Category Archives: chiller service

Chilling Plant Service

Chilling Plant Service

Our customer had been having high pressure service problems on his chilling plant

Transducer Required Chilling Plant Service

The 4-20mA transducer needed service on the chilling plant. It was reading low by a long shot. Therefore, the PLC was not bringing the fans on as it should. The pressure in the high side of the system was getting up to 40 bar. This is because the refrigerant was R410a- it has a higher head pressure than other commonly used HFC refrigerants, such as, R407c. We ordered the replacement transducer which is fitted with a female fitting

Chilling Plant Service Leaks

He concentrated his attention on the high side of the system to start with. Then, found a leak on a fitting, a leak on the pressure relief valve fitting and a leak on the liquid line near the drier. The leak on the fittings were re sealed with Loctite- they were removed, cleaned and refitted. The leak on the liquid line was re sealed by removing the section of pipe, removing any remaining solder then the section of pipe was re made

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Pressure Test

The remaining parts of the system were leak tested then the chilling plant was put on a pressure test to ensure the whole system was leak free. The pressure test was satisfactory and so the evacuation process could be started

Evacuation Process 

Each of our engineers has a powerful vac pump to speed up the dehydration process on the chilling plant being serviced. This means that a deep vacuum can often be pulled on the same day instead of the usual overnight process. The nitrogen and other non condensables were removed quickly and the Torr gauge came down to the pressure where moisture was being removed. At this pressure, any moisture is forced to boil off around the system

Recharging of the Chilling Plant Being Serviced

In the photo, the chilling plant is being recharged at the end of the service work. It is being recharged into the liquid side of the evaporator. All readings were okay when running the system and further leak tests were carried out at normal operating pressures

Read more about refrigerant reclamation by following this link to Wikipedia | Click Here


Carrier Chiller Service in Moscow

Carrier Chiller Service

Category : chiller service

 

Our customer in Moscow had been emailing our technical support desk regarding the service of his Carrier chillers

Flow Issues

There had been ongoing issues with blocked strainers on the water system. Each time they were cleaned, they blocked back up again. A large dirt trap near to the chiller also needed to be repeatedly cleaned out. A problem with dirt being carried round the water system

Flush Out Service for the Carrier Chillers

The end user had employed a local company for a flush out service for the Carrier Chillers. The company first drained the water system and refilled it with various chemicals. There is a chemical to lift the dirt off the inside of the pipe. Another chemical to carry it back. Another chemical to bond with the heavier elements

Carrier Chiller Service Readings

The readings taken during the Carrier chiller service were wrong by a long shot. There was a serious restriction in flow to the chiller. Safety devices were activated on the chiller to prevent system failure. If not for these safety devices- the chiller would be ruined. More than one device was preventing the chiller from freeze up

0161 370 7193

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Service of the Water System

The water system was drained down to service the plant. The inlet to the evaporator was removed for inspection. A Considerable amount of sludge was found to be blocking the inlet to the evaporator. The pipe was bolted back on, the water system was refilled then emptied in the reverse direction to the water flow. The water system was filled again and system readings taken

Service to the Carrier Chiller

The service to the Carrier Chiller was found to be satisfactory as the water system readings were okay. No safety devices were being activated and a good run was achieved from the Carrier chiller. All other readings were taken as part of giving the chiller a full heath check. As always a detailed Tick Sheet was completed. Our engineer demonstrated to the on site engineers how to back flush should the issue arise again

Read about legionella and how it can affect a chilled water system on Wikipedia 


Chilled Water System Service near Saint Basil's Cathedral

Global Chilled Water System Service

Moscow Visit

Always good to get out of the country to carry out chilled water system service around the globe. Just had a little free time this visit to see Red Square and Saint Basil's Cathedral. Most of the visit was bogged down resolving issues

Electrical Problems

One of the water cooled chillers was pumping down due to electrical problems. One of the solenoids for the evaporator was not opening. All checked out okay with the solenoid coil and valve. Following the wiring diagram lead to the relay board. The relay board is responsible to run various components around the compressor. It was not obviously blown and there were no dry soldered joints on the back. I decided to tighten up the wiring and unplug, then plug all the connectors back in. When I ran the chiller again the problem went away

Chilled Water System Global Service

As we provide a global service for chilled water systems: we cannot get back the day after leaving site. Therefore, after resolving the above issue, I ran the system in local with some of the other systems off to prove it. All was okay. After completing the rest of the service on the chillers I put the whole of the plant back in Auto to prove it all together

0161 370 7193

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Flow Switch Failure During Global Chilled Water System Service

The flow switch failed in one of the most remote plant rooms in the globe for chilled water system service. This is due to security issues. As one of the service checks- I tried to trip the chiller on flow fail. The chiller did not stop. I didn't want to valve off the water system repeatedly as the air handlers are old and 'dead heading' could cause failure. Instead I decided to use the Hand/ Off/ Auto switch for the pump. There are two adjusting screws on the flow switch. After several attempts I got it to settle down, then carried out tests to make sure it would not happen again

Read More industry news on the Refcom website

 


Chilled Water System EEV Service

Chilled Water System Service of EEV

The Expansion Valve Required Chilled Water System Service

Chilled water system service was being carried out because the mechanical parts of the expansion valve had failed. This particular valve is prone to this fault. It is an OEM part so our technician found the voltage for the motor and found a similar part with the same amount of steps

Electronic EEV Driver

The EEV driver was found to be functioning satisfactorily. Sometimes, depending on how the mechanical part has failed, this can be overloaded and burned out

Electronic Component Refurbishment

Where electronic parts, such as the EEV driver, are found to be burned out- Maximus Chillers has a refurbishment laboratory at head office. We have the capability to strip down the component and fault find where it has blown. Usually it is quite simple: the jammed mechanical part of the electronic expansion valve has burned out the power control on the driver for example. More complex fault finding and component replacement on the circuit board can be carried out also. Another option is to replace the driver with a like for like swap or retrofit to a different driver. In any case- we have the ability for: any part- any problem- any refrigerant anywhere

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Pump Down of the Chilled Water System

The chilled water system was easily valved off and pumped down. This saves on the time and recovery vessel to pump the refrigerant out

Remove and Replace

Once pumped down, our engineer removed and replaced the valve, sealing it on it's knife edge seal. The wire was passed up the conduit and into the panel. The wiring colour scheme was different on the new valve so some time was taken to ensure it was wired up correctly

Open it up and Switch it on

After leak testing, the refrigerant system valves were opened back up and the plant switched back on. The correct superheat and subcooling valued were achieved concluding a successful chilled water system service visit

To read the Institute of Refrigeration guide to expansion valves Click Here


Chiller Evaporator after Service

Water Chiller Service of Evaporator

Service to Water Chiller Shell of Evaporator

Not often does water chiller service to chiller evaporator fault occur. Usually the evaporator has frozen up and burst the tubes inside the shell. This fault involved the shell of the chilled water system itself bursting. On close inspection- the shell was made out of thin steel- not the usual heavy rolled steel. It looked like the near end on the photo had sagged down, causing the evaporator shell to buckle

Replacement of Evaporator

This option would be expensive due to the cost of the evaporator. It would be a difficult  visit because of access issues. The builders decided to site the water chillers round the back of the building. This makes glycol chillers very difficult to service. A dedicated lift and shift company would be needed to get the old chiller evaporator out and the new on in. There is a difficult corner to get round where the evaporator would have to be tilted up to get it round. Also, a fence wound have to be taken down around the chillers. Of course security is an issue but so is chilled water system service to glycol chillers and air cooled chillers

0161 370 7193

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Water Chiller Service with Silver Solder

Because of the above it was decided by the customer to attempt water chiller service using silver solder. The Risk Assessment Method Statement allowed for the chilled water system service to be carried out with a half hour fire watch. The oxy-acetylene lines were leak tested prior to the job. Both leaks were soldered up but despite the evaporator being drained down, there was still water and steam trying to get out. Not the best water chiller service soldering resulted- but it held

Air Cooled Chiller Paintwork

Because air cooled chillers are usually outside- the chiller paintwork is essential. Poor water chiller service of paintwork will reduce the it's life. After preparing the surface, direct to rust paint was applied so as to protect it for the future

Lagging Service for Glycol Chiller

The main purpose of Armour Flex lagging is to reduce heat gain from the environment to the water chiller being serviced. This provides protection from the elements for the glycol water chiller as well

See the Institute of Refrigeration Evaporator efficiency Click Here

 


Service of the chiller's Fan Speed Controllers

Chiller Service of Fan Decks

Category : chiller service

Chiller Service of Fan Decks Bodger Watch

The chiller service of fan decks is usually very good, but this is bodger watch!

A new customer of ours was telling me about this little guy that used to come to carry out chiller service of fan decks. He was reported to have been running around like the apprentice- ringing everybody up! Then when help came, it came in the form of this huge big man who proceeded to get stuck in the chiller! You couldn't make it up! This is bodger watch! The customer needed some professional chiller service from Maximus Chillers

Repeated Leaks on Chilling Plant

Our engineer found the head pressure control was bringing the fans thumping on and off forwards and backwards. During a chiller service visit the fans were found to be rattling the frame and juddering the chiller into leaks

0161 370 7193

service@maximuschillers.com

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Learning How to Think

Instead of just swapping like for like parts. Our engineers have the capability to think outside the box and make changes to chiller design. Our ex-services engineers attend the Maximus School of Chillers at Head Office in Droylsden, Manchester. Read More on the Chiller Company page

Fan Speed Controller

Maximus Chillers fitted off the shelf, Carel fan speed controllers from our stores, on a chiller service visit. We fitted one for each system. These fan speed controllers are stand alone- they do not need to be integrated into existing chiller service controls. When the pressure builds up- the fan speed controller speeds the fans up from the minimum (cut in) to the maximum (same volts as the incoming supply)

Chiller Service of Fan Decks Seamless Operation

Now the fan speed controllers are fitted- there are no more leaks. Any chiller can be made to settle down into seamless operation. This is done through chiller service and chiller upgrade

Are you a factory manager or facilities manager? Tired of expensive service for your chillers? Look no further than Maximus Chillers Click Here

Visit the Institute of Refrigeration to read a paper on the comparison between air cooled condensers and evaporative condensers


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