A detailed Air Cooled Compression Chiller DAILY preventive maintenance checklist
General Inspection
- Check the temperature gauges for current readings.
- Compare readings against the manufacturer's specifications.
- Inspect pressure gauges for any abnormalities.
- Document any discrepancies for further evaluation.
- Look for puddles or moisture on the ground.
- Examine hoses and connections for dampness.
- Check for signs of rust or corrosion on equipment.
- Report any findings immediately.
- Listen for hissing, clanking, or grinding sounds.
- Feel for excessive vibrations on the chiller body.
- Record any irregularities and assess their significance.
- Consider consulting a technician if issues persist.
- Look for rust spots or peeling paint.
- Check for dents or physical damage to the housing.
- Ensure any protective coatings are intact.
- Document any damage for repair scheduling.
- Verify that panels are properly latched.
- Check gaskets for wear or degradation.
- Ensure no gaps are present that could allow air leaks.
- Report any missing or damaged components.
- Inspect the surrounding area for debris or equipment.
- Ensure that vents are unobstructed.
- Clear any obstacles that may restrict airflow.
- Verify that the airflow direction is appropriate.
- Look for visible dust or dirt accumulation.
- Check for bent or damaged fins.
- Clean any debris carefully without causing damage.
- Assess overall cleanliness for efficient operation.
- Inspect each bracket for tightness.
- Use a wrench to tighten any loose fasteners.
- Check for signs of wear on fasteners.
- Document any replacements needed.
- Look for cracks or fraying in the insulation.
- Check for moisture accumulation around insulation.
- Ensure insulation is intact for energy efficiency.
- Report any damaged sections for repair.
- Inspect connections for oil spots or residue.
- Listen for hissing sounds near valves.
- Use a leak detection solution if necessary.
- Document any signs of leakage immediately.
- Check for blockages in the drain line.
- Inspect the drain pan for standing water.
- Clean any debris from the drain opening.
- Test the drain by running the chiller briefly.
- Inspect the base for cracks or settling.
- Ensure the chiller is level and stable.
- Check for any signs of shifting or movement.
- Document any concerns about structural integrity.
- Inspect all guards for proper installation.
- Ensure no covers are missing or damaged.
- Check that safety features are operational.
- Report any deficiencies to maintenance staff.
Electrical Components
- Use a torque wrench to check tightness.
- Look for any signs of rust or corrosion.
- Clean connections with a suitable electrical cleaner.
- Re-torque connections if necessary.
- Use a soft brush or vacuum to remove dust.
- Wipe surfaces with a damp cloth.
- Check for any signs of moisture or damage.
- Ensure ventilation openings are unobstructed.
- Manually activate each safety interlock.
- Verify that alarms sound or display correctly.
- Reset interlocks after testing.
- Document any issues found during the test.
- Inspect insulation for cracks, fraying, or discoloration.
- Use a multimeter to check continuity.
- Replace any damaged wiring immediately.
- Ensure all connections are secure.
- Check that breakers are in the 'on' position.
- Test each circuit breaker by toggling it.
- Replace any blown fuses.
- Document any issues in maintenance logs.
- Look for discoloration or melting.
- Check for proper operation of moving parts.
- Clean contacts with a contact cleaner if necessary.
- Replace any worn components.
- Inspect grounding connections for corrosion.
- Use a multimeter to test grounding integrity.
- Tighten loose grounding connections.
- Document grounding status in logs.
- Press each emergency stop button to test.
- Ensure that the chiller shuts down immediately.
- Reset the emergency stop and check operation.
- Replace any faulty buttons or switches.
- Check VFD display for error codes.
- Listen for unusual sounds during operation.
- Verify settings against operational parameters.
- Document any discrepancies found.
- Access PLC interface and check for alerts.
- Review logs for any recent errors.
- Perform necessary troubleshooting for issues.
- Document findings and actions taken.
- Use a clamp meter to measure current.
- Check voltage levels at input and output.
- Compare readings to manufacturer specifications.
- Record results for future reference.
- Check each indicator light for functionality.
- Replace any burnt-out bulbs.
- Test indicators under different operational conditions.
- Document any non-operational indicators.
- Listen carefully for unusual sounds during operation.
- Use a vibration meter to check for abnormalities.
- Inspect components that produce noticeable noise.
- Document any findings for further investigation.
- Inspect each connection for clear labeling.
- Use a label maker to replace any missing labels.
- Verify that labels match circuit diagrams.
- Document any changes made to labeling.
- Examine logs for frequency of electrical issues.
- Identify any patterns or trends in failures.
- Schedule follow-up actions based on findings.
- Discuss findings with the maintenance team.
Cooling System
- Turn off the chiller and disconnect power.
- Use a soft brush or vacuum to remove dirt from coils.
- Rinse coils gently with water if necessary.
- Ensure coils are dry before reconnecting power.
- Power on the chiller and observe fan operation.
- Listen for unusual noises indicating issues.
- Check for any objects obstructing fan blades.
- Ensure fan blades are clean and free of debris.
- Check the sight glass for clarity and bubbles.
- Use pressure gauges to measure refrigerant levels.
- Compare readings with manufacturer's specifications.
- Add refrigerant if levels are low, following safety protocols.
- Turn off the chiller and remove access panels.
- Look for ice accumulation or rust on coils.
- Use a soft cloth to remove ice if present.
- Report corrosion issues for further inspection.
- Monitor temperature changes at the inlet and outlet.
- Listen for hissing sounds indicating valve function.
- Inspect for leaks or visible damage.
- Test valve adjustment if system performance is poor.
- Check for nearby objects or vegetation blocking airflow.
- Ensure the area around the condenser is clear.
- Measure airflow using an anemometer if necessary.
- Trim back any obstructions to maintain airflow.
- Inspect insulation for cracks, tears, or moisture.
- Replace damaged insulation to prevent energy loss.
- Ensure seams are sealed to maintain effectiveness.
- Check for signs of mold or mildew.
- Power on the compressor and monitor performance.
- Listen for abnormal noises such as grinding or rattling.
- Check for vibrations using your hand or a vibration meter.
- Document any irregularities for further analysis.
- Use thermometers to measure inlet and outlet temperatures.
- Calculate the temperature differential.
- Ensure differential is within manufacturer specifications.
- Report significant deviations for troubleshooting.
- Check drain pan for standing water or debris.
- Inspect drain line for clogs or leaks.
- Clear any blockages to ensure proper drainage.
- Ensure the drain line slopes downward away from the pan.
- Test control settings and monitor responses.
- Check sensor readings against expected values.
- Calibrate sensors if readings are inaccurate.
- Report any faulty controls for repair.
- Inspect fittings and joints for signs of oil or frost.
- Use a leak detection solution to identify leaks.
- Tighten connections if leaks are found.
- Document findings and schedule repairs as needed.
- Perform a visual inspection of all components.
- Clean any visible dirt or debris.
- Check for signs of wear or corrosion.
- Schedule maintenance for any components in poor condition.
Fluid Levels
- Locate the oil reservoir.
- Use a dipstick to check the oil level.
- Add the recommended oil type if low.
- Ensure the oil is clean and free of debris.
- Seal the reservoir properly after checking.
- Locate the water level indicators.
- Check for any visible leaks in the system.
- Ensure water levels meet manufacturer specifications.
- Inspect valves for proper operation.
- Confirm that water is circulating effectively.
- Check the glycol reservoir for fill level.
- Verify the glycol concentration with a refractometer.
- Add glycol if levels are below the recommended range.
- Inspect for any leaks in the glycol lines.
- Record the glycol level for future reference.
- Inspect all refrigerant lines for visible damage.
- Use a leak detection kit to check for leaks.
- Record the current refrigerant level.
- Ensure proper pressure readings on gauges.
- Report any discrepancies or leaks immediately.
- Check the expansion tank for any physical damage.
- Ensure the tank is filled to the manufacturer's specified level.
- Look for any signs of corrosion or rust.
- Verify that the pressure relief valve is functioning.
- Document the level for maintenance records.
- Check for any blockages in the drain line.
- Ensure the drain pan is clear of debris.
- Inspect the float switch for proper operation.
- Empty the pan if the level is too high.
- Record the condition of the drain system.
- Test fluid samples for additive concentration.
- Refer to manufacturer's guidelines for acceptable levels.
- Add inhibitors if levels are low.
- Document the levels and any adjustments made.
- Verify that the additives are compatible with the system.
- Check the reservoir for secondary fluid levels.
- Ensure no leaks are present in the secondary circuit.
- Record the current fluid level and temperature.
- Verify fluid quality for contaminants.
- Report any issues to maintenance personnel.
- Check the water supply line for leaks.
- Ensure the water level is at the recommended height.
- Inspect the make-up water valve for proper operation.
- Document the flow rate and pressure.
- Check for any unusual noises in the water supply.
- Use pressure gauges to check system pressure.
- Compare readings to operational standards.
- Adjust pressure if necessary using the appropriate valves.
- Look for any signs of pressure fluctuations.
- Record all pressure readings for monitoring.
- Inspect sight glasses for cleanliness and clarity.
- Ensure level indicators show accurate fluid levels.
- Clean any dirty sight glasses as needed.
- Check for signs of wear or damage.
- Document the condition of all indicators.
- Inspect the evaporator for any leaks or damage.
- Measure the coolant level against manufacturer guidelines.
- Add coolant if levels are low.
- Ensure proper circulation within the evaporator.
- Record the coolant level for future reference.
Filters
- Remove filters from their housing carefully.
- Inspect for dirt, dust, and damage.
- Clean reusable filters with water or compressed air.
- Replace filters that are damaged or beyond cleaning.
- Reinstall filters securely in their housing.
- Locate the water strainer in the system.
- Shut off the water supply to avoid spills.
- Remove the strainer and inspect for debris.
- Clean the strainer with water and a brush.
- Reinstall the strainer and restore water supply.
- Access the refrigerant filters in the chiller.
- Inspect for signs of clogging or damage.
- Replace filters if they are excessively dirty or damaged.
- Ensure proper alignment during installation.
- Document any replacements performed.
- Examine the filter housing for cracks or corrosion.
- Check seals and gaskets for integrity.
- Ensure there are no loose parts or fittings.
- Report any issues to maintenance.
- Clean housing surfaces as needed.
- Check the fit of each filter in its housing.
- Ensure seals are intact and secure.
- Gently press filters into place if necessary.
- Verify there is no gap between filters and housing.
- Test for airflow consistency after sealing.
- Inspect the area around filters for musty smells.
- Look for visible mold growth or moisture.
- Clean any areas showing signs of mold.
- Consider applying disinfectant if necessary.
- Report persistent odors to maintenance for further action.
- Consult the chiller’s manual for filter specifications.
- Compare installed filters with the required specifications.
- Replace any filters that do not match.
- Ensure compatibility with system performance.
- Document any discrepancies found.
- Install pressure gauges on both sides of the filter.
- Record baseline pressure drop readings.
- Regularly check and document the readings.
- Replace filters if pressure drop exceeds recommended limits.
- Analyze trends in pressure drop over time.
- Create a maintenance log for filters.
- Record the date and type of maintenance performed.
- Include filter specifications and any observations.
- Update the log immediately after maintenance.
- Ensure records are accessible for review.
- Locate pre-filters and secondary filters.
- Follow the same cleaning or replacement steps as primary filters.
- Ensure proper installation of new filters.
- Check for any required adjustments after replacement.
- Document maintenance actions taken.
- Measure airflow before and after filters.
- Ensure that airflow meets manufacturer specifications.
- Adjust blower speeds or damper positions if necessary.
- Inspect ductwork for blockages impacting airflow.
- Document airflow measurements and adjustments.
- Evaluate access points for accessibility.
- Ensure safety mechanisms are in place.
- Check for any obstructions around access areas.
- Verify that tools required for filter change are readily available.
- Report any safety concerns to management.
- Review filter materials against refrigerant specifications.
- Check for any chemical incompatibilities.
- Replace incompatible filters with suitable options.
- Consult manufacturer guidelines for materials.
- Document any changes made for future reference.
Safety Devices
- Locate all pressure relief valves.
- Manually open each valve to check for proper release.
- Ensure that valves close securely after testing.
- Check for any signs of corrosion or leaks around the valves.
- Identify all safety devices installed on the chiller.
- Verify each device operates without obstruction.
- Look for any physical damage or wear.
- Document any discrepancies or faults found.
- Locate all emergency shut-off switches.
- Test each switch to ensure it activates properly.
- Ensure switches are free from obstructions.
- Check signage indicating the location of switches.
- Inspect each interlock for physical damage.
- Test each interlock by activating the system.
- Ensure that all interlocks properly shut down the system when triggered.
- Document any malfunctions for further investigation.
- Locate low and high-pressure cut-out switches.
- Manually simulate low and high-pressure conditions.
- Verify that switches activate and deactivate as intended.
- Record results and address any issues immediately.
- Check all sensors for physical damage or corrosion.
- Confirm sensors are installed at the correct locations.
- Calibrate sensors against a known reference temperature.
- Replace any faulty sensors promptly.
- Walk around the chiller area to check signage.
- Clean any signs that are dirty or obscured.
- Replace any signs that are faded or damaged.
- Ensure compliance with safety regulations for signage.
- Activate alarms and indicators to test functionality.
- Check sound levels and visibility of indicators.
- Ensure that alarms are distinct and audible.
- Document any failures and arrange for repairs.
- Locate the emergency stop button and check for obstructions.
- Test the button to ensure it stops the chiller immediately.
- Ensure the button is clearly marked and identifiable.
- Replace or repair any malfunctioning buttons.
- Check all safety guards for tightness and security.
- Ensure no gaps or weaknesses are present.
- Test the integrity of guards by applying light pressure.
- Address any loose or damaged guards immediately.
- Locate the refrigerant leak detection system sensors.
- Check for visible signs of leaks or damage.
- Test the system by simulating a leak condition.
- Ensure sensors are calibrated and functioning properly.
- Gather all documentation related to safety devices.
- Update records with any new findings or repairs.
- Ensure all changes are properly logged and dated.
- Distribute updated documentation to relevant personnel.
- Initiate a control system test sequence.
- Monitor system responses to safety interlocks and alarms.
- Document the performance and any discrepancies.
- Ensure that all safety protocols are adhered to during testing.
Documentation
Final Check
- Inspect all panels and doors for proper alignment.
- Check for any visible damage or wear.
- Ensure latches and locks are functioning.
- Apply pressure to verify they are sealed.
- Document any issues found.
- Inventory all tools used during maintenance.
- Remove all non-essential items from the area.
- Verify that no tools are left on or near the chiller.
- Place tools back in designated storage.
- Check for any leftover materials or debris.
- Observe the general condition of the chiller.
- Check for any visible leaks or issues.
- Ensure all safety protocols are followed.
- Confirm operational indicators are normal.
- Document any observations or concerns.
- Use a flashlight to inspect all connections.
- Look for wet spots or corrosion.
- Check gaskets and seals for integrity.
- Listen for hissing sounds indicating gas leaks.
- Document any findings for further investigation.
- Power on the chiller and observe lights.
- Check that each indicator light corresponds to its function.
- Replace any burned-out bulbs as needed.
- Ensure no warning lights are illuminated.
- Log the status of each indicator light.
- Inspect each guard for damage or misalignment.
- Ensure all screws and fasteners are tight.
- Verify that guards are designed for safety compliance.
- Check that no gaps exist that could lead to hazards.
- Document any required repairs or replacements.
- Locate the emergency stop button.
- Test the button to ensure it functions correctly.
- Check for any obstructions around the button.
- Confirm the label is clear and visible.
- Document the functionality of the button.
- Refer to operational guidelines for parameters.
- Check temperature and pressure gauges.
- Make adjustments as necessary to meet specifications.
- Ensure settings are stored in automated systems if applicable.
- Record any adjustments made.
- Listen for irregular noises during operation.
- Feel for unusual vibrations on the chiller body.
- Identify the source of any anomalies.
- Document findings for further inspection.
- Schedule repairs if necessary.
- Activate all automated settings and controls.
- Monitor responses for correct operation.
- Check for error messages or alerts.
- Document the performance of each automated function.
- Report any malfunctions to technical staff.
- Review previous maintenance logs for updates.
- Record any new findings from the day's inspection.
- Ensure all documentation is clear and accurate.
- File reports in the designated location.
- Confirm that all team members have access to logs.
- Check the status of previously noted issues.
- Verify that repairs or adjustments were completed.
- Document resolution of any outstanding items.
- Schedule follow-up if issues remain.
- Communicate with the maintenance team about unresolved issues.
- Remove any dust or debris from the area.
- Check for any obstructions near air intake vents.
- Ensure proper drainage is maintained around the unit.
- Inspect for any litter that could pose safety hazards.
- Document the cleanliness of the area.
Use in Manifestly