SEASONAL MAINTENANCE CHECKLISTS Johnson Controls

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SPRING CHECK LIST ABSORPTION CHILLERS Check starter and control panel. Leak test. Check hand valve diaphragms and replace as required. Check operation of purge unit. Change oil in the purge pump.

1 SPRING CHECK LIST ABSORPTION CHILLERS Check starter and control panel. Leak test. Check hand valve diaphragms and replace as required. Check operation of purge unit. Change oil in the purge pump. Lubricate purge pump motor and change belt. Clean magnetic strainer on the solution motor cooling circuits. Review manufacturer's recommendation for start-up. Check auxiliary equipment operation. Check and test all operating and safety controls. Check solution pump motor operation. Log all operating conditions after unit stabilizes. Add octyl alcohol. Trim solution concentration to maximum efficiency. A Lithium Bromide solution sample should be taken for test lab analysis. Review operation procedures. AUTOMATIC TEMPERATURE CONTROLS AIR COMPRESSOR Drain tank and check traps. Change oil and check oil pressure. Check belt and sheaves, then change as required. Change suction filter as required. Check unloader and check valve. Check high pressure safety valve. 1

2 Check motor operating conditions and lubricate. Check PE switch, starter and alternator. Record compressor run time. REFRIGERATED AIR DRYER Check refrigerant pressure. Check refrigerant temperature. Clean condenser and cover grilles. FILTER AND PRESSURE REDUCING STATION Check particle filters (change as required). Check oil filter (change as required). Check pressure reducing valve settings. Check low pressure safety valve. BOILER, CHILLER, CONVERTER PUMPS AND ZONE CONTROLS Calibrate all controllers. Calibrate all transmitter and receiver gauges. Check all PE switches. Check all control valves. Check all pilot positioners. Check all auxiliary control devices. FAN SYSTEMS AND HVAC UNIT CONTROLS Review sequence of operation. Check all dampers and lubricate. Check pilot positioners. Check all control valves. Calibrate all controllers. Calibrate all transmitters and receiver gauges. 2

3 Check all solenoid air valves, PE switches and air valves. Check all auxiliary control devices. ROOM TERMINAL UNIT CONTROLS Check all room thermostats. Check all control valves. Check operation of unit coil steam traps. Check operation of all dampers and lubricate. Check all PE switches, solenoid air valves and limit controls. Check operation of all auxiliary devices. CENTRIFUGAL CHILLERS Check main starter and control panel. Leak test. Inspect condenser tubes for fouling clean as necessary. Meg compressor motor and oil pump motor. Change oil and filters. Test oil for acidity. Check operation of purge unit. Clean purge drum and oil separator. Change oil in purge pump and oil separator. Lubricate purge pump motor and change belt. Lubricate inlet vane linkage. Check oil pump heater operation. Review manufacturer's recommendations for start-up. Check auxiliary equipment operation. Check refrigerant and oil levels. Check oil pump heater and purge oil heater. Check and test all operating and safety controls. 3

4 Log all operating conditions after unit stabilizes. Review operating procedures. Purge operation. Check sight glass and drain non-condensables from purge. An oil sample should be taken after start-up for test lab analysis. CHILLED WATER COIL COOLING Lubricate fan bearings per manufacturer's recommendation. Lubricate motor bearings per manufacturer's recommendation. Check belts and sheaves. Replace and adjust as required. Lubricate and adjust dampers and linkage. Inspect filters. Check motor operating conditions. Inspect electrical connections, contactors, relays and operating/safety controls. Check and clean strainers and humidifier. Check hand valves and steam traps. Check and clean drains and drain pans. Check heating coils. Secure unit panels and inspect roof curb flashing. COOLING TOWER Remove all debris from within and around unit then flush as required. Check and clean strainers, bleed, overflow and drain. Lubricate fan and motor bearings per manufacturer's recommendation. Change oil in gear reducer assembly per manufacturer's recommendation. Check belts, motor pulley and motor mounts. Replace and adjust as required. Inspect electrical connections, contactors, relays and operating/safety controls. Check motor operating conditions. Clean float valve assembly and check for proper operation. Check operating conditions. Adjust as required. 4

5 DIRECT EXPANSION COOLING SEASONAL MAINTENANCE CHECKLISTS Lubricate fan bearings per manufacturer's recommendation. Lubricate motor bearings per manufacturer's recommendation. Check belts and sheaves. Replace and adjust as required. Check and clean coils. Straighten fins as required. Lubricate and adjust dampers and linkages. Check and clean drain pan and drains. Inspect filters. Check motor operating conditions. Inspect electrical connections, contactors, relays and operating/safety controls. Check compressor oil level, acid test oil and meg motor. Check crankcase heater operation. Start compressor, check operating conditions and adjust as required. Secure unit panels and inspect roof curb flashing. Inspect for refrigerant leaks. Check operating conditions and adjust as required. HEAT EXCHANGER HUMIDIFIERS Visually check for leaks. Tighten connections. Verify pressure gauge and thermometer accuracy. Check and clean strainers. Check steam traps and hand valves. Check operating safety devices. Clean exterior surfaces as required. Check and clean strainers. Check steam trap and hand valves. Clean and check float assembly. Check and clean drains and drain pan. Clean heating element. 5

6 STEAM PRV SEASONAL MAINTENANCE CHECKLISTS Inspect electrical connections, relays, contactors and operating and safety controls. Clean plugged spray nozzles. Check unit operating conditions. Clean exterior surfaces as required. Verify accuracy of gauges. Check unit operation and lubricate as required. Clean as required. FANS & CENTRAL FAN SYSTEMS Check and clean fan assembly. Lubricate fan bearings per manufacturer recommendations. Lubricate motor bearings per manufacturer's recommendations. Check belts and sheaves. Replace and adjust as required. Tighten all nuts and bolts. Check motor mounts and vibration pads. Replace and adjust as required. Check motor operating conditions. Inspect electrical connections and contactors. Lubricate and adjust associated dampers and linkage. Check fan operation. Clean outside air intake screen. Check and clean drains and drain pans. Check and clean strainers, check steam traps and hand valves. Check filter advancing mechanism. Lubricate and adjust as required. Inspect filters. Check heating and cooling coils. Inspect humidifier. 6

7 Clean external surfaces as required. CONDENSERS AIR COOLED Remove all debris from within and around unit. Inspect for leaks. Check belts, pulleys and mounts. Replace and adjust as required. Lubricate fan and motor bearings per manufacturer's recommendation. Inspect electrical connections, contactors, relays and operating and safety controls. Check motor operating conditions. Check and clean fan blades as required. Check and clean coil. Straighten fins as required. Check operating conditions. Adjust as required. HOT WATER BOILERS Inspect fire side of boiler and record condition. Brush and vacuum soot and dirt from flues and combustion chamber. Inspect firebrick and refractory for defects. Patch and coat as required. Visually inspect boiler pressure vessel for possible leaks and record condition. Disassemble, inspect and clean low-water cutoff. Check hand valves and automatic feed equipment. Repack and adjust as required. Inspect, clean and lubricate the burner and combustion control equipment. Check burner sequence of operation and combustion air equipment. Check fuel piping for leaks and proper support Clean external surfaces as required. Clean boiler room. Review log. Log all operating conditions. Test low water cut-off and pressure relief valve. Check operating and safety controls. 7

8 Review boiler operation with boiler operator. PUMPS Lubricate pump bearings per manufacturer's recommendations. Lubricate motor bearings per manufacturer's recommendations. Tighten all nuts and bolts. Check motor mounts and vibration pads. Replace and adjust as required. Visually check pump alignment and coupling. Check motor operating conditions. Inspect electrical connections and contactors. Check and clean strainers, then check hand valves. Inspect mechanical seals. Replace as required or inspect pump packing. Replace and adjust as required. Verify gauges for accuracy. Clean external surfaces as required. Check suction and discharge pressures. RECIPROCATING CHILLERS Inspect for leaks. Check belts, sheaves and coupling alignment. Replace and adjust as required. Check compressor oil level, acid test oil and meg hermetic motor. Change oil and refrigerant filter-dryer as required. Check compressor crankcase heater operation. Check vibration eliminators. Replace or adjust as required. Inspect electrical connections, contactors, relays and operating/safety controls. Clean external surfaces as required. Review manufacturer's recommendation for start-up. Check auxiliary equipment operation. Energize crankcase heater per manufacturer's recommendation for crankcase warm-up. 8

9 Check and test all operating and safety controls. Start chilled water pump, condenser water pump and cooling tower. Check refrigerant charge, oil and oil pressure. Log all operating conditions, after unit stabilizes. Review operating procedures. Inspect chiller and make adjustments as required. Cycle operating controls and check unloaders. Review chiller operation. STEAM BOILERS Inspect boiler and burner, then make adjustments as required. Test low water cut-off and pressure relief valve. Check operating and safety controls. Review boiler operations with boiler operator. Log all operating conditions. Shut off burner and open electrical disconnect. Close fuel supply valves. Thoroughly blow down boiler. WATER TREATMENT COOLING TOWERS Operate all chemical bleed and feed equipment to assure proper operation. Chemically test the system water for proper bleed rate and treatment levels. Adjust the controls to obtain proper operation. Visually inspect the open portions of the system for evidence of corrosion, scale or slime and algae growth. Slug feed biocide and antiform to control slime and algae growth. Furnish a written report of the test and inspection results including recommendations. Inventory the remaining water treatment chemicals and reorder as required. 9

10 CLOSED SYSTEMS Chemical test the system water for proper treatment levels. Adjust the treatment level for proper operation. Furnish a written report of the test and inspection results including recommendations. ASSOCIATED EQUIPMENT UNIT VENTILATOR FAN COILS RADIATION Brush and vacuum grilles, coil, fan and unit interior. Lubricate fan and motor bearings per manufacturer's recommendations. Check belt and sheaves. Replace and adjust as required. Check and clean drains and drain pan. Check and clean strainers. Check steam traps and hand valves. Inspect filters. Check unit operating conditions. Lubricate and adjust dampers and linkage. Brush and vacuum grilles, coil, fan and unit interior. Lubricate fan and motor bearings per manufacturer's recommendations. Check belt and sheaves. Replace and adjust as required. Check and clean drains and drain pan. Check and clean strainers. Check steam traps and hand valves. Inspect filters. Check unit operating conditions. Lubricate and adjust dampers and linkage. Visually inspect fins/cast iron. Clean as required. Check and clean strainers. Check traps and hand valves. INDUCTION UNITS 10

11 Visually inspect coil. Clean as required. Check and clean drains and drain pans. Clean discharge grille. Check and clean strainers. Check and clean steam traps and hand valves. REHEAT COILS Visually inspect coil. Clean as required. Check and clean strainers. Check steam traps and hand valves. Inspect electrical connections, relays, contactors and operating and safety controls. BOXES DUAL DUCT AND VARIABLE AIR VOLUME Inspect box for duct work connection. Lubricate and adjust dampers and linkage. FALL PRESEASON CHECK LIST BOILERS Check safety relief valve. Check combustion controls. Check piping and connections. Check low water cutoff. Check water make-up system. Check room air intake system. Check valves. Check water level gauge glass and controls. Disassemble low water cutoff. Clean low water cutoff. Check contacts. Check mercury bulbs. Check wiring. Reassemble low water cutoff. 11

12 Clean internal surfaces (as required). Clean external surfaces (as required). Clean burner assembly. Clean make-up water components. Clean hi-water components. Clean fireside. Clean flues. Inspect refractory. Blowdown mud legs. Blowdown gauge glass. Blowdown feeder cutoff switch (steam). Prepare machine for winter conditions. Log machine condition at departure. ELECTRIC BOILERS OIL BOILERS Check magnetic contactors. Check pressure control. Check hi-limit switch. Check step controller. Check burner operation. Check burner control system. Check fuel pump. Check fuel valves (for tight seating). Check oil heater(s). Check tank heater. Check fluid system. 12

13 GAS BOILERS Check for fuel leaks. Check linkage. Check flame detection. SEASONAL MAINTENANCE CHECKLISTS Check flue gas temperature and content. Check burner operation. Check gas booster. Check gas regulator. Check linkage. Check for gas leaks. Check gas safety switch. Check gas valves (for tight seating). Check flue gas temperature and content. STEAM BOILERS Check condensate float valve. Check condensate return pumps. Check condensate tank. Check pumps. Check gas safety switches. Check pressure controls. Check draft fans/switches. HOT WATER BOILERS Check circulating pump system. Check water cutoff. Check water feeder. Check shutoff valves. 13

14 Check temperature controls. Check draft system. AUTOMATIC TEMPERATURE CONTROLS AIR COMPRESSOR Drain tank and check traps. SEASONAL MAINTENANCE CHECKLISTS Change oil and check oil pressure. Check belt and sheaves and change as required. Change suction filter as required. Check unloader and check valve. Check high pressure safety valve. Check motor operating conditions and lubricate. Check PE switch, starter and alternator. Clean and paint as required. REFRIGERATED AIR DRYER Check refrigerant pressure. Check refrigerant temperature. Clean condenser and cover grilles. Check drain trap and bypass valves. FILTER AND PRESSURE REDUCING STATION Check particle filters (change as required). Check oil filter (change as required). Check pressure reducing valve settings. Check low pressure safety valve. BOILER Calibrate all controllers. Calibrate all transmitter and receiver gauges. 14

15 Check all PE switches. Check all control valves. Check all pilot positioners. SEASONAL MAINTENANCE CHECKLISTS Check all auxiliary control devices. FAN SYSTEMS AND HVAC UNIT CONTROLS Review sequence of operation. Check all dampers and lubricate. Check pilot positioners. Check all control valves. Calibrate all controllers. Calibrate all transmitters and receiver gauges. Check all solenoid air valves, PE switches and air valves. Check all auxiliary control devices. ROOM TERMINAL UNIT CONTROLS Check all room stats. Check operation of unit coil steam traps. WATER TREATMENT OPEN STEAM BOILERS Operate all chemical bleed and feed equipment to assure proper operation. Chemically test the system water for proper bleed rate and treatment levels. Adjust controls to achieve proper operation. Furnish a written report of the test and inspection results including recommendations. Inventory the remaining water treatment chemicals supply and reorder as required. CLOSED SYSTEMS Chemically test the system water for proper treatment levels. Adjust the treatment level for proper operation. 15

16 Furnish a written report of the test and inspection results including recommendations. Inventory the remaining water treatment chemicals supply and re-order as required. FANS & CENTRAL FAN SYSTEMS Check and clean fan assembly. Lubricate fan bearings per manufacturer's recommendations. Lubricate motor bearings per manufacturer's recommendations. Check belts and sheaves. Replace and adjust as required. Tighten all nuts and bolts. Check motor mounts and vibration pads. Replace and adjust as required. Check motor operating conditions. Inspect electrical connections and contactors. Lubricate and adjust associated dampers and linkage. Check fan operation. Check and clean drains and drain pans. Check and clean strainers, check steam traps and hand valves. Check filter advancing mechanism. Lubricate and adjust as required. Inspect filters. Check heating coils. Inspect humidifier. ASSOCIATED EQUIPMENT UNIT VENTILATOR Brush and vacuum grilles, coil, fan and unit interior. Lubricate fan and motor bearing per manufacturer's recommendations Check belt and sheaves. Replace and adjust as required. Check and clean drains and drain pan. Check and clean strainers. Check steam traps and hand valves. Inspect filters. 16

17 Check unit operating conditions. SEASONAL MAINTENANCE CHECKLISTS Lubricate and adjust dampers and linkage. Clean and paint exterior surfaces as required. FAN COILS / UNIT HEATERS RADIATION Brush and vacuum coil, fan and housing as required. Lubricate fan and motor bearings per manufacturer's recommendations. Check belt and sheaves. Replace and adjust as required. Check and clean strainers. Check steam traps and hand valves. Inspect electrical connections, contactors, relays and operating/safety controls. Check unit operation. Adjust as required. Visually inspect fins/cast iron. Clean as required. Check and clean strainers. Check steam traps and hand valves. INDUCTION UNITS Visually inspect coil. Clean as required. Check and clean drains and drain pans. Clean discharge grille. Check and clean strainers. Check steam traps and hand valves. REHEAT COILS Visually inspect coil. Clean as required. Check and clean strainers. Check steam traps and hand valves. BOXES DUAL DUCT AND VARIABLE AIR VOLUME Inspect box for duct work connection. Lubricate and adjust dampers and linkage. MISC. HVAC EQUIPMENT HEAT EXCHANGER Visually check for leaks. Tighten connections. 17

18 HUMIDIFIERS STEAM PRV SEASONAL MAINTENANCE CHECKLISTS Verify pressure gauge and thermometer accuracy. Check and clean strainers. Check steam traps and hand valves. Check operating safety devices. Check and clean strainers. Check steam trap and hand valves. Clean and check float assembly. Check and clean drains and drain pan. Clean heating element. Inspect electrical connections, relays, contactors and operating and safety controls. Clean plugged spray nozzles. Check unit operating conditions. Verify accuracy of gauges. Check unit operation and lubricate as required. UNITARY EQUIPMENT HEATING STEAM, HOT WATER, ELECTRIC, GAS OR OIL BURNER Lubricate fan bearings per manufacturer's recommendation. Lubricate motor bearings per manufacturer's recommendation. Check belts and sheaves. Replace and adjust as required. Check cooling coil, clean and straighten fins as required. Lubricate and adjust dampers and linkages. Check and clean drain pan and drains. Inspect filters. Check motor operating conditions. Inspect electrical connections, contactors, relays and operating/safety controls. Check and clean strainers and check hand valves. Secure unit panels and inspect roof curb flashing. 18

19 Inspect, clean and lubricate the burner and combustion control equipment. Check burner sequence of operation and combustion air equipment. END-OF-SEASON AIR CONDITIONING CHECK LIST REFRIGERATION SYSTEMS GENERAL Pump down refrigeration system (if no longer required). Close inlet and outlet valves. Check vessel connections for leaks. Check condenser and receiver relief valves for leaks. Disconnect power supply to the control circuit. Tag "off season." Check refrigeration system and piping for possible repairs. Calibrate pressure gauges and thermometers. Check safety controls for proper setting and operation. Clean and tighten electrical connections. Lab test lithium bromide and refrigerant water samples. COMPRESSORS AND MOTORS Schedule full or partial dismantling of the compressor. Check valve wear. Check bearing wear. Check for misalignment. Drain, check and clean oil reservoir. Change oil filters, clean strainers. Take oil sample for laboratory analysis. Check oil heaters and controls. Check thrust bearing end-clearance and record. Inspect inlet damper mechanisms for cracks and wear. Clean all sight glasses. 19

20 Overhaul purge unit. SEASONAL MAINTENANCE CHECKLISTS Change oil in speed increaser gear sets. Check open drive motor couplings for wear and alignment. Clean motor windings and lubricate bearings. Cover motors subject to airborne contaminants. HEAT TRANSFER SURFACES Blow air through condenser to remove trapped water. Circulate anti-freeze solution through condenser and water piping. Remove condenser heads and clean tubes. Inspect condensers for signs of corrosion. Evaluate water treatment. COOLING TOWERS Disassemble, clean, reassemble float and ball-cock valves. Wash down interior of the cooling tower. Clean perforated head pans and spray nozzles. Drain and flush tower pans. Drain and flush pipelines. Drain and flush pumps. Lock closed automatic "fill" valves. Remove and clean strainers and screens. Inspect tower fans and drives for wear, cracking and corrosion. Cover fan and louver openings subject to airborne dirt. Check pump motor bearings and lubricate. Paint all metal parts subject to alternate wetting and drying. AIR COOLED CONDENSERS Clean, inspect and cover air cooled condensers. 20

21 Clean and check fan blades. SEASONAL MAINTENANCE CHECKLISTS Inspect and lubricate fan bearings. Loosen fan belts or remove. AIR HANDLING COILS Drain and flush coils with antifreeze solution. Clean coil face. Clean condensate traps. Clean and drain pans. Check and calibrate freezestat controls in air ducts. Install freeze alarms in ducts. FREEZING WEATHER CHECK LIST BOILER AND PIPING Drain and blow out all idle equipment. Check service water lines for possible freezing. Replace damaged insulation. Check tracing around control lines and transmitter boxes. Check all steam traps for proper function. COMPRESSOR AIR SYSTEMS Check air driers. Drain air tanks. Check aftercoolers and intercoolers. Drain, blow out, and flush with glycol all idle compressor jackets. AIR CONDITIONING AND REFRIGERATING SYSTEMS Drain, blow out, and flush all seasonal equipment, condenser lines, tubing and piping. Check all outside dampers. Cut back cooling tower fan speeds. 21

22 PRESSURE VESSEL VENTS Correct low spots in long runs. Drain loops and bends. SEASONAL MAINTENANCE CHECKLISTS Enlarge vent diameters at point of outside discharge. Protect vessel vents from ice or snow accumulation. RELIEF VALVES Protect against snow or ice accumulation. Clear relief valve body drains. Protect valve discs from freezing shut. Relocate relief valves to heated areas wherever possible. MECHANICAL EQUIPMENT Drain all idle pumps and compressors. Make sure jackets are vented. Provide proper lubrication for cold weather operation. Provide heated enclosures around operating equipment wherever possible. Install no-flow switches and alarms in cooling water lines. PERSONNEL AND PROCEDURES Institute a freeze-up procedure and educate all personnel in its use. Appoint a "weather watcher" to monitor weather reports. Instruct personnel in the proper methods of thawing out frozen equipment safely. Provide cold weather gear (gloves, heavy clothing, etc.). Recruit standby personnel to monitor instrumentation when needed. Set up priority for steam usage in order to keep critical equipment in use and provide adequate tracing steam. Copyright 1986, 2009, By Refrigeration Service Engineers Society. 22

CENTRIFUGAL CHILLER. Lubrication System Pull oil sample for spectroscopic analysis.

CENTRIFUGAL CHILLER. Lubrication System Pull oil sample for spectroscopic analysis. CENTRIFUGAL CHILLER Annual Inspection Refrigerant Circuit Check and record refrigerant level Inspect for leak results Calculate refrigerant lass and report to the customer. Repair minor leaks as required