Here at Maximus Chillers, we carry out scroll chiller compressor maintenance to extend the lifespan and reduce downtime to your critical plant. This planning ahead is central to how we do things- we resolve small problems before they become big problems. Having the capability to do anything is part of what we call the MAXIMUS ADVANTAGE™ Any Chiller- Any Problem- Any Part- Any Refrigerant- Anywhere.
How they Work
The refrigerant vapour passes in between two scrolls (spirals) One of these is fixed, the other orbits backwards and forwards against the fixed scroll using a swing link. This creates a series of crescent shaped gas pockets in between the scrolls. These gas pockets get smaller in size as the refrigerant travels from the suction at the edge, down the spirals to the discharge at the centre. It then leaves downwards through a port. There are check valves to prevent back feeding of refrigerant during off cycles when other compressors on the same system are still running.
There are several gas pockets occurring at any one time through the scroll, therefore giving a smooth and continuous compression cycle. Other advantages are low internal friction resulting in a quiet operation and low vibration levels. These low vibration levels help to lower the occurrence of leaks around the compressor.
Oil Level during Scroll Chiller Compressor Maintenance
The correct oil level is noted on our detailed Tick Sheets for all of the compressors. This record helps with the diagnosis when things start to go wrong. We can look for a pattern where the level starts to drop off in the compressors on a particular system, then look at the other readings which may be the cause.
Oil Samples during Scroll Chiller Compressor Maintenance
At periodic intervals, we take oil samples which we analyse in our laboratory at Head Office in Droylsden. We look for white metal, coloured metal, refrigerant composition, acid and sludge. This means that we can notice, then resolve system issues before a costly compressor failure occurs.
Oil Changes during Scroll Chiller Compressor Maintenance
This kind of compressor is fitted with a service port for the draining and filling of oil. The correct procedure is followed due to system pressure being present inside. We then carry out the oil changes using our specialist oil handling tools. Our skilled engineers carry the correct PPE for the work being carried out. We also we provide Risk Assessment Method Statements for each job.
0161 370 7193
Crank Case Heaters
In the photo you can see the silver band of the crank case heaters at the bottom of the compressors. They keep the oil at the required temperature so as to not cause compressor wear on start up. The heaters also have the effect of ensuring that the refrigerant cannot condense into liquid during cold weather. As a compressor cannot compress a liquid, compressor failure would occur. A normally closed contact on the delta compressor starter contactor usually runs the heater: it drops out when the compressor starts. The function of all of these heaters is checked on each maintenance visit.
It is critical that the discharge temperature is not too high, as this is the cause of the refrigerant breaking down into acid and sludge as previously mentioned. The acid rots the insulation on the copper windings inside the compressor. When this has occurred, an electrical failure will result in the compressor, causing the fuses to blow and a fault condition on the chiller. Compressor swap out is the cure which is expensive and inconvenient. We take the discharge temperature readings during the maintenance so as to fault find the cause.
Adequate suction pressure is needed to ensure good oil return to the compressor and prevent low pressure trips. As the refrigerant entrains the oil around the system, a good mass flow rate is needed, or the oil will just ‘pool’ in the bottom of the evaporator. Poor oil return will result in a seized compressor. Therefore, particular attention is taken to the low pressure gauge by our engineers. System adjustments or recommendations are made to ensure the seamless operation of your plant. If system overhaul is required, a Quote will be submitted at the end of the visit.
0161 370 7193
Compressor Holding Down Bolts
There are usually four of these on each compressor. They fit though a steel sleeve which, in turn, fits through a rubber mount. The whole assembly is bolted into the frame of the chiller. The function is to securely hold the compressor in place and to dissipate vibration. We check the tightness is correct with our torque wrenches and change the rubbers periodically. A compressor rattling around uncontrollably, especially during start up and stopping causes catastrophic leaks around the compressor. This usually leads to the whole, or the most part of the refrigerant charge being lost to atmosphere.
Motor Protection Module
A resistance sensor embedded in the compressor windings plugs into this module on the S1 and S2 terminals. The fault feedback to the controls is on the M1 and M2 terminals. The power supply to the module is on the L and N terminals. When the windings start to get hot, the module detects this after a pre determined level of resistance is reached. The M2 terminal opens and volts drop out to the relay board, then a lower volt control signal drops out to the controller. We check the sensor resistance and compare it to a chart to ensure it is within the allowable range on each visit.
Wire Tightening during Scroll Chiller Compressor Maintenance
We waggle the motor connectors and check for any cracking to the wires which may lead to an earth sort out. We tighten the wiring on the compressor starter contactors and check the condition of the contactor contacts. These become ‘splattered’ causing an uneven amount of amps to the compressor. This volt drop causes the contactors to fail and will eventually cause compressor motor failure. We change the contactor contacts from our range of parts at Head Office.
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