Finally got a 500kWh air cooled chiller running last week that'd been offline for over 8 months.
It's a heat pump, so has HW and CW circuits, mainly for humidity control, although the HW circuit might occasionally be used in winter.
The list of repairs this week, in no particular order.
Replace the pressure tank on the HW circuit, the original had rusted away as no water treatment had been used in the previous 4 years.
Replace the pressure relief valve on the HW buffer tank.
Replace the cold water expansion valve, constantly blowing off even though system pressures seem ok.
Install check valves in the water supply lines to both circuits as only one RPZ valve was used, and the water from both circuits could backflow and Inter mingle.
Replace the batteries (only one set so far) for the EXV drivers.
Replace the suction pressure transducer for the System 1 EXV and pressure test system (currently has a holding charge of 320psi, one of our blokes replaced the guts of the EXV 12 months ago as the pinion had wound itself off the rack in the stepper motor)
Try and make the bloody thing start, it was getting an enable and a cooling call from the BMS, but it wouldn't boot up. That was a hair tearer for a few hours. I thought the processor or expansion card was fried, the readout/display had failed on the processor but the remote display was working. Mucking around with my meter on various voltage free points somehow made the thing work, and it hasn't missed a beat since???
And I haven't mentioned the ridiculous amount of severe corrosion on both the chiller and AHU, (this AHU isn't weatherproof, yet it's sitting on top of a shopping centre...) or the really bad metal clad insulation, the crazy number of metal ties that have snapped from corrosion, and the CW entering probe temp that bounces between 85° and 135° and 'no value'
When I finally found the probes, they are under the AHU and they aren't even in wells, they'd just been slid under the metal sheathing.
So easy to get to
This thing is only 4 years old, and I need to make it limp along for another 18 months.
Probably $400,000 that's been ****ed away because the purchasing people were too cheap to use something decent.
This is why we're paid the big bucks....



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