting until replacement parts are needed beforehand can result in significant downtime and production delays. The average repair cycle for some core components is 7-10 days, and this time can be extended if they’re out of stock. Therefore, it’s ideal to stock frequently used parts in advance to expedite repairs and replacements. This article explains common wearing parts and critical spare parts to help you plan ahead.

Classification and Management of Chiller Spare Parts

Chiller spare parts come in many types and quantities. To facilitate procurement and management, they can be categorized from the following four perspectives:

Function-Based

The most common classification method is based on the main system modules within the chiller.

• Refrigeration System: The core components used in the refrigeration cycle largely determine the equipment’s cooling efficiency and stability, including the compressor, condenser, evaporator, expansion valve, filter drier, and refrigerant.

• Electrical Control System: The components used in the electrical control system affect automatic and remote control functions, including PLC controllers, temperature sensors, contactors, relays, power modules, and display panels.

• Water circulation system: Consists of circulation pump, water filter, water tank, solenoid valve, flow switch, and water supply valve.

• Structural and auxiliary components: The fan, motor, vibration damper, seals, hinges, housing, and insulation are not directly involved in cooling, but they affect cooling efficiency and user experience.

Based on replacement frequency

Different components have different service lives. Procuring spare parts in advance can reduce downtime.

• High-frequency consumables: The filter drier, хладагент, seals, and fan blades require regular inspection, replenishment, or replacement during operation.

• Medium-frequency maintenance: Components such as the expansion valve, sensor, solenoid valve, water pump, and contactor generally begin to deteriorate after several years of operation and can be replaced during annual maintenance.

• Low-frequency replacement parts: The compressor, controller, and power board require infrequent replacement, but damage can cause the entire unit to fail.

Based on versatility

Components used in chillers include both universal and specialized parts.

• Universal parts: Universal parts have standardized dimensions and are compatible with many models. Examples include Y-type filters, temperature probes, valves, and seals. These parts can be purchased through multiple channels.

• Specialized Parts: The control boards and sensors used in some custom chillers are specific to the equipment and difficult to replace. This requires contacting the chiller supplier for custom parts.

Based on Purpose

• Maintenance: These spare parts are used for regular and preventative maintenance, such as filters, refrigerants, and lubricants.

• Troubleshooting: Some spare parts are only needed when a device malfunctions and requires replacement, including compressors, power boards, displays, and fans.

• Upgrades: These parts are rarely used and are only considered when upgrading energy efficiency, functionality, or adapting to new processes. Examples include higher-precision control systems and higher capacity water pumps.

Below is a categorized spare parts checklist, with suggested stocking levels based on typical replacement frequency.

Chiller Spare Parts Management List
Category	Part Name	Function Description	Stock Suggestion
Refrigeration System	Компрессор	Core part for refrigerant circulation	Да
	Испаритель	Absorbs heat and evaporates refrigerant	No
	Конденсатор	Releases heat and condenses refrigerant	No
	Расширительный клапан	Regulates refrigerant flow and system pressure	Да
	Dryer Filter	Removes moisture and impurities from system	Да
	Sight Glass	Shows refrigerant condition	No
	Хладагент	Working fluid for heat absorption and release	Да
Electrical System	Controller / PLC	Controls system logic and automates operation	Да
	Датчик температуры	Measures temperature and enables control	Да
	Contactor / Relay	Controls motor and compressor switching	Да
	Power Module	Provides stable power or voltage conversion	Да
	HMI (Human-Machine Interface)	Interface for parameter viewing and setting	Да
Water Circuit	Water Pump	Circulates cooling water or coolant	Да
	Water Filter	Filters debris and protects pump and heat exchanger	Да
	Solenoid Valve	Controls water flow on/off	Да
	Flow Switch	Detects water flow, triggers protection logic	Да
Structural Parts	Fan Motor	For air-cooled heat dissipation	Да
	Sealing Gasket	Ensures leakproof connections	Да
	Vibration Pad	Reduces vibration and protects structure	No
	Insulation Layer	Prevents heat loss and condensation	No

Советы

1. Spare part models must match the industrial chiller. List part models by equipment model in advance for easier procurement.

2. Consider using a CMMS (Computerized Maintenance Management System) to track inventory and maintenance history. Record parts that are frequently replaced during maintenance to facilitate spare part procurement.

3. Communicate with the chiller manufacturer for recommended spare parts packages. Purchasing from the manufacturer or an authorized service provider offers greater security.

4. Establish an electronic spare parts archive for long-term management.

Заключение

LNEYA provides a spare parts management list for all chillers. Most components in our equipment are standard, internationally renowned brands, making purchasing easier. We can also provide spare parts packages if needed. If you have questions about spare parts management or would like a quote, please contact LNEYA!