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M M a a i i n n t t e e n n a a n n c c e e P P r r o o c c e e d d u u r r e e s s
2. Inspect fuses to ensure they are secure, of correct
amperage ratng, undamaged and functioning.
3. Energize each compressor and check refrigerant
pressures, signs of overheating, and oil leaks.
Check for noises and for leaks with an electronic or
bubble leak detector. Inspect flared fittings,
refrigeration gauges, compressor connections,
braze joints, pressure switches, and access ports on
Schrader valves.
W W A A R R N N I I N N G G
R R e e f f r r i i g g e e r r a a n n t t u u n n d d e e r r H H i i g g h h P P r r e e s s s s u u r r e e ! !
F F a a i i l l u u r r e e t t o o f f o o l l l l o o w w i i n n s s t t r r u u c c t t i i o o n n s s b b e e l l o o w w c c o o u u l l d d r r e e s s u u l l t t i i n n
a a n n e e x x p p l l o o s s i i o o n n w w h h i i c c h h c c o o u u l l d d r r e e s s u u l l t t i i n n d d e e a a t t h h o o r r
s s e e r r i i o o u u s s i i n n j j u u r r y y o o r r e e q q u u i i p p m m e e n n t t d d a a m m a a g g e e . .
S S y y s s t t e e m m c c o o n n t t a a i i n n s s r r e e f f r r i i g g e e r r a a n n t t u u n n d d e e r r h h i i g g h h p p r r e e s s s s u u r r e e . .
R R e e c c o o v v e e r r r r e e f f r r i i g g e e r r a a n n t t t t o o r r e e l l i i e e v v e e p p r r e e s s s s u u r r e e b b e e f f o o r r e e
o o p p e e n n i i n n g g t t h h e e s s y y s s t t e e m m . . S S e e e e u u n n i i t t n n a a m m e e p p l l a a t t e e f f o o r r
r r e e f f r r i i g g e e r r a a n n t t t t y y p p e e . . D D o o n n o o t t u u s s e e n n o o n n - - a a p p p p r r o o v v e e d d
r r e e f f r r i i g g e e r r a a n n t t s s , , r r e e f f r r i i g g e e r r a a n n t t s s u u b b s s t t i i t t u u t t e e s s , , o o r r r r e e f f r r i i g g e e r r a a n n t t
a a d d d d i i t t i i v v e e s s . .
4. De-energize each compressor and inspect terminals
for pitting, corrosion, and loose connections.
5. Inspect that the oil level is visible in each
compressor and not discolored. Annual oil samples
should be taken to be analyzed for destructive
acids, corrosive materials, or metal deposits.
6. Inspect and record the compressor amperage
draws and voltage.
7. Record water/glycol mixture flow to ensure it meets
design specifications.
8. Tighten rotalock nuts at the compressors. The
recommended torque is 80 lbf for 2 inch and larger
and 60 lbf for rotalock nuts smaller than 2 inch.
9. Inspect all copper lines and control capillary tubing
to ensure that the lines are separated and not
vibrating against one another or the frame or
housing.
10. Ensure all refrigeration lines are properly supported
to prevent vibration from causing premature failure
of copper piping.
11. Inspect all insulation on piping and control sensors.
Repair and replace as necessary.
12. Inspect entire plumbing system for leaks.
13. Review logged alarms and look for repetitive
trends. The chiller can retain the previous 200
alarms with time and date of occurrence.
14. If equipped, inspect crankcase heaters to verify
proper operation.
15. Sample refrigerant to analyze for moisture or acid.
16. Inspect operating pressures and temperatures and
ensure the chiller has a full refrigerant charge.
52
Pump and Tank Maintenance Tasks
For chillers equipped with a tank and pump module,
additional maintenance steps are required at least
every six months:
1. Ensure that the pump, motor, and the immediate
area are clear of dirt, debris, leaves, animal nests,
and so forth.
2. Ensure pump mountings are secure and fasteners
are tight to prevent pipe movement and eventual
failure.
3. Inspect pump for proper rotation.
4. Check pump for leaks and excessive noise while in
operation.
5. Lubricate pumps as recommended by the
manufacturer. Refer to the pump manufacturer's
operating and maintenance manual for lubricating
instructions, if any are required.
6. Test and record the motor amp draw under full
load.
7. Test the pump overload protection device. Adjust if
necessary.
Maintenance Tasks
The maintenance tasks described herein present the
basic, minimal, steps required to successfully complete
a task. Local policies and protocols may require more
elaborate procedures with additional checks and
inspections.
Inspection Methods
Appropriate inspection for modern chillers can be
described as "hands on." Where possible and
appropriate, visual inspection should include touching
the component or apparatus being inspection. The
sense of touch provides additional feedback regarding
temperature, texture, tightness, and dryness that "eyes
only" inspection cannot match. Habitually touching
each item to be inspected also ensures that items are
not subconsciously skipped during the inspection
process. For a summary of tasks, see , Recommended
Chiller Service Intervals.
W W A A R R N N I I N N G G
H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! !
F F a a i i l l u u r r e e t t o o d d i i s s c c o o n n n n e e c c t t p p o o w w e e r r b b e e f f o o r r e e s s e e r r v v i i c c i i n n g g c c o o u u l l d d
r r e e s s u u l l t t i i n n d d e e a a t t h h o o r r s s e e r r i i o o u u s s i i n n j j u u r r y y . .
D D i i s s c c o o n n n n e e c c t t a a l l l l e e l l e e c c t t r r i i c c p p o o w w e e r r , , i i n n c c l l u u d d i i n n g g r r e e m m o o t t e e
d d i i s s c c o o n n n n e e c c t t s s b b e e f f o o r r e e s s e e r r v v i i c c i i n n g g . . F F o o l l l l o o w w p p r r o o p p e e r r
l l o o c c k k o o u u t t / / t t a a g g o o u u t t p p r r o o c c e e d d u u r r e e s s t t o o e e n n s s u u r r e e t t h h e e p p o o w w e e r r
c c a a n n n n o o t t b b e e i i n n a a d d v v e e r r t t e e n n t t l l y y e e n n e e r r g g i i z z e e d d . . V V e e r r i i f f y y t t h h a a t t n n o o
p p o o w w e e r r i i s s p p r r e e s s e e n n t t w w i i t t h h a a v v o o l l t t m m e e t t e e r r . .
ARTC-SVX001B-EN
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