Chiller Preventive Maintenance Daily / Weekly / Monthly Log Sheet
Standardised log for recording daily, weekly, and monthly preventive maintenance checks on industrial chillers. Covers refrigerant pressures, condenser coil condition, water treatment parameters, electrical integrity, safety cutouts, and corrective actions — all in one auditable form.
This log sheet provides a structured daily, weekly, and monthly inspection regime for industrial chillers. It captures critical operating parameters — suction/discharge pressures, condenser approach temperature, oil level, refrigerant charge, water treatment chemistry, electrical insulation values, and safety cutout functionality — ensuring proactive detection of degradation before unplanned downtime. Compliance with ASHRAE 15, CSA B52, and manufacturer warranty requirements is supported through consistent documentation.
- Lockout/Tagout — isolate chiller electrical disconnect and verify zero energy before opening panels or accessing refrigerant circuits. Use group LOTO if multiple technicians are involved.
- Required PPE: safety glasses, cut-resistant gloves, dielectric boots, hearing protection (if compressor enclosure is opened). Carry refrigerant-grade gloves and face shield when handling refrigerant.
- Required tools: manifold gauge set, thermometer/pyrometer, refrigerant leak detector (electronic or UV), megger (500 V), water test kit (pH, conductivity, inhibitor level), and manufacturer O&M manual.
- Environmental conditions: chiller room must be well-ventilated. If refrigerant leak is suspected, use continuous monitoring and evacuate if concentration exceeds 1,000 ppm.
Inspection / Log Matrix
| Status (P/F) | Inspection Item / Task | Tolerance / Threshold | Actual Reading |
|---|---|---|---|
| [ ] Pass [ ] Fail | Suction pressure (low side) — each circuit | Per OEM spec ± 5 % | ______ psig |
| [ ] Pass [ ] Fail | Discharge pressure (high side) — each circuit | Per OEM spec ± 5 % | ______ psig |
| [ ] Pass [ ] Fail | Oil level in sight glass — each compressor | Between ¼ and ¾ sight glass | ______ / ¾ |
| [ ] Pass [ ] Fail | Condenser approach temperature | ≤ 10 °F (5.5 °C) above ambient | ______ °F / °C |
| [ ] Pass [ ] Fail | Evaporator approach temperature | ≤ 6 °F (3.3 °C) above setpoint | ______ °F / °C |
| [ ] Pass [ ] Fail | Refrigerant sight glass — moisture indicator | Green (dry) / yellow (wet) — must be dry | _____ / dry |
| [ ] Pass [ ] Fail | Condenser coil cleanliness — visual & pressure drop | No visible debris; ΔP ≤ 1.5 × clean baseline | ______ inH₂O |
| [ ] Pass [ ] Fail | Water treatment — pH, conductivity, inhibitor residual | pH 7.0–8.5; cond. < 600 µS/cm; inhibitor > 80 % | pH ___ / ___ µS |
| [ ] Pass [ ] Fail | Flow switch operation — evaporator & condenser | Closes within 5 s of flow established | ______ s |
| [ ] Pass [ ] Fail | Vibration — compressor bearing housing (velocity) | ≤ 0.25 in/s (6.4 mm/s) peak | ______ in/s |
| [ ] Pass [ ] Fail | Electrical — megger test (motor windings to ground) | ≥ 1 MΩ at 500 V; trending no drop > 25 % | ______ MΩ |
| [ ] Pass [ ] Fail | Safety cutouts — high-pressure, low-pressure, freeze-stat | Each trips within spec; reset manually verified | ______ / ______ / ______ |
Defect / Corrective Action Log
| Date / Time | Item # | Issue Identified | Corrective Action Taken | WO # |
|---|---|---|---|---|
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
By signing below, the inspector verifies that all items have been checked according to the manufacturer's specifications and facility safety standards. Any out-of-tolerance condition has been recorded in the Defect / Corrective Action Log.