seasonal maintenance checklists · check operation of purge unit. change oil in the purge pump....

Service Application Manual SAM Chapter 630-90

Section 22

SEASONAL MAINTENANCE CHECKLISTS Johnson Controls

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.

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Section 22


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.



Calibrate all transmitters and receiver gauges.

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Section 22


Check all solenoid air valves, PE switches and air valves.


ROOM TERMINAL UNIT CONTROLS

Check all room thermostats.


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 refrigerant and oil levels.

Check oil pump heater and purge oil heater.


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Section 22


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.



Clean float valve assembly and check for proper operation.

Check operating conditions. Adjust as required.

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Section 22


DIRECT EXPANSION COOLING




Check and clean coils. Straighten fins as required.

Lubricate and adjust dampers and linkages.

Check and clean drain pan and drains.

Inspect filters.



Check compressor oil level, acid test oil and meg motor. Check crankcase heater operation.

Start compressor, check operating conditions and adjust as required.


Inspect for refrigerant leaks.

Check operating conditions and adjust as required.

HEAT EXCHANGER

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.

HUMIDIFIERS

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.

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Section 22


Inspect electrical connections, relays, contactors and operating and safety controls.

Clean plugged spray nozzles.

Check unit operating conditions.

Clean exterior surfaces as required.

STEAM PRV

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.


Tighten all nuts and bolts.

Check motor mounts and vibration pads. Replace and adjust as required.


Inspect electrical connections and contactors.

Lubricate and adjust associated dampers and linkage.

Check fan operation.

Clean outside air intake screen.


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.

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Section 22


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 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 boiler room.

Review log. Log all operating conditions.

Test low water cut-off and pressure relief valve.

Check operating and safety controls.

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Section 22


Review boiler operation with boiler operator.

PUMPS

Lubricate pump 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 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.


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.



Review manufacturer's recommendation for start-up.


Energize crankcase heater per manufacturer's recommendation for crankcase warm-up.

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Section 22



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.

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Section 22


CLOSED SYSTEMS

Chemical test the system water for proper treatment levels.

Adjust the treatment level for proper operation.


ASSOCIATED EQUIPMENT UNIT VENTILATOR

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.



Inspect filters.



FAN COILS






Inspect filters.



RADIATION

Visually inspect fins/cast iron. Clean as required.

Check and clean strainers. Check traps and hand valves.

INDUCTION UNITS

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Section 22


Visually inspect coil. Clean as required.


Clean discharge grille.

Check and clean strainers. Check and clean steam traps and hand valves.

REHEAT COILS




BOXES—DUAL DUCT AND VARIABLE AIR VOLUME

Inspect box for duct work connection.


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.

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Section 22


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

Check magnetic contactors.

Check pressure control.

Check hi-limit switch.

Check step controller.

OIL BOILERS

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.

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Section 22


Check for fuel leaks.

Check linkage.

Check flame detection.

Check flue gas temperature and content.

GAS BOILERS

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.

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Section 22


Check temperature controls.

Check draft system.

AUTOMATIC TEMPERATURE CONTROLS AIR COMPRESSOR

Drain tank and check traps.

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 transmitter and receiver gauges.

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Section 22


Check all PE switches.


Check all pilot positioners.


FAN SYSTEMS AND HVAC UNIT CONTROLS

Review sequence of operation.

Check all dampers and lubricate.

Check pilot positioners.



Calibrate all transmitters and receiver gauges.

Check all solenoid air valves, PE switches and air valves.


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.


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


Section 22



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.



Tighten all nuts and bolts.

Check motor mounts and vibration pads. Replace and adjust as required.



Lubricate and adjust associated dampers and linkage.

Check fan operation.


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


Lubricate fan and motor bearing per manufacturer's recommendations




Inspect filters.

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Section 22




Clean and paint exterior surfaces as required.

FAN COILS / UNIT HEATERS

Brush and vacuum coil, fan and housing as required.





Check unit operation. Adjust as required.

RADIATION

Visually inspect fins/cast iron. Clean as required.


INDUCTION UNITS



Clean discharge grille.


REHEAT COILS



BOXES—DUAL DUCT AND VARIABLE AIR VOLUME

Inspect box for duct work connection.


MISC. HVAC EQUIPMENT HEAT EXCHANGER

Visually check for leaks. Tighten connections.

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Section 22


Verify pressure gauge and thermometer accuracy.


Check operating safety devices.

HUMIDIFIERS

Check and clean strainers. Check steam trap and hand valves.

Clean and check float assembly.


Clean heating element.


Clean plugged spray nozzles.


STEAM PRV

Verify accuracy of gauges.

Check unit operation and lubricate as required.

UNITARY EQUIPMENT—HEATING STEAM, HOT WATER, ELECTRIC, GAS OR OIL BURNER




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 and clean strainers and check hand valves.


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Section 22


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.

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Section 22


Overhaul purge unit.

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.

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Section 22


Clean and check fan blades.

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.

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Section 22


22

PRESSURE VESSEL VENTS

Correct low spots in long runs.

Drain loops and bends.

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.

seasonal maintenance checklists · check operation of purge unit. change oil in the purge pump....

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