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FORM 160.76-O1
ISSUE DATE: 6/15/2015
SECTION 7 - PREVENTIVE MAINTENANCE
It is the responsibility of the owner to provide the nec-
essary daily, monthly and yearly maintenance require-
ments of the system.
IMPORTANT – If a unit failure occurs
due to improper maintenance during the
warranty period; Johnson Controls will
not be liable for costs incurred to return
the system to satisfactory operation.
In any operating system it is most important to pro-
vide a planned maintenance and inspection of its func-
tioning parts to keep it operating at its peak efficiency.
Therefore, the following maintenance should be per-
formed when prescribed.
COMPRESSOR
1. Oil Filter – When oil pump VSD frequency in-
creases to 55 hz to maintain target oil pressure.
When the oil filter is changed, it should be in-
spected thoroughly for any aluminum particles
which would indicate possible bearing wear.
If aluminum particles are found this should be
brought to the attention of the nearest Johnson
Controls office for their further investigation and
recommendations.
2. Oil Changing – The oil in the compressor must
be changed annually or earlier if it becomes dark
or cloudy. However, quarterly oil analysis can
eliminate the need for an annual change provided
the analysis indicates there is no problem with the
oil.
COMPRESSOR MOTOR
1. Check motor mounting screws frequently to in-
sure tightness.
2. Meg motor windings annually to check for dete-
rioration of windings.
GREASED BEARINGS
Motor Operation and Maintenance manuals are sup-
plied with the chillers providing maintenance sched-
ules and instructions for the specific motors. The fol-
lowing are lubrication schedules for the most common
motors:
JOHNSON CONTROLS
MOTOR RE-LUBRICATION INSTRUCTION
All motor manufacturers have slightly different re-
quirements for the exact amount of grease to be added,
and the exact interval for re-greasing. The suggested
amount should be 1.5 cubic inches of grease, and the
interval should be 1000 hours to 1400 hours between
re-lubrications. York Optiview control panels provide
a warning message to re-lubricate bearings at 1000
hours. When the run clock reaches 1400 hours without
lubrication, software will shut down the chiller until
re-lubrication has been acknowledged.
Grease Gun Calibration -
Grease guns should be calibrated to determine the
number of pumps required to get 1.5 cubic inches of
grease. This can be accomplished by forming an open-
top cardboard cube, one inch by one inch by one inch.
Pump grease into this container until grease is level
with the top, counting the number of pumps. When
the grease is level with the top, this is the amount for
one cubic inch. Multiply this number of pumps times
1.5 to get the number of pumps for York chiller motor
bearings.
Over-greasing can be as detrimental as
lack of greasing. A bearing housing that
is totally filled with grease can run 20 de-
grees centigrade higher temperature than
one with the proper amount of grease.
Type of Grease –
All standard York chiller motors utilize a polyurea
grease, formulated for high-speed rolling element
bearings. Only two greases are approved by all our
motor manufacturers, and these are:
1st Choice:
Exxon / Mobil Polyrex EM
Grainger Part Number 5XB54
2nd Choice: Texaco / Chevron SRI #2
There are a few exceptions, such as Reliance Q-frame
motors built from 1997 to 2003, and some special or-
der motors such as high-voltage motors from ABB. In
these cases use only the grease called for by the mo-
tor manufacturer. In the case of those Reliance mo-
tors, there is a metal tag affixed to the motor calling for
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