HFC Chiller Service

Green Bitzer compressor being vacuumed during HFC chiller service

HFC Chiller Service

The HFC chiller being serviced in the photo is 600kw. It consists of two systems with a large Bitzer compressor for each system. It has a bespoke Micro Control System front end to run the machine and stop it should there be a fault condition. The chiller had been reported by the customer to have tripped out on a low pressure fault.

HFC Chiller Diagnosis Service

The readings of superheat and subcooling are available in the controller of the HFC chiller being serviced. This removes the need to fit instrumentation carried by our engineers. The process of diagnosis was therefore speeded up. The result being that the chiller was found to be running short of refrigerant.

Return Visit to Decant the Refrigerant

A Quote was submitted to the customer for approval. Once the Order was raised, a convenient time was arranged to return to site and carry out the HFC chiller service. The remaining charge of refrigerant was decanted into our recovery vessels with one of our fast pump out units which are carried by each of our engineers.

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Looking Around the Pipework for a Leak

Nitrogen, an inert gas, was introduced into the system to assist in the location of the leak. The leak was quickly found on one of the end turns of the condenser.

Brazing and Pressure Testing

Our engineer made good the leak using his brazing torch. Then, the integrity of the system was proven to industry standards with a system pressure test.

The Evacuation Process for HFC Chiller Service

The picture shows a 10 cfm (cubic feet per minute) vacuum pump being used to dehydrate the system during HFC chiller service. Each of our engineers carries a vacuum pump of this capacity as it speeds up the process. One refrigerant hose being fitted to the discharge pipe and another, smaller hose being fitted to the suction pipe. The system being vacuumed to a deep vacuum.

Recharge and Run Testing

After the chiller had been recharged with some of the charge of the refrigerant R134a, the remaining refrigerant was charged in its liquid phase, away from the compressor, until the superheat and subcooling values were within industry limits. A large amount of load was available as the chiller feeds an air blown film plastic manufacturing facility.

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Read more about a film blowing machine on Wikipedia | Click Here


Yellow oil drums, ammonia refrigerant cylinders and flammable flushing agent of chiller refurbishment supplier

Chiller Refurbishment Supplier

Maximus Chillers is an established chiller refurbishment supplier. Maximus means the highest and the greatest in Latin, so we pride ourselves in offering the highest and the greatest customer service and technical capability. There is never a job too big for Maximus Chillers- we are seasoned in following a problem through to the logical solution.

Chiller Refurbishment Supplier

Parts

Any part is available to our contract customers. We have a worldwide supply chain of the best suppliers. This means any part or refrigerant can be sourced at your convenience. When a part is not available, a different part of the same design specifications is selected and usually delivered same day. By same day we mean: the part is loaded into a van- then and there- and driven to site!

Oil and Refrigerant

We keep a stock of oil, refrigerant and other materials in our stores- see picture. This provides you with 'round the corner' convenience to your factory or facility. Whatever kind of ammonia grade specialist oil you require- we have it on the shelf. With a comprehensive range of other chemicals and solvents- Maximus Chillers completes the picture.

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Chiller Refurbishment Diagnosis

Our engineers are in their comfort zone while carrying out diagnosis during chiller refurbishment- that is what they do best! Even when a fault involves wiring that disappears into a loom, down the other end of the machine, with no wiring diagram- Maximus Chillers can help. Usually, however, faults are obvious to our engineers or can be found easily.

Technical Support Desk

Our contract customers enjoy the full benefit of our global technical support desk. We offer real time technical support with manuals being sent electronically to site. Where a time difference is involved, we arrange a time convenient to both locations, or answer emails when the office opens in the morning. If we can talk you through over the phone, we can get you up and running with the minimal disruption to your process.

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Chiller Condenser Retrofitting

Visit the ASHRAE for Standards and Guidelines Under Continuous Maintenance


A chiller condenser retrofitting lifting operation outside in the compound

R407c Chiller Condenser Retrofitting

We recently undertook the job to carry out bespoke R407c chiller condenser retrofitting in the North West.

Rusted and Corroded Condenser

The old condenser looked alright on the surface- the fins were in good condition. The chiller condenser was 18 years old and when an attempt to repair a leak was carried out- the condenser leaked further along. This is because of the warming of rusted and corroded copper with an oxy-acetylene torch.

R407c Chiller Condenser Retrofitting

We arrived on site to measure up for the job. The ‘V’ chiller condenser being retrofitted was built to order. We manufactured an exact replica to the same specifications and sizes of the old one. The operating pressures and high pressure cut out limit were taken into account in the design and the use of materials.

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Lift Out of the R407c Chiller Condenser being Retrofitted

On the day of the lift and shift we isolated the panel and checked it was dead, then we removed the panel and laid it on it’s front. This was to access the rivets behind the panel. These rivets, the ones on the other end of the chiller and around the lid were removed using a tool. The fans were disconnected and removed to make the lid lighter to lift off. Then, we attached slings to the chiller condenser and lifted both halves of the 'V' out.

Lift In of the Chiller Condenser being Retrofitted

This part we did not want to get wrong as the R407c chiller condenser being retrofitted was brand new and did not have a mark on it. A reverse of the removal- it fitted perfectly just the same as the old one. With the lid lifted back on and the fans in- time for brazing then the pressure test.

Pressure Test, Dehydration and Recharge

The pressure test was satisfactory so our engineer put the system on vac for dehydration purposes and the removal of non condensables. After a deep vacuum was achieved the system was recharged and run tested. No issues were found.

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Read more about air cooled condensers at the Institute of Refrigeration Click Here


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