Information Prior to Commencement
Customer and System Information
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Farm Supply Number - (Add photo of gate plate)
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Client Business Name
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Customer Name (Farm Owner)
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Physical Address - Inspection Location
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Telephone Number
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Farm Manager
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Farm Manager Email Contact:
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Farm Managers Telephone Number
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Date Service is Conducted On
Contact Customer to Gain Entry
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Has the customer been contacted and he is aware that you are on site?
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Question the farmer asking him if he has had any alarms or is aware of any repairs that may need carried out.
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Is there a sign in procedure on site
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If a sign procedure exists has this process been followed.
CoolCARE Dealership and Technician Details
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CoolCARE dealership carrying out maintenance
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Name of service technician/s
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Telephone number of senior service technician
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E-mail of senior service technician
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Type of service being carried out.
- Yearly Maintenance
- Major Service Year 7 or 60,000 run hours
Existing Chilling System details
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Existing Chilling System - General comments
VariCOOL Chilling System Type
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Chiller Purpose
- Vat Cooling ONLY
- Plate Heat Exchanger Cooling ONLY
- Vat & Plate Heat Exchanger Cooling
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Photo of the Chilling System Identification Plate.
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Serial Number of Chilling System
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Photos of Chilling Condition (Before Commencing Maintenance)
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What is the Refrigerant Used In VariCOOL
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R454B is an A2L refrigerant, No naked flames should be used while gas is contained in the system !! Read and review the attached (Material Safety Data Sheet).
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Have you read and do you understand the Health and Safety risks around A2L Refrigerants
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R410A has a GWP value of 2,088
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Is there any visible signs of refrigerant leakage?
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Add photos of the areas indicating leakage
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What is the general condition of the system upon initial inspection.
Condenser Coil Maintenance
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Signal generator fitted to the fan speed signal wire as per SOP-VC-MAIN-VCII (Section 1)
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List why the signal generator was not needed to run the fan during condenser coil cleaning.
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Condenser coil ambient temperature unscrewed and remove condenser coil guards ?
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Take photograghs of the condenser coils when the mesh has been removed before commencing cleaning.
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Take picture of corflute fitted to two condenser coil sides.
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Has Coil cleaner been applied using the Technical Procedure in SOP-VC-MAIN-VCII (Section 1.13-4)
- Yes
- No
- Unkown at this time
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Has condenser coil been cleaned using the Technical Procedure in SOP-VC-MAIN-VCII (Section 1.15)
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Please take pictures of all of the cleaned condenser coil surfaces
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Condenser coil mesh removed and cleaned as per procedure. SOP-VC-MAIN-VCII (Section1)
- Yes
- No
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Corflute placed over condenser surfaces in prep for external cleaning.
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Verify that section 1 of SOP-VC-MAIN-VCII was followed.
Cleaning
External Cleaning
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Please take pictures of the chilling system once cleaning detergent is applied with the foam cannon. SOP-VC-MAIN-VCII (Section 2.4)
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Please take pictures of the chilling system once system is scrubbed down and pressure washed. SOP-VC-MAIN-VCII (Section 2.5-6)
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Please take a picture of the pedestal and pipework connecting system once wiped down and cleaned.
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Please take picture of the chilling system when corflute is removed and the condenser gurads and temp probe bracket are refitted.
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Verify section 2 of SOP-VC-MAIN-VCII was followed.
Hydronic and Electrical Cabinet Internal Cleaning
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Please take pictures of the internal of the hydronic cabinet before commenceing cleaning.
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Please take pictures of the electrical cabinet before commencing cleaning.
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Please take pictures of the electrical and hydronic cabinet after completing the cleaning regimine detailed in section 3 of SOP-VC-MAIN-VCII.
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Please Verify that section 3 of SOP-VC-MAIN-VCII was followed.
Glycol Testing and Top-Up
Glycol Testing and Top Up.
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Please open service door and take a picture of the glycol level sensor.
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Take a sample of glycol from the fill valve place in refractomemter lens and take a picture of the glycol percentage.
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Record the litres of Glycol or Water that has been added to gain the freeze point of between -16 and -20 deg c .
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Once the glycol or water has been added take a sample of glycol from the fill valve place in refractomemter lens and take a picture of the glycol percentage.
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Was the pump run and glycol mixture circulated for more that 2 minutes
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Please re-test the glycol percentage using a refractomemter having circulated the buffer tank mixture for at least 2 minutes.
Glycol Buffer Tank Topup Reset
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Please take a picture of the buffer tank top-up screen to show litres of water since last glycol check.
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Please record the original (Topups Since Glycol Check).
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Please record the (Litres Since Glycol Check)
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Please take a picture of the buffer tank topup screen once the reset has been achieved following section 4 of SOP-VC-MAIN-VCII (Section 4.12)
Refrigerant Circuit Examination
- Refrigerant Charge Check
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Take short video of the refrigerant sight glass while chiller is running in milking mode.
Threaded and Schrader Valve Connections Check
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Please take a picture of the pressure relief valve thread, is any oil residue visible
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Please take a picture of the pressure transducer schrader valve connection, is any oil residue visible
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Please take a picture of the high pressure safety switch schrader valve connection, is any oil residue visible
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Please take a picture of maintenance ports schrader valves, is any oil residue visible
Check Control Condition of Electronic Expansion Valve
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Following procedure SOP-VC-MAIN-VCII (Section 5.6) take a picture of the superheat control panel
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Is the valve controlling a steady 8 deg superheat when in milking mode
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Is the valve position steady and not at 100% opening.
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Is the valve controlling a suction pressure above 4.0 bar when running in milking mode.
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Please confirm that you have followed and completed the procedure SOP-VC-MAIN-VCII (Section 5)
Desuperheater Maintenance
Isolation and Filter Cleaning
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Is the isolator valve closed
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Once the filter bowl has been removed from the take a picture of the contamination of the filter.
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Has the filter been cleaned and refitted to the valve assembly.
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Once the pressure regulator has been removed please take a picture of the contamination of the filter.
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Has the filter been cleaned and refitted to the pressure regulator.
Maximum Water Flow Test
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When performing task set out in SOP-VC-MAIN-VCII (Section 6.6) please take a picture of the hot water flow meter
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Please record the flow meter displayed flow rate when testing maximum flow as per SOP-VC-MAIN-VCII (Section 6.6)
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Was the flow rate above 8 litres per minute?
Glycol Hydronic Checks and Maintenance
Isolate Circuit and Tighten Couplings
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Supply and return valves have been isolated
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Buffer tank supply and return lines have been isolated.
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Hydronic couplings shown in section 7 of SOP-VC-MAIN-VCII have been tightened.
Glycol Filter Maintenance
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When the glycol filter is removed please take a picture of the contamination of the filter.
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Are the threaded connections on each side of the filter assembly and flow meter free from leaks.
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Please remove assembly and reseal threaded unions.
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Did the filter have the secondary gause and was it removed.
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Has the filter been cleaned and refitted into the filter assembly.
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Please check the flow rate on the flow meter and record the value.
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Has the section 8 of SOP-VC-MAIN-VCII been fully completed.
Electrical Maintenance (Powered OFF)
Electrical Isolation
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Has the chilling systems main isolator in the farm electrical distribution board been switched to off is a method of to prevent the livening of this circuit while you work on section 9 of the procedure.
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Do not carry out the technical procedure listed in section 9 without the mains power being isolated to the electrical cabinet !
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Is a method of to prevent the livening of this circuit while you work on section 9 of the procedure.
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Please ensure that the circuit cannot be livened while working on the chilling system.
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Have you tested the main incomer with a multimeter to check that no voltage is being fed to the mains supply cable feeding the VariCOOL chiller.
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Please note that voltage can exist on the VSD power connections for up to 60 seconds after isolation.
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Do not work on section 9 of the procedure without the electrical cabinet being isolated at the main switchboard. (This may result in death or serious injury).
Terminal Tightening
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Has the main isolator top and bottom been tightened.
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Have the mains circuit breakers been tightened on both the top and bottom terminals.
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Have the small low voltage terminations been tightened.
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Have the sprung terminations had a tug test performed.
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Please take a picture of the electrical fan filters before being cleaned.
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Please take a picture of the electrical fan filters after being cleaned.
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Please take a picture of the cleaned electrical cabinet.
Electrical Maintenance (LIVE WORKS)
Risk Assessment
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Are you aware of the hazards presented with working in an electrically livened cabinet and do you recognise the risk of electrical shock if a lack of care is taken while performing section 10 of SOP-VC-MAIN-VCII
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Do not conduct section 10 of SOP-VC-MAIN-VCII move to section 11
Current Draw Testing
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Once the machine is livened and running in Milking mode test the current draw of the glycol pump on all three phases. Follow section 10.1 to 10.9 in SOP-VC-MAIN-VCII . list each draw on each phase.
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Take picture of the set point on the thermal overload and list its setpoint.
Readings from Electrical Instrumentation
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Please take picture of kW/hr meter reading.
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Follow section 10.14 of SOP-VC-MAIN-VCII and record the required values from the VSD HIM Module
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Record display 15-01 Running hours
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Record display 15-02 kW/Hrs Counter
Field Instrumentation and Equipment Maintenance
Milking and Vat Chilling Inputs Testing
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Do the proximity sensors on each vat 3 way handle illuminate when metal is placed on the sensor and does the VariCOOL make a loud long beep.
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Trace wiring fault and check for blown fuses seek assistance from CoolCARE if nessesary. Replace sensor if nessesary. Refer to the electrical wiring diagrams available from CoolCARE.
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Did the temperature sensor require adjustment to match the reading shown on the IR33 display.
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Record the temperature offsets once calibration has finished.
Vat Manifold Inspection.
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Inspect the solenoids on the vat manifolds and plate heat exchangers. Do they have signs of overheating or swelling.
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Inspect blue bypass valve caps on the vat manifold and ensure they have not been screwed down on to the restriction plunger.
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Have all overides been disabled
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please ensure that any input overides are switched off before leaving site.
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Please take 4 pictures of the chilling system now that the service has been completed as per section 11.16 of SOP-VC-MAIN-VCII
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Has section 11 been completed in SOP-VC-MAIN-VCII
