General System Overview
- Comprehensive inspection of entire chiller system for leaks, corrosion, damage.
- Review operating hours log and verify within monthly service intervals.
- Analyze alarm history for recurring issues and patterns.
- Inspect piping insulation integrity and repair as needed.
- Check structural supports and vibration isolators.
- Clean equipment room and ensure proper ventilation.
Control System Analysis
- Download and analyze monthly trend data from Tracer™ system.
- Calibrate temperature and pressure sensors.
- Update control software/firmware if available.
- Test all control sequences and safety interlocks.
- Verify BAS communication and data accuracy.
- Backup control parameters and settings.
Screw Compressor Service
- Perform detailed inspection for wear, abnormal sounds, or vibration.
- Measure and record vibration levels at multiple points.
- Check rotor alignment and end play measurements.
- Test slide valve operation through full range.
- Verify discharge temperature protection functioning.
- Document compressor performance metrics.
Oil System Maintenance
- Pull oil sample for laboratory analysis.
- Change oil filter elements (document pressure drop).
- Clean or replace oil strainer.
- Test oil heater functionality and temperature regulation.
- Verify oil separator efficiency (carryover test).
- Check oil cooling system operation and cleanliness.
Refrigerant System Analysis
- Perform comprehensive leak test using electronic detector.
- Verify refrigerant charge and adjust if necessary.
- Test and record superheat/subcooling at various loads.
- Inspect filter drier and replace if pressure drop excessive.
- Check economizer operation and intermediate pressure.
- Verify refrigerant quality (moisture and acid test).
Electrical System Testing
- Perform insulation resistance test on motor windings.
- Check and torque all electrical connections.
- Test control circuit components and replace worn parts.
- Verify motor current balance across all phases.
- Inspect and test VFD operation and cooling (if equipped).
- Clean electrical panels and check for proper ventilation.
Water System Service
- Perform water quality analysis and adjust treatment.
- Clean Y-strainers and document debris found.
- Verify flow rates meet design specifications.
- Inspect pump seals and packing for leaks.
- Test water flow switches and adjust setpoints.
- Check expansion tank pre-charge pressure.
Heat Exchanger Cleaning
- Inspect tubes for fouling, scaling, or biological growth.
- Perform tube cleaning if approach temperature elevated.
- Check tube sheet and gaskets for leaks.
- Verify proper refrigerant distribution in circuits.
- Document approach temperatures before/after cleaning.
Safety System Testing
- Test all pressure safety switches and verify setpoints.
- Verify oil pressure differential protection.
- Test emergency shutdown sequence completely.
- Check relief valve certifications and operation.
- Verify all safety labels are legible and in place.
- Update emergency contact information posted.
Performance Analysis
- Calculate monthly average kW/ton efficiency.
- Compare energy consumption to previous months.
- Analyze capacity vs.
- Review setpoint optimization opportunities.
- Document performance degradation trends.
- Calculate monthly runtime and cycling statistics.
Documentation & Compliance
- Complete detailed maintenance log with all findings.
- Update equipment history and maintenance records.
- File refrigerant usage reports per EPA requirements.
- Document water treatment compliance.
- Review and update safety data sheets (SDS).
- Schedule next major maintenance activities.