A detailed Air Cooled Compression Chiller WEEKLY preventive maintenance checklist
General Inspection
- Examine external casing for dents, rust, or cracks.
- Check for any loose components or fasteners.
- Look for evidence of oil or refrigerant leaks.
- Inspect electrical connections for corrosion or fraying.
- Listen for grinding, squealing, or rattling sounds.
- Identify if noises vary with changes in load or speed.
- Use a stethoscope for detailed sound localization.
- Document any persistent sounds for further analysis.
- Inspect all joints and fittings for signs of leaks.
- Use a leak detection solution to identify gas leaks.
- Check around the compressor and evaporator connections.
- Monitor for any moisture accumulation around the unit.
- Inspect hinges and latches for proper function.
- Ensure no gaps exist when panels are closed.
- Check for any signs of tampering or damage.
- Confirm that safety interlocks are operational.
- Look for tears, cracks, or signs of moisture intrusion.
- Ensure insulation is securely fastened along the lines.
- Assess for any signs of mold or mildew growth.
- Replace any damaged insulation immediately.
- Examine all mounting bolts and brackets for rust.
- Check for any signs of movement or shifting.
- Ensure supports are stable and securely anchored.
- Document any structural concerns for repair.
- Check for droppings, nests, or chew marks.
- Inspect insulation and hidden areas for pests.
- Seal any entry points to prevent future infestations.
- Consult pest control if infestation is confirmed.
- Clear any plants, leaves, or trash near the unit.
- Maintain at least three feet of clearance around the chiller.
- Inspect for any potential fire hazards nearby.
- Ensure proper drainage to prevent water pooling.
- Inspect all labels for fading, peeling, or damage.
- Ensure that safety and operational labels are visible.
- Replace any illegible labels with new ones.
- Verify that all tags reflect current information.
- Look for cracks, tears, or excessive wear on pads.
- Ensure mounts are securely fastened and not degraded.
- Check for any signs of rust or corrosion.
- Replace worn pads to reduce vibration transmission.
- Ensure drain pan is free of obstructions.
- Check for standing water or overflow conditions.
- Look for algae or mold and clean as needed.
- Verify that the drain lines are clear and functional.
- Use a level to check across the top of the chiller.
- Adjust feet or use shims as necessary for leveling.
- Ensure that the unit is not leaning or tilted.
- Document adjustments made for future reference.
- Wipe down surfaces to remove dust and grime.
- Check fans and coils for dust buildup.
- Ensure no debris is stuck in the unit's airflow areas.
- Maintain a regular cleaning schedule to prevent buildup.
Electrical Components
- Use a torque wrench to check tightness.
- Look for any discoloration or rust.
- Clean connections with a suitable electrical contact cleaner.
- Check all indicator lights for functionality.
- Test buttons and switches for responsiveness.
- Ensure display screens show correct readings.
- Press each emergency stop button firmly.
- Verify that all equipment stops immediately.
- Reset the system to ensure normal operation.
- Inspect fuses for visible damage or burns.
- Test circuit breakers by toggling on and off.
- Replace any faulty components immediately.
- Look for fraying, discoloration, or exposed wiring.
- Check for signs of overheating like melting.
- Ensure all connections are secure and intact.
- Inspect grounding connections for corrosion.
- Verify tightness using a torque wrench.
- Test grounding continuity with a multimeter.
- Listen for clicking sounds during operation.
- Check for overheating or discoloration.
- Test operation using a multimeter.
- Use a multimeter to check voltage levels.
- Measure current with a clamp meter.
- Compare readings to manufacturer specifications.
- Power down the system before cleaning.
- Use a dry cloth to wipe surfaces.
- Avoid using liquid cleaners on electrical components.
- Listen for grinding, humming, or rattling sounds.
- Inspect components for loose parts.
- Document any abnormalities for further investigation.
- Compare current system with existing diagrams.
- Update any changes in wiring or components.
- File the revised schematics in a designated location.
- Run a test cycle on the timers or PLCs.
- Check for correct timing and sequence.
- Document any discrepancies for troubleshooting.
- Inspect all labels for visibility and clarity.
- Replace faded labels with new, clear ones.
- Use a labeling machine for consistency.
Refrigerant System
- Use a gauge to measure refrigerant levels.
- Inspect joints and fittings for signs of leakage.
- Apply soapy water on suspected areas to check for bubbles.
- Document any leaks found and plan for repair.
- Take readings from pressure gauges and temperature probes.
- Compare values against manufacturer specifications.
- Record readings for future reference.
- Investigate any deviations from normal parameters.
- Check the sight glass for clear visibility.
- Look for bubbles, indicating low refrigerant levels.
- Ensure the sight glass is free from contaminants.
- Document findings and address any issues.
- Examine lines for any physical damage or corrosion.
- Check for signs of rust, cracks, or pinholes.
- Ensure all lines are securely fastened.
- Report any damaged lines for replacement.
- Locate all service ports on the refrigerant system.
- Check for physical damage or blockage.
- Ensure caps are present and in good condition.
- Document any accessibility issues.
- Check for proper operation of the expansion valve.
- Listen for unusual sounds during operation.
- Adjust settings according to manufacturer guidelines.
- Document any adjustments made.
- Inspect the receiver for any debris or contaminants.
- Check for proper refrigerant flow into the receiver.
- Ensure that the receiver is not overfilled.
- Document the condition and any necessary cleaning.
- Check insulation for tears, wear, or moisture.
- Ensure insulation is properly fitted and secured.
- Replace damaged insulation as needed.
- Document insulation condition and any replacements.
- Tighten any loose connections using appropriate tools.
- Inspect connections for signs of leakage.
- Use leak detection methods to verify integrity.
- Document the condition of connections.
- Listen for abnormal sounds during operation.
- Check for excessive vibrations during compressor operation.
- Inspect mounting and support structures for stability.
- Document any concerns for further investigation.
- Log ambient temperature and humidity levels.
- Record operating temperatures and pressures.
- Compare recorded data against historical performance.
- Identify any trends that may require attention.
- Verify the type of refrigerant in use.
- Consult the manufacturer’s specifications for the correct refrigerant.
- Check labels on refrigerant containers for compliance.
- Document any discrepancies found.
- Check current refrigerant inventory against records.
- Update records to reflect any changes made.
- Ensure compliance with local regulations on refrigerant management.
- Document completed inventory reviews.
- Identify refrigerants needing recovery or disposal.
- Schedule appointments with certified technicians.
- Document all recovery and disposal actions taken.
- Ensure compliance with environmental regulations.
- Check accumulator for signs of liquid refrigerant presence.
- Inspect for blockages or restrictions in flow.
- Ensure proper insulation and mounting of the accumulator.
- Document findings and any issues.
- Inspect refrigerant lines for frost or ice buildup.
- Determine if frost indicates low refrigerant levels.
- Check insulation and airflow around affected areas.
- Document any frost issues and recommend actions.
- Activate the electronic expansion valve and monitor performance.
- Check for proper opening and closing response.
- Verify control signals are functioning correctly.
- Document any operational issues found.
Cooling Fans
- Listen for unusual sounds during operation.
- Check for smooth fan rotation without any wobbling.
- Ensure fans start and stop correctly without delays.
- Monitor the power consumption to identify irregularities.
- Turn off and isolate power to the fans.
- Use a soft brush or vacuum to remove loose debris.
- Wipe blades with a damp cloth to eliminate stubborn dirt.
- Ensure surrounding areas are free of obstructions.
- Identify lubrication points on the motor.
- Use appropriate lubricant as per manufacturer specifications.
- Apply lubricant without over-saturating or spilling.
- Check for any signs of leakage post-lubrication.
- Inspect for cracks, chips, or deformities on blades.
- Ensure blades are securely attached to the hub.
- Compare with replacement blades to confirm compatibility.
- Document any replacements made for record-keeping.
- Inspect belts for wear, fraying, or cracking.
- Use a tension gauge to check proper tension.
- Adjust tension as required according to specifications.
- Replace belts that are damaged or worn.
- Check for rust, dents, or cracks in the housing.
- Clean any rusted areas and apply protective coating.
- Ensure all screws and fasteners are intact.
- Replace damaged housing if structural integrity is compromised.
- Check bolts and screws for tightness.
- Inspect mounts for any signs of wear or damage.
- Use a vibration meter to check for excessive vibration.
- Repair or replace any faulty mounts as necessary.
- Use a tachometer to measure fan speed.
- Compare measured speed to manufacturer’s specifications.
- Adjust speed settings if necessary to match specs.
- Document any discrepancies for follow-up.
- Inspect wiring for signs of wear, melting, or discoloration.
- Ensure all connections are tight and secure.
- Use a multimeter to check for continuity.
- Replace any damaged wires or connectors.
- Measure airflow at the outlet of the fan.
- Compare readings to manufacturer specifications.
- Identify any restrictions or blockages affecting airflow.
- Make necessary adjustments to improve airflow.
- Check control panel settings for accuracy.
- Test manual overrides if applicable.
- Ensure automatic settings respond correctly.
- Document any anomalies in control operation.
- Record date and time of inspection.
- List any issues found and corrective actions taken.
- Note any parts replaced or serviced.
- Ensure documentation is filed in maintenance records.
Filters and Airflow
- Turn off the chiller and ensure safety protocols are followed.
- Remove the air filter from its compartment.
- Inspect for dirt, dust, or blockages.
- Replace with a new filter if heavily soiled.
- Reinstall the filter securely and restore power.
- Visual check for any debris or objects near intake/discharge.
- Remove any obstructions like leaves, trash, or equipment.
- Ensure there are no structural barriers.
- Document any findings and actions taken.
- Check a clearance zone of at least 3 feet around the unit.
- Remove any nearby equipment or materials.
- Ensure no outdoor plants or structures block airflow.
- Confirm that airflow is not restricted by nearby fences.
- Turn off the chiller and disconnect power.
- Remove the air filters from their housing.
- Use mild soap and water to wash filters thoroughly.
- Rinse and allow filters to dry completely before reinstallation.
- Reinstall filters securely and restore power.
- Visually examine ductwork for visible damage or corrosion.
- Check for gaps or cracks in joints and seams.
- Use a smoke pencil to identify air leaks.
- Seal any identified leaks with appropriate duct tape or sealant.
- Ensure ducts are properly insulated.
- Locate the airflow measurement points as specified by the manufacturer.
- Turn on the chiller and allow it to stabilize.
- Use an anemometer to measure airflow at each point.
- Compare readings to manufacturer specifications.
- Document any discrepancies for further investigation.
- Inspect all duct connections for secure fittings.
- Ensure ducts are straight and free from bends.
- Adjust or realign ducts as necessary.
- Tighten any loose connections with appropriate fasteners.
- Confirm that no obstructions are present.
- Turn off power to the chiller before inspection.
- Remove any protective covers from fans.
- Inspect blades for dirt, debris, or physical damage.
- Clean blades using a soft brush or cloth.
- Replace any damaged blades as needed.
- Check the manufacturer's specifications for fan speed.
- Use a tachometer to measure fan RPM.
- Compare RPM readings with specifications.
- Adjust fan speed settings if necessary.
- Ensure all electrical connections are secure.
- Inspect intake areas for visible mold or mildew.
- Use a cleaning solution to remove any growth.
- Ensure proper drainage to prevent future growth.
- Improve ventilation if necessary to reduce humidity.
- Consider using anti-microbial treatments if needed.
- Inspect access panels for secure closure.
- Check for missing or damaged latches and seals.
- Repair or replace any faulty components.
- Ensure all panels are properly aligned and fit snugly.
- Document any issues and schedule repairs as needed.
- Check the temperature and humidity around the unit.
- Ensure there are no obstructions within the airflow path.
- Monitor environmental changes that may affect performance.
- Adjust landscaping or structures if necessary.
- Record conditions for future reference.
- Create a cleaning schedule based on environmental conditions.
- Use a soft brush or cloth to remove dust and debris.
- Clean the condenser coils carefully to maintain efficiency.
- Inspect for signs of corrosion or wear during cleaning.
- Document cleaning activities for maintenance records.
Condenser Coils
- Look for dirt, dust, and debris on the surface.
- Check for physical damage like dents or cracks.
- Note any areas of discoloration or wear.
- Use a soft brush to gently remove dirt.
- Apply a manufacturer-approved cleaning solution.
- Rinse thoroughly with water to remove residue.
- Inspect for rust or flaking paint.
- Look for white chalky deposits indicating scaling.
- Document any areas requiring treatment or repair.
- Examine fins for bends or kinks.
- Use a fin comb to straighten any bent fins.
- Ensure fins are evenly spaced and not obstructing airflow.
- Inspect the area surrounding the coils.
- Remove any leaves, trash, or equipment nearby.
- Confirm that vents are clear for optimal airflow.
- Check all mounting brackets and supports.
- Ensure there is no rust or wear on supports.
- Tighten any loose connections as necessary.
- Inspect joints and connections for oil residue.
- Use a leak detection solution if needed.
- Report and repair any detected leaks immediately.
- Measure the inlet air temperature.
- Measure the outlet air temperature.
- Calculate the differential and compare with specifications.
- Inspect insulation for tears, wear, or moisture.
- Replace any damaged or missing insulation.
- Ensure insulation is securely fitted to prevent energy loss.
- Check the drain pan for clogs or debris.
- Ensure water flows freely through the drain.
- Look for signs of rust or water damage.
- Listen for unusual noises from the fan motor.
- Check the fan speed and functionality.
- Ensure that the fan is effectively cooling the coils.
- Record findings in the maintenance log.
- Note any corrective actions taken.
- Schedule follow-up tasks for unresolved issues.
Drainage System
- Visually examine the drain for any visible clogs.
- Use a flashlight to check hard-to-see areas.
- Clear any blockages using a flexible brush or compressed air if necessary.
- Remove any leaves, dust, or other debris from the drain pan.
- Wipe down the pan with a damp cloth.
- Inspect for rust or damage and address any issues.
- Listen for operational sounds from the pump.
- Check the pump's electrical connections for any loose wires.
- Observe the pump while it operates to ensure it is effectively removing water.
- Look for water stains or pooling near connections.
- Check for corrosion or wear on the joints.
- Tighten any loose fittings to prevent leaks.
- Use a level to check the slope of the drain line.
- Ensure the slope is directed toward the drainage point.
- Adjust the line if necessary to maintain proper drainage.
- Manually lift the float switch to observe the pump operation.
- Ensure the pump activates as the float is raised.
- Reset the float switch and check for proper return operation.
- Inspect the surface of the drain pan for discoloration.
- Use a suitable cleaner to scrub away any growth.
- Rinse the pan thoroughly after cleaning.
- Check the insulation for tears, holes, or moisture damage.
- Replace any damaged insulation as needed.
- Ensure insulation is securely attached to the drain lines.
- Check all connections for tightness.
- Look for any signs of wear that could cause disconnection.
- Reinforce connections if necessary to ensure security.
- Walk around the chiller unit to inspect for any signs of water accumulation.
- Check the ground and surfaces for dampness.
- Document any findings for further investigation.
- Use a dedicated section in the maintenance log for drainage notes.
- Include details on any issues found and actions taken.
- Sign and date the log entry for accountability.
Safety Devices
- Ensure valves are accessible.
- Open and close valves manually.
- Check for leaks or unusual noises.
- Confirm that valves return to closed position.
- Document any issues for repair.
- Locate cutouts on the chiller.
- Manually trigger cutouts to verify operation.
- Check reset mechanisms for proper function.
- Ensure indicator lights are operational.
- Replace any faulty components immediately.
- Test alarm activation by simulating faults.
- Listen for audible alarms and check visual indicators.
- Ensure alarms reset correctly after testing.
- Check alarm documentation for any discrepancies.
- Report any non-functional alarms for maintenance.
- Identify thermal protection devices in the system.
- Test devices by exceeding temperature limits safely.
- Confirm devices activate and shut down equipment.
- Inspect for any physical damage or wear.
- Document and address any failures immediately.
- Locate all interlocks and switches.
- Test each switch for proper functionality.
- Check for signs of wear or damage.
- Ensure that switches are easily accessible.
- Document any issues and schedule repairs.
- Use a certified pressure gauge for comparison.
- Check readings against known pressure values.
- Calibrate or replace gauges that are inaccurate.
- Ensure mounting is secure and stable.
- Document calibration results for maintenance records.
- Activate alarms to test sound and visibility.
- Ensure alarms are loud enough and lights are bright.
- Check reset functions for proper operation.
- Inspect connections for wear or corrosion.
- Document any alarms that fail to operate.
- Conduct a visual inspection of all wiring.
- Look for frayed wires, loose connections, or corrosion.
- Check insulation for integrity.
- Ensure all connections are tight and secure.
- Report any damaged wiring for immediate repair.
- Inspect pathways and access points to safety devices.
- Remove any obstructions or hazards.
- Mark emergency access points clearly.
- Ensure access is known to all personnel.
- Document any access issues found.
- Check existing documentation for relevance.
- Update labels to reflect current device status.
- Ensure all safety devices are clearly labeled.
- Archive outdated documents appropriately.
- Distribute updated documentation to relevant staff.
- Inspect all safety devices and associated hardware.
- Look for rust, corrosion, or physical cracks.
- Check for any loose components or fittings.
- Document findings and schedule repairs as needed.
- Ensure inspection is thorough and systematic.
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