Category Archives: Chilled Water Systems

Chilled water system repair of condenser to a silver chiller with blue compressors

Chilled Water System Condenser Repair

Chilled Water System Condenser Beyond Repair

The repair of the condenser was required on this chilled water system because the previous company had been chasing leaks round in a circle. Therefore, the customer had decided to buy a new condenser. This was our first job with a new Contract, so we wanted to make a good impression.

Condenser Removal

There was no refrigerant in the system so our engineer cut the discharge and liquid line to the condenser. He then removed the rivets so the frame could be taken apart. Lifting equipment was fitted to the old condenser to aid the removal. Then, slings were fitted and a forklift truck removed the old condenser.

Condenser Replacement

Our engineer supervised the condenser replacement. He found that the new condenser did not fit correctly. The new condenser was 5mm thicker than the old one. It was decided to lift it back out and angle grind the frame to make more room. Once this was completed, the new condenser fitted correctly and was bolted in place.

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Pipework Repair

The pipework had to be repaired and brazed in. Then, the standard practice of a pressure test to ensure the integrity of the system.

The Evacuation Process

Having passed the pressure test, our engineer set up the vac pump and started the evacuation process. This is to dehydrate the system by pulling a vacuum of less than 2 Torr. Any moisture in the system will boil away and leave the system dry.

Recharge and Test Operation

The refrigerant is R410a. Our engineer put around half the charge in, then trimmed the remaining charge according to the superheat and subcooling values. He monitored the system for the rest of the day- looking for leaks as the plant was at operating pressures of 30 Bar. All was well, so the customer signed off the paperwork as he was pleased with the capability of our engineer.

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Read about air cooled condenser installation at the Institute of Refrigeration | Click Here


Global chilled water system service near Saint Basil's Cathedral

Global Chilled Water System Service

Moscow Visit

Always good for our engineers to get out of the country to carry out global chilled water system service. He 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 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. Our engineer decided to tighten up the wiring and unplug, then plug all the connectors back in. When he ran the chiller again the problem went away.

Chilled Water System Global Service

As we provide a global service: we cannot get back the day after leaving site. Therefore, after resolving the above issue, our engineer 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, he put the whole of the plant back in Auto to prove it all together.

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Flow Switch Failure During Global Chilled Water System Service

Due to security issues, this one of the most remote plant rooms for a flow switch to fail. The chiller did not stop when a test was carried out. Our engineer didn't want to valve off the water system as the air handlers are old and 'dead heading' could cause failure. Instead he decided to use the Hand/ Off/ Auto switch for the pump. After several attempts of trimming he got the switch to settle down, then carried out tests to make sure it would not happen again.

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Chilled water system maintenance showing flow switch at 0 reading

Chilled Water System Maintenance

Maintenance of the Chilled Water System Flow Switch

The chilled water system flow switch requires regular maintenance due to a to build up of contaminants on the sensor. Over time, slime accumulates giving false readings. The problem is relatively easy to sort out: a wipe with a cloth.

Retrieving the sensor

The more difficult part is retrieving the sensor. It is fixed with a bolt into the water system. Therefore, there is pressure inside the water system. This pressure is handled and the glycol drained into vessels.

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Checking the Fault Out Level

As you can see from the picture: there is a green light on 0. This indicates that the pump is off, not to be confused with pressure. With the pump on: the green lights go all the way up to 9 with the fault out level showing red on 7. Flickering between the numbers indicates that the flow rate is starting to drop off.

Maintaining the Chilled Water System Fault Out Level

Using a terminal driver and the manual that comes with the flow switch: the buttons can pressed a number of times to 'self test' Also, the fault out level can be set.

Testing the Flow Switch

The flow switch is manually tested using one of two methods. This ensures that the switch will function correctly when it needs to.

Maximus Chillers offers the whole package for the maintenance of your plant. With state of the art equipment and the best engineers- we complete the picture. Weather you have a small problem like the above mentioned flow switch, or a big problem like compressor failure- Maximus Chillers can help.

Any Chiller- Any Problem- Any Part- Any Refrigerant- Anywhere- The MAXIMUS ADVANTAGE™

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Read more about flow measurement on Wikipedia.


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