Air-cooled chiller compressor failure diagnosis

Air-Cooled Chiller Compressor Failure Diagnosis – EKG M&E Sdn Bhd

At EKG M&E Sdn Bhd, we offer expert compressor failure diagnosis services for air-cooled chillers, helping you quickly identify the root cause of performance breakdowns and restore your system to full operation. Compressor failure can result from a range of issues—including electrical faults, mechanical wear, refrigerant problems, or improper maintenance—and early, accurate diagnosis is key to preventing costly downtime and future recurrence.

Why Compressor Failure Diagnosis Is Essential

• Identifies the exact cause of failure, preventing guesswork

• Helps prevent repeat failures and secondary damage

• Reduces repair time, costs, and operational disruption

• Supports data-driven decisions for repair or replacement

• Ensures system efficiency, safety, and performance restoration

Common Causes of Compressor Failure We Diagnose

• Electrical faults (winding burnout, contactor failure, phase loss)

• Refrigerant issues (low charge, flooding, contamination)

• Mechanical damage (bearing failure, valve breakage, locked rotor)

• Lubrication problems (oil starvation, contamination)

• Overheating due to poor airflow or overloading

• Improper installation or alignment

Our Compressor Failure Diagnosis Process

Visual and Operational Assessment
We begin with a full inspection of the compressor and chiller system, noting symptoms such as noise, vibration, oil leakage, and system shutdown behavior.

Electrical Testing
Using tools like megohmmeters, clamp meters, and thermal imagers, we check:

• Motor windings and insulation resistance

• Voltage and current balance

• Control circuit functionality

• Start-up and load behavior

Mechanical Analysis
We assess:

• Shaft rotation and internal noise

• Bearing condition

• Oil quality and circulation

• Discharge and suction pressures

Refrigerant System Check
We test for:

• Low or high refrigerant pressure

• Flash gas at the expansion valve

• Refrigerant contamination or acid presence

• Liquid slugging or migration to the compressor

Root Cause Identification and Reporting
You receive a detailed report outlining:

• Primary failure cause

• Contributing factors

• Damage assessment

• Recommended next steps (repair, overhaul, or replacement)

Benefits of Our Compressor Failure Diagnosis

• Avoids unnecessary part replacements

• Helps plan targeted and cost-effective repairs

• Prevents future failures through root cause correction

• Reduces downtime with accurate and fast diagnostics

• Supports equipment warranty and insurance claims

Why Choose EKG M&E Sdn Bhd?

• Experts in chiller systems, compressors, and root cause analysis

• Equipped with advanced diagnostic tools for electrical and mechanical faults

• Experience with all major air-cooled chiller compressor types

• Trusted by industrial, commercial, and facility managers nationwide

• Full service from diagnosis to repair and recommissioning

Final Thoughts

When a compressor fails, you need answers fast. With EKG M&E Sdn Bhd’s air-cooled chiller compressor failure diagnosis, you get clear, accurate insights and reliable solutions to restore performance and prevent future breakdowns. Contact us today to schedule a diagnostic assessment.