• 2023 Chill-Pro Spring Claims Highlights

    10-year-old Centrifugal chiller. Cause of Loss: Variable Speed Drive failure.
    DESCRIPTION: Power module for 100 HP VFD Starter failed. Further investigation revealed two burnt
    spots in the power module. The cause of the burnt was electrical arcing in the power module. The main
    drive assembly was replaced, and the chiller unit returned to service. The unit was repaired and

    14-year-old Magnetic Bearing, screw chiller. Cause of Loss: Magnetic bearing compressor failure.
    DESCRIPTION: Investigation revealed that on the date of loss – Turbocor Compressor Number 2 was
    operating at high output temperature. The unit was shut down and found that rotor magnetic bearing
    had failed. Turbocor compressor is not field repairable and requires replacement of the compressor. I
    have attached to this report a diagram of how the magnetic bearings are configured in the compressor.
    The manufacturer discounted the new compressor 32% after the core was returned. No other damage
    noted to chiller other than compressor failure.

    16-year-old air cooled Screw chiller. Cause of Loss: Screw compressor failed.
    DESCRIPTION: Compressor bearings failed causing compressor motor to seize. Replaced compressor,
    buss bars and fittings. Unit has been returned to service.

    9-year-old air cooled Scroll chiller. Cause of Loss: Scroll compressor failed.
    DESCRIPTION: Technicians were called out to the facility when the 210-Ton Scroll Chiller stopped working.
    Initial inspection found that one of the compressors on the chiller unit had stopped working. Further
    inspection of the compressor found that some of the contactors had welded closed. Due to the nature of
    the contactors welded closed, they could not simply be replaced, the entire compressor needed to be
    back to service.

    25-year-old Reciprocating chiller. Cause of Loss: Reciprocating compressor pistons failed.
    DESCRIPTION: Technicians were called to troubleshoot an issue with the 150-Ton Reciprocating chiller.
    Technicians discovered that the suction line for the compressor had broken, and refrigerant was leaking
    from the chiller unit. Technicians repaired the broken line and re-started the chiller.

    Within 4 hours of restarting, the suction line was broken again, and more refrigerant was lost. Technicians repaired the
    suction line to the chiller and restarted it. The technicians continued to monitor the compressor and
    suctions line. It was later revealed that the compressor attached to the recently repaired suction line was
    vibrating excessively. The vibrations caused another break in the suction line. Further investigation by
    the revealed that the compressor had broken pistons. The broken compressor pistons caused the unit to
    vibrate excessively causing damage to compressor suction line. A new compressor was installed, and the
    chiller system returned to service.

  • 2022 Chill-Pro® Summer Claims Highlights

    • 10-year-old, 120 Ton Air cooled Screw chiller. Cause of Loss: Drive rotor fused to compressor casing

    DESCRIPTION: Damage to Screw compressor while in operation. The male, or rotor driver, was found
    fused to the discharge wall of the compressor casing. The rotors were separated from the discharge wall
    during disassembly. Both the male and female rotors were found to be damaged. In addition to the
    damage found to the rotors, a significant amount of damage was also found on the discharge wall of the
    compressor. All thrust and counter thrust bearing appeared to be in good working order. The
    compressor required replacement as repair was not an option based on initial damage review.

    • 16-year-old, 500 Ton Centrifugal chiller. Cause of Loss: Ruptured O-Ring, refrigerant leak

    DESCRIPTION: 500 Ton Centrifugal Chiller had major leaks. Loss reported as major leak on chiller.
    Further communication with the insured revealed that an O-Ring blew out releasing an excessive amount
    of freon from the system. Contractor confirmed the damage to O-Ring. It appears that O-Ring was
    damaged and could not hold Freon in the system. The O-Ring was replaced, and Freon was added to the
    system. The bulk of claim cost was refrigerant recovery.

    • 15-year-old, 80-ton Scroll chiller. Cause of Loss: Electrical arcing, failed compressor

    DESCRIPTION: On date of loss, Technicians were called out when one of the six compressors on the 80-
    ton scroll chiller unit stopped working. Testing of the unit found that the compressor had shorted to
    ground. The compressor was replaced, and the unit was returned to service.

    • 10-year-old, 150 Ton Magnetic Bearing chiller. Cause of Loss: Stripped set screw, compromised seal

    DESCRIPTION: Our investigation found that on the date of loss, technicians were called out to diagnose a
    failure on the 150 Ton magnetic bearing chiller. Technicians found the system inoperable on a
    temperature alarm. Initial inspection found that the system had lost most of the refrigerant in the
    circuit, which caused the unit to overheat and force a shut down. Technicians traced the leak to a section
    of the line where a screw holding the sections together had been stripped out. Due to this section no
    longer being sealed properly, the refrigerant was released from the system. Technicians recovered the
    remaining refrigerant and repaired the section of the refrigerant line. They recharged the system with
    R134A refrigerant and re-started the chiller.

    • 10-year-old, 450 Ton Centrifugal chiller. Cause of Loss: Circuit board failure due to power surge

    DESCRIPTION: During service call chiller was found to be inoperable. Troubleshooting procedure
    revealed failure of 4 printed circuit boards. Replaced circuit boards and restarted 450-ton Centrifugal
    Chiller. No further maintenance performed.

Office: 800-704-7685
101 E. Washington Bl, 10th Floor
Fort Wayne, IN 46802