Annual service - water-cooled and air-cooled chiller systems
Estimated duration: 4 - 8 hours • Frequency: every 12 months
Equipment Details
| # | Service Action (Annual Additional Items) | Type | Done | Notes |
|---|---|---|---|---|
| Refrigerant System | ||||
| 1 | Full refrigerant leak test (electronic detector on all joints and fittings) | TEST | ☐ | |
| 2 | Update refrigerant register / F-gas log | RECORD | ☐ | |
| 3 | Verify safety data sheets for refrigerant on site | CHECK | ☐ | |
| Compressor | ||||
| 4 | Compressor oil analysis (send sample for acid test, moisture, metal content) | SAMPLE | ☐ | |
| Heat Exchangers | ||||
| 5 | Eddy current test on condenser / evaporator tubes (water-cooled, if due per schedule) | TEST | ☐ | |
| 6 | Clean evaporator tubes (water-cooled) | CLEAN | ☐ | |
| Instrumentation and Calibration | ||||
| 7 | Calibrate all temperature sensors and pressure transducers | CALIBRATE | ☐ | |
| 8 | Calibrate chilled water flow meter | CALIBRATE | ☐ | |
| Variable Speed Drive (if Fitted) | ||||
| 9 | Inspect VFD / variable speed drive (fan, amps, fault log) | INSPECT | ☐ | |
| Electrical | ||||
| 10 | Electrical insulation resistance test (megger on compressor motor windings) | TEST | ☐ | |
| Performance Testing | ||||
| 11 | Full chiller performance test (measure COP / EER at design conditions) | TEST | ☐ | |
| Valves and Compliance | ||||
| 12 | Inspect and exercise all isolation valves | INSPECT | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Notes |
|---|---|---|
| Refrigerant | R-134a, R-410A, R-407C or as specified | Do not top up without leak test |
| Compressor oil | POE or mineral per manufacturer | Oil sample required annually |
| Condenser water treatment | Biocide, anti-scale, corrosion inhibitor | Water-cooled systems only |
Specifications are general guidelines. Always refer to the chiller manufacturer's service manual for your specific make and model. Refrigerant handling requires an appropriate licence.
Parts / Consumables Required (Annual Additional)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Oil sample kit (bottle, label, prepaid postage) | 1 | ☐ | |
| 2 | Calibration equipment (reference gauges, RTD) | 1 set | ☐ | |
| 3 | Tube cleaning brushes / balls (water-cooled) | As req. | ☐ | |
| 4 | Replacement sensors (if failed during test) | As req. | ☐ | |
| 5 | Electronic refrigerant leak detector | 1 | ☐ | |
| 6 | Insulation resistance tester (megger) | 1 | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Facilities Manager