1

TABLE OF CONTENTS

ABSTRACT....................................................................................................................................8

CHAPTER 1 INTRODUCTION.................................................................................................9

CHAPTER 2 OVERVIEW OF MAINTENANCE ENGINEERING........................................10

CHAPTER 3 DETAILED DESCRIPTION OF AIR CONDITIONING...................................11

3.1 Scope of Air Conditioning..............................................................................................11

3.2 Types of Air conditioning system...................................................................................11

3.3 Application of Air conditioning system..........................................................................13

3.4 Construction details of air conditioning system..............................................................14

CHAPTER 4 CENTRAL AIR CONDITIONING SYSTEM....................................................15

4.1 Background of central AC..............................................................................................15

4.2 Advantages of a central AC system:...............................................................................15

4.3 Disadvantages of a central air conditioning system:.......................................................15

4.4 Detailed Classification of Central Air conditioning system...........................................16

4.5 Basic Classifications of central air conditioning systems...............................................17

4.5.1 Split Air Conditioner...............................................................................................17

4.5.2 Packaged Air Conditioner........................................................................................18

4.6 Comparison between split and packaged air conditioner using different criteria...........18

4.7 Construction Detail of Central Air Conditioning System...............................................19

4.7.1 Working Mechanism of Central air conditioning system........................................19

4.8 Installation and Location of Air Conditioners................................................................21

CHAPTER 5 MAINTENANCE PROCEDURE OF CENTRAL AC SYSTEM.......................23

5.1 Objective of maintenance................................................................................................23

5.2 Classification of maintenance.........................................................................................23

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 5.3 Inspection and maintenance of Central AC System........................................................24

5.3.1 General Overview of Problems in AC system.........................................................24

5.3.2 General Inspection tips for A/C...............................................................................25

5.3.3 Preventive Maintenance for AC units......................................................................25

5.3.4 Maintenance Procedure............................................................................................26

5.3.5 Maintenance procedure partwise.............................................................................27

CHAPTER 6 CORROSION DANGER ON THE CENTRAL AC SYSTEM...........................31

6.1 Corrosion.........................................................................................................................31

6.1.1 Reason for corrosion................................................................................................31

6.1.2 Effect from corrosion...............................................................................................31

6.2 Corrosion Control...........................................................................................................32

CHAPTER 7 CONDITION MONITORING TECHNIQUES...................................................34

7.1 Condition Monitoring.....................................................................................................34

7.2 Condition Monitoring Techniques..................................................................................34

7.3 Condition Monitoring Techniques for Central AC.........................................................35

CHAPTER 8 FAILURE ANALYSIS OF CENTRAL AIR CONDITIONING SYSTEM.......36

8.1 Common Causes of A/C Failure.....................................................................................36

8.2 Reasons to Perform A Failure Analysis..........................................................................37

8.3 Failure analysis tools.......................................................................................................38

8.3.1 Fault Tree Analysis..................................................................................................38

8.3.2 Failure mode and effect analysis.............................................................................40

CHAPTER 9 TOOLS AND EQUIPMENT FOR INSPECTION, MAINTENANCE AND

MONITORING..............................................................................................................................46

9.1 Inspection tools...............................................................................................................46

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 9.2 Tools for Air conditioning Maintenance.........................................................................48

9.3 Monitoring tools..............................................................................................................49

CHAPTER 10 USE OF COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM

FOR CENTRAL AC SYSTEM.....................................................................................................51

10.1 Computerized Maintenance Management System..........................................................51

10.2 Use of CMMS in HVAC.................................................................................................51

10.3 Best software related to CMMS for AC..........................................................................52

CHAPTER 11 SAFETY HAZARDS AND PRECAUTIONS.................................................53

11.1 Safety Hazards................................................................................................................53

11.2 Safety Precautions...........................................................................................................53

11.3 HVAC Technician Responsibilities................................................................................55

11.4 Homeowner's Responsibilities........................................................................................56

CHAPTER 12 BUDGETING & COST CONTROL TECHNIQUES IN MAINTENANCE

AND OPERATION.......................................................................................................................57

12.1 Maintenance Budgeting..................................................................................................57

12.2 Role of preventive maintenance in cost control..............................................................57

12.3 Replacement of HVAC equipment on time for cost control...........................................58

12.4 Vetting commercial HVAC vendors for cost control.....................................................58

CHAPTER 13 TECHNICAL DOCUMENTATIONS.............................................................59

CHAPTER 14 CONCLUSION & RECOMMENDATION.....................................................61

CHAPTER 15 REFERENCE...................................................................................................62

CHAPTER 17 APPENDIX......................................................................................................64

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 LIST OF FIGURES

Figure 1 Classification of Central Air conditioning System.........................................................16

Figure 2 Classification of all air system under central air conditioning system............................17

Figure 3 Schematic Diagram of Air handling unit........................................................................19

Figure 4 AC system of a house including a network of warm air and cold air ducts....................20

Figure 5 Central AC cools with an outdoor compressor and condenser coil connected to an
indoor furnace fitted with an evaporator coil................................................................................21

Figure 6 Air conditioning unit.......................................................................................................22

Figure 7 AC problem tree..............................................................................................................24

Figure 8 Condition Monitoring Flow chart...................................................................................34

Figure 9 Fault Tree Analysis of central AC system......................................................................39

Figure 10 Combustible Gas Leak Detector...................................................................................46

Figure 11 Air Quality Meter..........................................................................................................47

Figure 12 AC 600A True RMS HVAC/R Clamp Meter...............................................................47

Figure 13 Honeywell Transmission Risk Air Monitor Bundle.....................................................48

Figure 14 Tools for Air Conditioning Maintenance......................................................................49

Figure 15 Maintenance checklist...................................................................................................59

Figure 16 Maintenance Checklist II..............................................................................................60

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 LIST OF TABLES
Table 1 Details of the EBEs...........................................................................................................40

Table 2 Severity Scale...................................................................................................................42

Table 3 Occurrence Scale..............................................................................................................42

Table 4 Detection Scale.................................................................................................................43

Table 5 FMEA Table.....................................................................................................................43

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 LIST OF ABBREVIATIONS

HVAC Heating, Ventilation and Air Conditioning

AC Air Conditioning

CMMS Computerized Maintenance Management System

EBE Extended Basic Event

7
 ABSTRACT

Air Conditioning has been defined as the process for treating air, so as to control simultaneously
its temperature, humidity, cleanliness and distribution to meet the requirements of the
conditioned space. It became evident nowadays that modernization influences domestic and
commercial HVAC industry, and thus high technological and energy-efficient central air
conditioning systems are demanded. This report describes the classification and proper operation
of central AC systems with detailed schematics. Proper maintenance can measurably extend the
overall lifespan of a machine, so this report discusses different methods of machine inspection
and maintenance. This report contains information on corrosion and prevention methods, as well
as various condition monitoring techniques. In addition to this error analysis, the use of CMMS
systems and security measures when using various tools are presented.

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 CHAPTER 1 INTRODUCTION

To keep our environment to our desired temperature, the air conditioning system is the device
that helps us achieve that. The system is so common that one can experience its effect anywhere
we enter. It can be installed in our house, office, cars, even a modern religious centre now have
it. in short, it can be used in both domestic and commercial environments Cooling is generally
achieved in the air conditioning system through a refrigeration cycle, but sometimes evaporation
or free cooling is employed. The system can also be made based on desiccants (chemicals that
eliminate moisture from the air). Most AC system stores and rejects heat in pipes called
subterranean.

Central air conditioning is one of the most convenient and energy-efficient ways to get relief
from the hot, humid summer weather throughout Connecticut. The system is powered by an
exterior cooling compressor. Similar to other air conditioners, ducts on the walls or floors are
utilized to distribute the cooled air around the building once it has been blown out by a fan and
cooled. The ducts will detect heated air in the space, and the air will be brought back to the air
conditioner to be forced outside.

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 CHAPTER 2 OVERVIEW OF MAINTENANCE ENGINEERING

Maintenance Engineering is the discipline and profession of applying engineering concepts to the
optimization of equipment, procedures, and departmental budgets to achieve better
maintainability, reliability, and availability of equipment. It is the occupation that uses
engineering theories and practices to plan and implement routine maintenance of equipment and
machinery. This must be done in conjunction with optimizing operating procedures and budgets
to attain and sustain the highest levels of reliability and profit.

Maintenance engineers are often required to have knowledge of many types of equipment and
machinery. A person working in the field of maintenance engineering must have in-depth
knowledge of or experience in basic equipment operation, logistics, probability, and statistics.
Experience in the operation and maintenance of machinery specific to a company's particular
business is also frequently required. Since the position normally requires oral and written
communications with various levels of personnel, excellent interpersonal communication and
participatory management skills are also desirable. Maintenance engineering positions require
planning and implementing routine and preventive maintenance programs. In addition, regular
monitoring of equipment is required to visually detect faults and impending equipment or
production failures before they occur [1].

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 CHAPTER 3 DETAILED DESCRIPTION OF AIR CONDITIONING

3.1 Scope of Air Conditioning

In great-grandfather’s day, air conditioning was confined to winter comfort; that is, to heating the
home to a comfortable temperature in the winter by means of open fireplaces or stoves. Later,
decided improvements were made in the heating equipment by the introduction of steam and hot
water heating, but air conditioning was still confined to winter comfort. Less than fifty years ago
human beings were content to be comfortable in winter and terribly uncomfortable during the
sweltering humid heat of summer [2].

Until recently, modifying the summer heat as well as warming the house in the winter was an
unknown factor in our daily lives. As air conditioning has developed, the many improvements
and advantages, such as removing dust from the air to create a thoroughly sanitary condition,
have widened its scope and use, not only for human comfort, but also in many manufacturing
processes where the use of air conditioning has become so extensive that it is a “must”. By
cleaning the air, controlling the amount of moisture in the air, and maintaining the air at a proper
temperature, great improvement is shown in the quality of the products and savings are made
possible by the reduction of material spoilage attributed to dust, bacteria or fluctuating
temperatures. The scope of air conditioning in industry is enormous. It is well worth it to
specialize in commercial air conditioning, because industrial plants of all kinds require properly
engineered and adjusted air conditioning systems

3.2 Types of Air conditioning system

There are several type of air conditioning systems based on different criteria and standards, some
major ones are listed below.

1. Mini-split and multi-split systems

Both multi split air conditioners and mini split air conditioners can heat and cool multiple rooms
or areas in a home. The key difference between the two is that anyone can set different
temperatures for different rooms with a multi split system while the same temperature applies to
all rooms with a mini split system [3].

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 2. Ducted central systems

A ducted air conditioner consists of two units—an indoor unit typically installed in the ceiling,
and an outdoor unit. The two units work together to perform a refrigeration cycle, with
conditioned air circulated and delivered via a series of ducts and vents. It’s usually the ideal
system for larger buildings, due to its efficiency and ease of control [4].

Ducted air conditioning is a refrigerated cooling system that uses refrigerant to change air
temperature. Refrigerant is a substance that can easily change between gas and liquid, and as it
goes through this process, it changes temperature. The ducted system uses this temperature
change to cool or heat air that it pulls from the house.

3. Central plant cooling

Central air conditioning systems are generally used to cool large homes or buildings such as
gyms or offices. These central systems are the most common type of air-cooling systems as they
are quick and efficient at cooling down larger areas.

The system works from a cooling compressor, which is located outside. Much like other air
conditioners, a coil filled with refrigerant is used to cool the air, which is then blown out by a fan
and circulated throughout the building with the use of ducts located on the walls or floors. If
there is warm air in a room, the ducts will register the heat and the air will then be transported
back to the air conditioner to be pushed outside [5].

4. Portable units

Portable air conditioners are similar to window air conditioners. They are also placed in a single
unit with all its components enclosed inside but the difference is that it is a free-standing unit and
therefore can be moved from room to room. All it requires is a power outlet to power it up &
access to a window where the unit’s air can be exhausted from using its funnel.

portable air conditioner is good for temporary space cooling or wherever it’s not practical to
install a window or split air conditioner. They are very handy and smaller versions can even be
used for kennels or bathrooms. Portable ACs can be singl- hose that takes in air from inside a
room and

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expel it outdoors. Or, dual-hose which pulls air from the outdoors using one hose, this air cools
the compressor and is then exhausted outdoors from the other hose.

Since a portable unit sits indoors, its evaporator fan runs continuously to evaporate the
condensed moisture that is collected inside the unit[5].

5. Packaged air conditioner

While traditionally, an air conditioning system is comprised of two parts; an outdoor condenser
and an indoor air handler, in a packaged air conditioner unit, all of the parts are enclosed in a
single box, usually located on the outside wall or roof of a building.

Packaged air conditioning systems have a higher cooling or heating capacity, making them ideal
for use in larger houses or commercial buildings. They work by installing the single component
and connecting the system to ducts laid throughout various rooms. By using electricity as its
power source, the unit circulates the refrigerant through the coils. Warm air is then pulled in by a
fan and passes over the cold evaporator coil, cooling it. The cool air is then pushed through the
ducts into the building.

6. Window unit and packaged terminal

These used to be a very common choice for controlling the temperature in a small room. They
contain the compressor, condenser, coils and the evaporator all in one single unit. Window air
conditioners are designed to fit into the window of a room, so they generally don’t need any
significant home modifications for installation. Wall units are very similar, except they need a
hole made in the room’s wall in order for them to fit [5].

3.3 Application of Air conditioning system

Air conditioning is required for

 Providing thermal comfort to humans and other living beings – Comfort air conditioning.
 Providing conditions required for various products and processes in industries –
Industrial air conditioning.

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3.4 Construction details of air conditioning system

Below are the components of the air conditioner used for commercial purposes[6]:

1. Compressor:

The compressor is the engine of the system as it works with a fluid that easily transforms the gas
into a liquid. Its primary function is to convert low-pressure gas into a high-pressure gas, which
has a high temperature. in its working, the gap regions between molecules get narrowed down
with a produced energized gas. This energized gas which also known as a refrigerant is released
from the compressor and enters the condenser.

2. Condenser Coil:

The condenser coil contains a fan that cools the high-pressure gas and converts it into a liquid.
The product obtained used by the evaporator to do the work. The compressor and condenser are
ones placed outside of the house.

3. Thermostat:

The thermostat maintains the temperature of an air conditioning system as it regulates the heat
energy inside and outside of it. depending on the design, a thermostat can set manually or
automatically.

4. Evaporator:

Evaporators are air conditioning components found inside the house near the furnace. It’s
connected to the condenser with an extreme thin pipe. The high-pressure gas is transformed into
a low-pressure liquid of the air conditioner. The liquid is then converted to gas due to the
decreasing pressure. The fluid or refrigerant is what takes away the heat from the and cools it off.
The evaporator releases the fluid in form of a gas in order to get compressed again by the
compressor. All of these happens in a cyclic fashion[6].

5. Air Handler and Blowing Unit:

This air conditioner components work together to draw the air to the evaporator and distribute
cool air over the room. A duct system facilitates the passage of airflow in the room.

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 CHAPTER 4 CENTRAL AIR CONDITIONING SYSTEM

4.1 Background of central AC

In central air conditioning, air, water, or both are used as working fluids to produce the required
heating and/or cooling, and therefore In a central station air conditioning system, all the
component of the system are grouped together in one central room and conditioned air is
distributed from the central room to the re-quired places through extensive duct work. The
central air conditioning system is generally used for the load above 25 tons of refrigeration and
2500 m3 /min of conditioned air. It is may be of interest to note that each type of the central air
conditioning systems has several systems of sometimes different configurations, and the use of
any system depends on its advantages and disadvantages.

4.2 Advantages of a central AC system:

 It cools all the rooms connected to ducts at once, thus creating a cooler & regulated
environment around the house in minimum time.

 Since cool air is circulated in all rooms, humidity is reduced around the house, making
the overall environment more comfortable.

4.3 Disadvantages of a central air conditioning system:

 It consumes a lot of energy resulting in higher energy bills.

 Such units may lose efficiency & effectiveness in case a problem arises in the ducts.

 Some find the outdoor unit to be unattractive but it can be hide creatively around the
backyard.

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4.4 Detailed Classification of Central Air conditioning system

based on working fluids, central air conditioning systems can be classified into three groups
namely:

 All-air systems: in these systems air is used as working fluid for heating and/or cooling
purposes.
 All-water (hydronic) systems: in these systems water is used as working fluid for
heating and/or cooling purposes.
 Air-water systems: in these systems both air and water are used as working fluids for
producing heating and cooling purposes. Detailed classification can be seen in flowchart.

Central Air
conditioning
System

Air water All water All Air System

System System

Induction unit
system
Primary air fan
coil system

Single Piping
System
Multi Piping
System

Direct return Reversed Return 4-Pipe System 3-Pipe system

Figure 1 Classification of Central Air conditioning System

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 All-Air System

Constant
Volume Multi Zone Unit
Reheat System
Induction System
System Variable Air
Voulme
Dual Duct
System

Conventional
System

Single duct
Conventional
Single duct
System
Conventional
System

Figure 2 Classification of all air system under central air conditioning system

4.5 Basic Classifications of central air conditioning systems

Central air conditioning systems come in two basic designs: split and packaged. Split systems are
the most commonly used type, and are split between an outdoor and an indoor unit, as the name
suggests. In a packaged/ductless system, all the components are housed in one unit that is
installed outside the home. Split and packaged systems both contain the same components and
can provide the same amount of cooling, but there are some differences.

4.5.1 Split Air Conditioner

The two parts of a split system are:

Indoor unit – A metal cabinet that contains the evaporator coil. This is installed inside the
house, usually in a utility closet or the attic. It’s usually the same cabinet that houses the furnace.
hoIf the house doesn’t have a furnace; the evaporator coil works as part of an air handler.

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Outdoor unit – A metal cabinet that contains the condenser, compressor and expansion valve.
This is located outside the home, usually on a concrete slab.

These two units are connected by refrigerant lines that run underground and conduct refrigerant
back and forth between the units.

4.5.2 Packaged Air Conditioner

Packaged air conditioners are similar to window air conditioners since all the components are
housed in one single unit. Unlike window A/Cs, however, packaged air conditioners are installed
outside the home, usually on the roof, and can cool the whole building. Some even contain a
heating system, such as a furnace, eliminating the need for a separate furnace indoors.

Two types of condensers are used in packaged systems:

Air-cooled – These condensers are cooled by the surrounding air. These are more common for
residential use.

Water-cooled – These condensers require a cooling tower, so they’re used primarily for large
commercial applications where water is plentiful.

4.6 Comparison between split and packaged air conditioner using different criteria

Energy efficiency – In general, split systems are more energy efficient than packaged systems.
Split systems are available with Seasonal Energy Efficiency Ratio (SEER) numbers of up to 24,
whereas packaged systems don’t often achieve SEER numbers above 18. SEER 18 is still
considered high efficiency.

Labor costs – Installation costs for a split system are typically higher than for a packaged
system. That’s because installing a split system involves working both outside and inside the
house, as well as connecting the two units. Installing a packaged system requires only outdoor
work with no need to connect different pieces of equipment. Split systems also need to be
charged with refrigerant whereas packaged systems may come pre-charged.

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Space requirements – If the open areas (attic and/or basement) in home are limited to
conveniently accommodate an A/C indoor unit, a packaged system (mini split) may be a better
option. These systems are well suited to homes without attics or basements.

Ease of maintenance – Because a packaged system has all of its components in one unit,
maintenance is somewhat more convenient than for split systems.

4.7 Construction Detail of Central Air Conditioning System

The whole system can be divided into three parts,

 Plant room, which includes compressor, condenser and motor.

 Air handling unit room (AHU room).
 Air distribution system (Ducting).

Figure 3 Schematic Diagram of Air handling unit

4.7.1 Working Mechanism of Central air conditioning system

When the thermostat signals the air-conditioning system to lower air temperature, a whole
sequence of events begins.

First, the air-handling unit kicks on, drawing room air in from various parts of the house through
return-air ducts. This air is pulled through one or more filters, where airborne particles such as
dust and lint are removed—in fact, sophisticated filters may remove microscopic pollutants as
well. Then the air is routed to air-supply ductwork through which the blower pushes it back to

19
the rooms.

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 Figure 4 AC system of a house including a network of warm air and cold air ducts

Every air conditioner has three main parts: a condenser, an evaporator, and a compressor. With a
typical “split system,” the condenser and the compressor are located in an outdoor unit. The
evaporator is mounted on or in the air-handling unit, which is often a forced-air furnace. With a
“package system,” all of the components are combined in a single outdoor unit that may be
located on the ground or on the roof.

Refrigerant circulates through copper tubing that runs between the evaporator and the condenser.
This refrigerant receives and releases heat as it raises and lowers in temperature, changing from
liquid to gas and then back to liquid. The refrigerant is especially cold when it begins to circulate
through the indoor coil.

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 Figure 5 Central AC cools with an outdoor compressor and condenser coil connected to an indoor furnace
fitted with an evaporator coil.

As the air handler pushes warm air across the coil, the refrigerant absorbs so much heat from the
air that it turns into vapor. As a vapor, it travels to the outdoor compressor, which pressurizes it
and moves it through the outdoor coil. There it jettisons the heat through coils or thin metal
“fins.” A fan in the compressor also helps to dissipate the heat. The refrigerant then passes
through an expansion device that converts it to a low-pressure, low-temperature liquid, which
returns to the indoor coil. And so, the cycle goes.

4.8 Installation and Location of Air Conditioners

If the air conditioner is installed correctly, or if major installation problems are found and fixed,
it should perform efficiently for years with only minor routine maintenance. However, many air
conditioners are not installed correctly. As an unfortunate result, modern energy-efficient air
conditioners can perform almost as poorly as older inefficient models[7].

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 Figure 6 Air conditioning unit

Things that technician should follow when installing a new central air conditioning system[8]:

 Allows adequate indoor space for the installation, maintenance, and repair of the new
system

 Ensures there are enough supply registers to deliver cool air and enough return air
registers to carry warm house air back to the air conditioner

 Installs duct work within the conditioned space, not in the attic, wherever possible

 Seals all ducts with duct mastic and heavily insulates ducts

 Locates the condensing unit where its noise should not be disturbing

 Locates the condensing unit where no nearby objects will block airflow to it

 Verifies that the newly installed air conditioner has the exact refrigerant charge and
airflow rate specified by the manufacturer

 Locates the thermostat away from heat sources, such as windows or supply registers.

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 CHAPTER 5 MAINTENANCE PROCEDURE OF CENTRAL AC
SYSTEM

5.1 Objective of maintenance

 To optimize the reliability of equipment and infrastructure.

 To ensure that equipment and infrastructure are always in good condition.
 To enhance, through modifications, extensions, or new low-cost items, the productivity
of
 existing equipment or production capacity.
 To train personnel in specific maintenance skills.
 To ensure environmental protection.

5.2 Classification of maintenance

There are two main types of maintenance categories that can further be sub-divided into various

maintenance-type groups, which is shown below.

Figure: Classification of Maintenance

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5.3 Inspection and maintenance of Central AC System

5.3.1 General Overview of Problems in AC system

Poor performance resulting from aging systems, partial equipment failure, poor original design
and workmanship, improper service, and lack of maintenance is commonplace. These problems
result in increased energy use and utility bills, reduced occupant comfort, accelerated equipment
degradation, and in some cases risk to homeowners

A key challenge to understanding refrigeration system performance is that there are many
possible sources of degradation, and there is rarely an obvious indication which part (or often,
parts) of the system is failing. Furthermore, system performance characteristics encountered in
the field depend on ambient conditions and the fault status. In spite of the complexity of multiple
faults and highly variable performance, HVAC technicians providing service calls are expected
to improve system efficiency, often within a short-scheduled time window.

Figure 7 AC problem tree

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5.3.2 General Inspection tips for A/C

For the general inspection for A/C system, following the listed condition can help[8].
 Check Compressor clutch. With the engine running, does the compressor clutch engage
when the A/C is on? If not, it may indicate a low (or empty) refrigerant charge or an
electrical problem.
 Listen for rapid clicking or cycling noises at the compressor. This could also be
indicative of low refrigerant or another problem.
 Check whether the A/C is blowing cold air. If not, it may have a low refrigerant charge in
the system. Pressure gauges can be used to check the charge. If it’s low, add the proper
refrigerant for the system to bring it to full charge.
 Listen for knocking or rumbling sounds near the compressor, with the engine running and
the A/C “off”. These could indicate a failing compressor clutch and/or loose mounting
hardware.
 Check whether A/C component mounting bolts are in place and secured tightly. If not,
tighten any loose or rattling bolts.
 Ensure that caps are installed on the A/C service ports. These are needed to seal the
refrigerant and also to help keep out dirt.
 Check all belts for cracks, wear and glazing. Have them replaced at the first sign of any
of these conditions.
 Check for belts that vibrate while the engine is running and A/C is on. This may indicate
a defective automatic belt tensioner or the need to tighten the belt.
 Examine all A/C and cooling system hoses for cuts, abrasions, weak spots or signs of
leakage. Leakage is generally indicated by areas with an accumulation of dirt and oil,
particularly at connections and fittings.
 Ensure that the condenser is free from obstructions, such as leaves or insects. These could
reduce airflow and diminish A/C performance.

5.3.3 Preventive Maintenance for AC units

Preventive maintenance on HVAC system will not only ensure that the equipment is operating at
maximum efficiency but it will also extend the life of that equipment. Government research
shows that a regular tune-up of the heating and cooling system will save the money in the long

26
run because

27
of reduced energy costs. The high efficiency air conditioners on the market now can cut electric
bills significantly but only if they are properly maintained[9].

When a trained service technician comes to the home to perform the maintenance check, they
will do several things:

 Check refrigerant levels and inspect for leaks

 Clean and straighten condenser coils to ensure proper air flow
 Check gas connections for leaks
 Tighten all electrical connections
 Lubricate all moving parts
 Test thermostat to make sure it’s cycling the system on and off properly
 Check air filter

5.3.4 Maintenance Procedure

Part Failure mode Inspection Mitigation

Compressor Compressor breakdown Result in no Gas pressure sensor and

which can be caused by pressurization and lubricant level meter,
either motor or contractor flow of the Standby motors. Assess
failure. refrigerant which Risk/cost balance.
will ultimately Temperature detection in
result in no control panels.
heating/cooling.

Blower Fan Air flow decreased, Loss of The air flow is Rational speed detector
control of critical parameters. very low. Can be and motor temperature
worn fan belt, distressed fan detected manually gauge, Standby fans.
motor, dirt, and lack of by measuring the
Assess Risk/cost balance.
lubrication. air pressure.
Vibration monitor

28
 Expansion Regulating is not work Results Less Leakage sensors, Bubble
Valve properly, clogged expansion cooling/heating check
valve, Leaky ducts Results Less
cooling/heating

Evaporator Heat is not exchanging, Improper Blast off dust with

making lot of noise exchange of compressed air, Substance
indoor heat. detector sensor
Irregular
humidity.

Condenser Soil, dust, leaves, and grass Inability to Regular cleaning,

clippings that have collected maintain Substance detector sensor
on the condenser coils, conditions. in coils.
Corrosion. Water carry‐over.

Thermostat Sometimes the air Imbalance in Limiting how often we

Malfunction conditioner is in good shape periodic maintain switch the AC on and off.
but still fails to work. In this of temperature When weather is especially
situation, the electrical hot and humid, might
system could be the culprit. reduce strain on electrical
Electrical problems are most components by raising the
common in systems that get temperature setting instead
turned on and off frequently. of shutting the AC down.

5.3.5 Maintenance procedure partwise

Condenser Coils

 Turn off the air conditioning unit

 Remove the screws of the covers protecting the condenser coil.

29
  Use the compressed air or brush or chemical agent(if applicable) to remove the dust
in the coil fins
 Direct spray the nozzle so that it is parallel to the fins.
 Do not use spray at angle to the fins as they may
 bent or may cause damage to the coil.
 Let the liquid drip and dry all the components.
 Replace all the parts opened and turn on AC if no other unit maintenance is necessary.

Air Filters

 Switch off the air conditioning unit

 Remove or lift the cover of the indoor A/C unit
 Remove Air Filter
 Clean using jet pump or vacuum or running
 water to remove the dust
 Let the filter dry
 Install the air filter
 Put back the indoor A/C cover and start the unit

Evaporator Coils

 Turn off the air conditioning unit

 Remove the access panel air conditioner’s air blower unit
 Use the compressed air or brush or chemical agent(if applicable) to remove the dust
in the coil fins
 Direct spray the nozzle with evaporator cleaning liquid so that it is parallel to the fins.
Do not use spray at angle to the fins as they may bent or may cause damage to the coil.
 Let the liquid drip and dry all the components.
 Replace all the parts opened and turn on AC if no other unit maintenance is necessary.

Drain Line and Drain Tray

 Switch off the air conditioning unit so that the maintenance work can be run.
 Locate the drain line

30
  Find out the drain tray
 Clean the drain tray with the pressurized air and inspect the drain line
 Flow water through the drain to remove dust
 Clean the drain line with clothes once all the water dried out
 Replace the drain line

AC Fan and Blower

 Turn off the air conditioning unit

 Remove the clutter i.e., removing the dust particles
 from the outdoor condenser
 Remove the cover and vacuum the fins
 Remove the wire from the fan motor and simultaneously the fan motor
 Oil up the motor and replace all item to complete the process.

Vents and Ducts

 Switch off the air conditioning unit

 Remove the air vents and ducts covers present with the assist of screwdrivers.
 Use the vacuum or air to blast away all the dust.
 Use the spray jet or scrubber to remove other remaining dust in vent and duct area.
 Use the detergent water to soak vent and duct.
 Clean the vents and ducts with the clothes
 Clean the air filter or replace it if necessary
 Turn on the AC unit back

AC Capacitor

 Turn off the air conditioning unit.

 Disconnect the capacitor from the unit.
 Discharge the capacitor by shorting the terminals using the piece of wire
 Capacitors must be discharged before testing to prevent damage to the meter.
 Connect the meter leads to the capacitor terminals and should be in resistance mode.
 Observe the deflection of the meter pointer

31
  If the capacitor is defective, mark it using the permanent marker or masking tape.
 Check the loose terminal connection.
 Tighten if any found and clean control panel
 Place back and check operation

Air compressor

 Read the User Manual

 Tighten the Nuts and Bolts.
 Clean the Intake Valves.
 Inspect the Hoses.
 Change the Air Filter.
 Drain Condensate from The Tanks.
 Clean the Compressor Fuel Tank.
 Inspect the Air Compressor Shutoff System.

32
 CHAPTER 6 CORROSION DANGER ON THE CENTRAL AC
SYSTEM

6.1 Corrosion

Corrosion is a common problem in a number of metal devices and appliances. A result of long-
term moisture exposure, it can develop quickly along evaporator and condenser coils and
potentially lead to the failure of the air conditioning system.

6.1.1 Reason for corrosion

Outdoor AC units are constantly exposed to the elements, and moisture in particular poses a
threat since it can trigger corrosion on the AC’s metal coils. Although the AC cabinet can keep
water away from most of the AC parts, it can’t provide complete protection. Water can get in via
the unit’s grille, or the AC can be afflicted with formicary corrosion [10].

Formicary corrosion is a type of corrosion caused by the reaction of copper to formaldehyde. It

produces weak patches along the copper and affects the indoor components of an air conditioner.
It’s also one of the most common causes of refrigerant leaks. Formaldehyde is found in many
homes, and it can be difficult to get rid of. Chlorine and fluoride, which are present in homes as
well, may also cause corrosion.

6.1.2 Effect from corrosion

The biggest danger from corrosion on an air conditioner is loss of refrigerant. Corrosion eats
away at the copper of refrigerant coils, allowing the high-pressure chemical to escape. Because
an AC is built for a specific amount of refrigerant (known as the unit’s charge) any drop in
refrigerant levels places the whole unit in danger. The air conditioner will lose cooling power,
but that’s only the start. The indoor coil will freeze over and eventually the compressor will
overheat and burn out. If the compressor fails, it’s usually best to replace the entire air
conditioner rather than pay to replace only the compressor[10].

33
Corrosion also leads to a decline in the efficiency of the coils, since the corrosion creates an
insulating layer against heat exchange. The air conditioner will become more expensive to run
(around 10%), which is often one of the first warnings signs of corrosion developing.

6.2 Corrosion Control

The way for corrosion control is mainly classified in three steps which are:

1. Reducing Corrosion

There are many ways to reduce corrosive effects, if not prevent them totally. Corrosion-resistant
materials, such as copper, stainless steel, PVC, plastics, and concrete, are used in the
construction or retrofit phase. However, these materials can be expensive. Another method is to
rustproof the system by coating metal surfaces with corrosion-resistant metals or compounds.
However, some heating and cooling systems are so large that, while you may be able to coat
a section here and there, coating the entire system is impractical.

The use of sacrificial anodes actually relies on corrosion itself to protect the system. These
anodes are pieces of metal, such as magnesium or zinc, that have a higher potential to corrode
than the base metal itself. In this system, metal bars are strategically installed on tube sheets or
baffles. The sacrificial anodes corrode instead of the equipment, and are periodically replaced.
However, sacrificial anodes can only protect selected parts of a heat exchanger. Thus, the tubes
will not be protected. Also, corrosion still goes on, releasing corrosive products into the water
and causing deposits the system.

2. Using Mechanical Equipment to Control Corrosion

The use of mechanical equipment to reduce the effects of corrosion is most common in the steam
heating systems of large commercial and institutional facilities. There are two primary systems,
which have many variations.

Ion exchange/softening is used to condition water prior to its entry into the system. Generally, a
polystyrene resin is used to remove and/or exchange various dissolved solids in the water that
contribute to the scaling and corrosion process. Another process is deaeration, which involves
removing the oxygen and carbon dioxide gases before they enter the boiler system. Any gases

34
that remain after deaeration are chemically removed. Deaeration is the most important dissolved
gas removal process in steam boiler systems. It is not an ultimate cure because both oxygen and
carbon dioxide can enter or develop later in the system. Therefore, there is usually need for
chemical treatment in addition to deaeration.

3. Corrosion Inhibitors

The most effective and economical way to control corrosion is corrosion inhibition, a
combination of mechanical and chemical control. An effective corrosion inhibitor program will
interrupt anode reactions and slow the reactions at the cathodes. Effective corrosion inhibiting
incorporates three steps:

 System cleaning

A clean system is most important for any corrosion control program. Oils, scale, and corrosion
deposits all contribute to corrosion by developing corrosion concentration cells. The system must
be clean to gain the maximum benefit from corrosion inhibition.

 Pretreatment

A newly cleaned piece of equipment is susceptible to corrosive attack. If placed back into service
without chemical treatment, the corrosive attack will start immediately. Pretreatment chemicals
lay down a coating on the metal to protect it during system start-up.

 Chemical treatment

When the system has been cleaned and pretreated, the ongoing protection process can begin.
The recommended levels of inhibitors must be maintained to assure protection. Corrosion
inhibitors must be used in favorable water conditions to perform properly. The acidity or
alkalinity (pH) of the water and its conductivity are important in the fight against corrosion.
Whenever pH drops below recommended levels, corrosion will increase.

Furthermore, when pH becomes too low, even the most powerful corrosion inhibitors are
ineffective because their protective coating is stripped away from the metal. Conversely, very
high pH can create scale problems and also prevent inhibitor films. Therefore, it is important to
keep pH within the recommended ranges.

35
 CHAPTER 7 CONDITION MONITORING TECHNIQUES

7.1 Condition Monitoring

Condition monitoring is the process of monitoring a parameter of the conditions of machinery,

such as vibration, temperature, etc., in order to identify a significant change indicative of a
developing fault. It is a major component of predictive maintenance. The use of condition
monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure
and avoid its consequences. Condition monitoring has a unique benefit in that conditions that
would shorten the normal lifespan of machinery can be addressed before they develop into a
major failure. Condition monitoring techniques are normally used on rotating equipment and
other machinery (pumps, electric motors, internal combustion engines, and presses), while
periodic inspection using non-destructive testing techniques and fit for service evaluation are
generally used for stationary plant equipment such as steam boilers, piping, and heat exchangers.
A Condition monitoring flowchart is shown in figure below [11].

Figure 8 Condition Monitoring Flow chart

7.2 Condition Monitoring Techniques

Condition monitoring (CM) is a maintenance approach that predicts machine health and safety
through the combination of machine sensor data that measures vibration and other parameters (in
real-time) with state-of-the-art machine monitoring software. Some of the condition monitoring
techniques are listed below:

 Temperature Monitoring

36
  Vibration Monitoring
 Acoustic Emission
 Ultrasound Testing
 Oil Analysis/ Tribology
 Radiography/Radiation Analysis/Neutron Radiography
 Laser Interferometry
 Electrical Monitoring
 Electromagnetic Measurement

7.3 Condition Monitoring Techniques for Central AC

As there are many condition monitoring techniques which are being used to inspect and monitor
any system, but only some of them are applicable while monitoring the condition of Central AC
System. Some parameters for condition monitoring for AC are listed below

1. Compressor oil
2. Pressure
3. Temperature
4. Vibration
5. Life usage

37
 CHAPTER 8 FAILURE ANALYSIS OF CENTRAL AIR
CONDITIONING SYSTEM

8.1 Common Causes of A/C Failure

Here are some causes which leads air conditioning system towards the failure [12].

1. Faulty Circuit Breaker or Fuse.

In the case of air conditioner failure, the first things that should checked are circuit breaker
and fuse. If there is need of replacement the fuse or reset the breaker, give system 15 minutes
to cool down first.

2. Refrigerant Leak.

If the refrigerant is not at the proper level, the air conditioner may not operate correctly.
Because refrigerant is harmful to the environment, any leak will need to be repaired and
recharged by a licensed technician.

3. Frozen Coil.

Regularly cleaning or replacing the air filter and keeping the ductwork clean are two good
rules to follow to prevent a frozen coil. Dirty air filters or blocked ductwork can cause air
flow problems in the system causing a frozen coil.

4. Damaged Fan Blades, Compressor, Electrical Connections and Contacts.

If the air conditioner is over five years old, and cycles on and off frequently, the air
conditioning system is at risk for premature failure. Annual maintenance will often catch
worn and damaged parts.

5. Neglecting Annual Maintenance.

Annual maintenance is essential to the air conditioner’s performance. A licensed technician

can identify potential problems before they occur. the system inspected at least once a year.

38
 6. Faulty Thermostat.

If the thermostat is not working correctly, the air conditioner may cycle on and off
frequently or fail to work. Consider all of the digital and technologically savvy thermostats
on the market today. Many models today can be set to adjust temperatures at set times or
even controlled remotely.

8.2 Reasons to Perform A Failure Analysis

It is valuable to understand why a component failed. Was there was a design flaw that
prevented it from performing its intended function? Perhaps it had a manufacturing or
material defect. Or, perhaps the product was used outside its design criteria, or exceeded its
useful life and wore out. The following outline the most common reasons to perform a failure
analysis [13].

1. Understand the root cause of a failure. Understanding the root cause is often the
fundamental part of the failure analysis process. This involves data collection to ascertain
whether failure occurred due to manufacturing or material defect or misuse. Note, Root
Cause Analysis can also be used to identify what led to something going right so it can
be duplicated in the future.

2. Take corrective action. Corrective actions can be taken to prevent recurrence of the
problem once the cause of failure has been determined. This may include a redesign of
the product or a review of the parameters that the product is being used in.

3. Improve future products. Improve manufacturing processes and product designs with
an understanding of the failure mode. This can prevent the problem from happening
again, prevent costly legal action or replacements, and protect a company’s reputation,
the environment, and personnel safety.

4. Prevent financial losses from failed components. Failure can be costly, whether due to
expensive outages, a stopping of production, or even legal action as a result. Undertaking
failure analysis can prevent these problems from growing or potential failures from
happening in the future.

39
 5. Ensure components meet standards that they are designed to. Failure mode and
effects analysis (FMEA) can help to meet standards for manufacturing processes, failed
components, products, or assets going forward.

6. Aid in the determination of accountability for failure. A failure analysis can determine
the cause of the failure and may also aid in assigning responsibility for the failure. This
can be used in legal proceedings to apportion blame and to protect from litigation.

8.3 Failure analysis tools

There are two failure analysis tools and they are:

 Fault tree analysis (FTA)

 Failure mode and effect analysis (FMEA)

8.3.1 Fault Tree Analysis

Fault tree analysis (FTA) is a graphical tool to explore the causes of system level failures. It uses
boolean logic to combine a series of lower level events and it is basically a top-down approach to
identify the component level failures (basic event) that cause the system level failure (top event)
to occur. Fault tree analysis consists of two elements “events” and “logic gates” which connect
the events to identify the cause of the top undesired event [14].

Fault tree analysis is an easier method than the Failure Mode and Effects Analysis (FMEA) as it
focuses on all possible system failures of an undesired top event. Whereas FMEA conducts
analysis to find all possible system failure modes irrespective of their severity.

40
8.3.1.1 Fault Tree Analysis for Central Air conditioning system

As per fault tree diagram of Central Air conditioning system, there are some systems and
subsystems which reduces the Air Conditioning performance

Failure of Central Air Conditioning

No Heating No Cooling

Reduced Capacity

Insufficient radiator
output power

Failure of
heating coil
Failure of supply fan
12
9 10 11

7 8 2 4
1 5 6

Figure 9 Fault Tree Analysis of central AC system

EBE ID Failure Mode N MTTF(Years)

1 AHU damper broken 4 20

2 Fan motor failure 3 35

3 Supply fan obstructed 3 31

4 Fan bearing failure 6 17

5 Radiator failure 4 25

41
 6 Radiator stuck valve 2 10

7 Heater stuck valve 2 10

8 Heat pump failure 4 20

9 Dirty Air Filter 3 15

10 Incorrect thermostat setting 2 17

11 Low refrigerant Level 4 25

12 Damaged Compressor 5 28

Table 1 Details of the EBEs

8.3.2 Failure mode and effect analysis

FMEA is a qualitative and systematic tool, usually created within a spreadsheet, to help
practitioners anticipate what might go wrong with a product or process. In addition to identifying
how a product or process might fail and the effects of that failure, FMEA also helps find the
possible causes of failures and the likelihood of failures being detected before occurrence.

Used across many industries, FMEA is one of the best ways of analyzing potential reliability
problems early in the development cycle, making it easier for manufacturers to take quick action
and mitigate failure. The ability to anticipate issues early allows practitioners to design out
failures and design in reliable, safe and customer-pleasing features.

8.3.2.1 Objectives of Failure Mode and effect analysis

 The FMEA's goal is to take steps to eliminate or reduce failures, starting with the
most critical ones.

 Failure modes and effects analysis also documents current knowledge and actions about
failure risks, which can be used for continuous development. To avoid failures, FMEA is
utilized during the design process.

42
43
8.3.2.2 Ten steps to conduct FEMA analysis

1.Review the design or process

2.Brainstorm potential failure modes

3.List potential failure effects

4.Assign Severity ratings

5.Assign Occurrence ratings

6.Assign detection rating

7.Calculate RPN

8.Develop an action plan to address high RPN’s

9.Take action

10.Reevaluate the RPN after the actions are completed

8.3.2.3 Variations related to FMEA approach

To facilitate assessing risk, failure modes are expressed on a scale of qualitative values that
identify different levels of hazard conditions. In the traditional FMEA approach, the RPN index
is determined by calculating the product of the three indexes: severity, frequency and detection:

RPN = S x O x D

In the RPN calculation, the assigned values on the three index qualitative scales are interpreted
as being numbers. `Information initially gathered on the qualitative scales’ is therefore
arbitrarily interpreted and utilized on a quantitative scale with different properties from the first
one.

44
 1. Severity

Severity is an assessment used to measure the importance of a failure mode. The scale of severity
depends on the result of a failure on component performance. The severity level can be defined
using the MTTR concept, low failure mode can be considered equal to low MTTR.

Table 2 Severity Scale

Severity Description

1-2 probably not detect the failure

3-4 Minor, low failure, not fully working, redundant appear

5-6 Moderate, caused system unworked, maintenance relatively

short, no redundant.

7-8 High, Harmful to the system, caused the system down in

period of time.

9-10 Very dangerous, dangerous to the system and operator

2. Occurrence

Occurrence is the frequency of an event that causes failure or can be called an opportunity of the
emergence of a failure. Differences on the occurrence rate can be differentiated by helping the
MTBF concept, if the time between each failure is relatively high, it can be said a high
occurrence value.

Table 3 Occurence Scale

Occurrence Description

1 More than a year

3 Between 4 to 6 months

5 Between 1 to 3 months

45
 7 Every month

9 Every time

3. Detection

It is used to measure the probability of failure that can be detected either by control system or by
manual inspection. In order to measure detection rates is highly subjective, according to the
failure detection appearances.

Table 4 Detection Scale

Detection Description

1 Easily detected

3 Detected by high probability

5 Detected by moderate probability

7 Detected by low probability

9 9Couldn’t be detected

Table 5 FMEA Table

Item Function Potentia S Potential O D RP Recommended

l failure E cause of C E N Action
mode V failure C T

Compre Transports Looseni 9 Material 1 2 18 Oscillation tests

ssor the medium; ng of faults,
Gas pressure sensor
Compresses fastenin loosening of
and lubricant level
the medium gs fastenings
meter

46
Gas Conducts Blockag 6 Bends, 2 1 120 Parallel procedures,
cooler heat to the e in blockages 0 pressure sensor
external refrigera switched in front of
environment nt flow the gas cooler,
plausibility control
via regulation
control

Expansi removes Regulati 5 Block due to 4 6 120 Leakage Sensor

on valve pressure ng is not external
from the work impurities
liquid properly

Condens Eject heat to Leakage 6 Pipe rupture 6 7 252 Brazing

er the And air
surrounding jam
from the
system.

Evapora To maintain heat is 5 Problem in 7 2 70 Substance detector

tor the room not pipe or heavy sensor
temperature exchang dust particle Servicing of filter
with ing around the
coil

Control To operate Short 7 Voltage 4 8 224 PCB kit change

System the function circuit fluctuation
remotely and
smartly

47
Refriger Heating and Mixing 7 Mistake due 4 8 224
ant cooling agent with to regular
external servicing
agent/
moisture

48
 CHAPTER 9 TOOLS AND EQUIPMENT FOR INSPECTION,
MAINTENANCE AND MONITORING

9.1 Inspection tools

Inspection tools can be used to inspect the system to identify the probable or certain
failures. Here are some inspection tools which are one of the must have tools for inspection.

1. Combustible Gas Leak Detector

The Gas Leak Detector is designed for residential and small commercial applications. The
semiconductor sensor responds to all combustible gases. It provides accurate, consistent
detection. An 18 in. flexible detector wand allows to pinpoint the location of the leak or check to
see if the completed work was successful.

Figure 10 Combustible Gas Leak Detector

2. Air Quality
Meter

The Air Quality Meter AQM4 is an ideal instrument for indoor air quality (IAQ) diagnostics
which includes measuring CO2 and CO levels, air temperature, dew point, wet bulb temperature,
and humidity. Poor indoor air quality causes tiredness, inability to concentrate, and even illnesses
such as Sick Building Syndrome. The portable AQM4 is based on the nondispersive infrared
(NDIR) technology for CO2 measurement that is useful for verifying HVAC systems
performance and air ventilation control. The meter features a large LCD display, a housing
designed to help air ventilation for quick and accurate response, and a mini USB to PC download

49
function for analysis.

50
 Figure 11 Air Quality Meter

3. True RMS HVAC/R Clamp Meter

AC 600A True RMS HVAC/R Clamp Meter is applied to motor or line currents, controls voltage
or system board voltage checks, circuit continuity or specified resistance, quick check of live
wires, and diode malfunctions/unbroken paths.

Figure 12 AC 600A True RMS HVAC/R Clamp Meter

4. Honeywell Transmission Risk Air Monitor Bundle

Honeywell Transmission Risk Air Monitor Bundle includes V2 white monitor with 1st yr SW
license, USC version charging/power adapter, and Wall Mount Kit. The HTRAM is a cost-
effective monitor for use in schools, restaurants, and other small-to-medium sized buildings that
51
alerts users when conditions are present that may increase the risk of exposure to airborne viral
transmission. Honeywell proprietary technology monitors CO2 levels, coupled with user-
controlled settings to account for human activity levels in an indoor area. Identifies air quality
conditions that are driven by common activities and variables such as average room size, number
of people present, breathing rate, and duration. The monitor provides indications using a traffic
light pattern (green, yellow, or red) and a sound alarm so users can be aware of conditions that
may increase the risk of airborne transmission based on detectable CO2 levels. Recommended
for
coverage of 800-1000 square feet. This indoor air monitor incorporates an easy-to-read digital
display, rechargeable battery, and Bluetooth and Wi-Fi capability for connectivity to the mobile
application and online dashboard.

Figure 13 Honeywell Transmission Risk Air Monitor Bundle

9.2 Tools for Air conditioning Maintenance

 Gauge Manifold  Torch Drill Machine
 Digital Clamp  Swaging Tool  Measuring Tape
multi Meter  Level  Pipe Cutter
 Nose Plier  Oil Filter Wrench  Hammer
 Screw Driver  Tubing Cutter  Wire Cutter
 Screw Wrench  Tube  Flashlight/Headlap
 L Key Set Bender  Core Removal
 Vacuum Pump (Manual) Tool
 Gas Welding 
Machine

52
 Figure 14 Tools for Air Conditioning Maintenance

9.3 Monitoring tools

Here are some monitoring tools that is needed to monitor the condition of the Central Air
Conditioning System.

1. Anemometers

An anemometer measures the speeds and directions of both wind and gas. This kind of tool
comes in two forms: a hot-wire and a vane. For technicians, a handheld hot-wire is the most
common for HVAC jobs, while vane-styled anemometers are usually used outdoors.

2. Balometers (Airflow Capture Hoods)

This kind of tool is used to measure the volume of air being exerted out of grilles and diffusers in
HVAC systems. Nowadays, many of these tools have gone digital, which can make it easier for a
technician to use and accurately record measurements. Usually, the fabric hood and the frame
come in different sizes in order to adjust to different size grilles and diffusers; however, ours
provide unique interchangeability that can fit many shapes and sizes of HVAC components.

53
3. Duct Leakage Testers

This instrument measures the airtightness of forced air heating, ventilating, and air-conditioning
(HVAC) ductwork. It provides step-by-step test configuration and automated leakage
testing based on the SMACNA HVAC Air Duct Leakage Test Manual and is accurate to ±2.5%
of reading.

4. Hygrometer

This tool measures the amount of humidity (or water vapor) in the air. Considering these kinds of
leakage and water problems are often dealt with issues regarding HVAC installations,
hygrometers can ensure the air conditioning is at status quo. Hygrometers are also great to
recommend to homeowners so they can constantly keep an eye on the air quality in their homes.

5. Borescope (Distance Meter)

this kind of tool measures distances like length, volume, and much more. Especially for more
complicated jobs, these often Bluetooth-friendly devices can take human error out of
measurements and ensure precision while installing HVAC units.

54
 CHAPTER 10 USE OF COMPUTERIZED
MAINTENANCE MANAGEMENT SYSTEM FOR
CENTRAL AC SYSTEM

10.1 Computerized Maintenance Management System

A computerized maintenance management system (or CMMS software) is software that helps
maintenance teams manage all their maintenance activities in one place. That includes being able
to plan, track, measure, and optimize everything from work orders to inventory and reporting. To
sum it up, a CMMS is what maintenance teams at industrial, asset-intensive companies use to
organize information, make sure work gets done, and measure the impact of that work[15].

CMMS software provides the platform and workflow to manage the maintenance operation,
including reactive maintenance, preventive maintenance, and predictive maintenance. A CMMS
solution centralizes facility maintenance information and enables to automate any asset
maintenance task.

A CMMS also eliminates paperwork and time-consuming activities, thereby freeing the staff to
take on more important tasks and enabling them to be more productive and proactive.

10.2 Use of CMMS in HVAC

An HVAC system usually has a lifespan of 15‒20 years, but if it’s not cared for properly, it
could fail sooner. If someone choose to ignore HVAC system maintenance, it will end up
purchasing a new one sooner rather than later. Scheduling regular maintenance checkups will
prolong the life of HVAC system and helps to save money. HVAC CMMS software
maintenance management can help to stay on top of important HVAC maintenance work and
reduce downtime. Some features of CMMS system are listed below [16].

 Automatically add photos, manuals, instruction sheets and build the digital equipment
service logbook

 Access the service history: see at a glance the parts changed, fluids removed, power
supply controls, units cleaned and filters changed.

55
  Encode the contracts, create maintenance task lists with the instructions and checks to be
performed

 Automatically trigger preventive maintenance plans

 Manage deadlines and get notification for technical inspection.

With CMMS software, facility managers can easily keep track of everything that needs to
be done—scheduling maintenance jobs, recording maintenance history, prioritizing tasks,
and more. It can reduce disruptions and extend the life of the HVAC systems by
improving the preventive maintenance process, which helps to saves organization both
time and money, two big benefits that everyone likes.

10.3 Best software related to CMMS for AC

1. Daikin Air Conditioner Monitoring Tool

It can communicate with wide range of air conditioning systems including Splits, SkyAirs and
VRVs to show/record operation parameters for service diagnosis or commissioning work.
Recorded operation data can be sent to other person by email.

2. Sentree Monitoring Tool

Sentree gathers the following A/C performance data minute-by-minute and uploads it to
AlertAQ™ for analysis: vapor and liquid line pressure and temperature, calculated superheat and
subcooling, average run time, amperage draw, ambient temperature and other information.
Whenever there is a problem, assigned users receive an instant alert on their phone via text, email
and in-app notification

56
 CHAPTER 11 SAFETY HAZARDS AND PRECAUTIONS

11.1 Safety Hazards

Technician safety must be a central focus in day-to-day operations to avoid dangerous and costly
HVAC accidents.

Danger lurks in some of the most unsuspecting places, and industry professionals should not
only adhere to best HVAC servicing procedures, but stay vigilant for common hazards as well.
That’s why we’ve identified the eight biggest HVAC safety hazards and collected the best
HVAC safety standards all in one place[17].

To prevent common HVAC accidents, HVAC technicians should protect themselves from:

 Electrical HVAC safety hazards

 Chemical exposure

 Inadequate equipment inventory

 Respiratory hazards

 Ladder liability

 Unprofessional conduct

 Extreme weather

11.2 Safety Precautions

HVAC technicians are regularly exposed to on-the-job hazards and risky situations. Safety is a
must, no matter how seemingly basic the task at hand might seem. here are 7 must-know safety
tips that will help to avoid any disasters[18]:

1. Make Protective Gear a Priority

Be sure to wear a respirator to avoid breathing in any harmful particles such as dust and debris,
and fumes from noxious gases.

 Make sure to wear either a face shield or safety goggles to keep eyes safe.

57
 Wear gloves and arm protectors while handling any glass or sheet metal.
 Wearing slip-resistant shoes will ensure the ability to maintain a steady footing
2. Use the Proper Tools and the Right Times
 Improperly use a tool or opt for the wrong tool at the wrong time can cause further
damage to a property, getting injured, or harm those nearby.
 Make sure that tools are always in good working condition. Routine tool maintenance is
necessary to detect any defects or damage in the tools and to keep them working as they
should.
 Proper tool safety will always be a big part of maintaining a safe environment
3. Be Able to Identify Hazards

It’s always better to take the extra time to be sure of being safe and to do the job right than to
rush it and end up with an injury or additional damage to the hands.

4. HVAC Technicians Should Practice Chemical Safety

 Make certain to always follow the safety procedures while storing or transporting any
type of chemical substance.
 Never mix chemicals, even if they seem to be similar.
5. Avoid Taking Shortcuts
 As an HVAC technician working with electricity, chemicals, and sometimes extreme
temperatures, exercising caution means taking the time. While anyone might be tempted
to rush a repair along, the priority should be safety.
 Always follow full procedure and avoid taking shortcuts, no matter how simple the job
seems.
6. Make Sure to Avoid Shock
 Electric shock is most likely to occur while dealing with a water leak within an HVAC
system. The best thing to do to stay safe when working on a system while water is present
is to turn off the main circuit breaker ahead of time
 take the necessary precautions to minimize any risk of electrocution or electric shock.

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11.3 HVAC Technician Responsibilities

the trusted HVAC technician is the best source for information about the home's central air
conditioning system. The technician should be able to properly maintain, troubleshoot, provide
parts for, and make necessary repairs to the air conditioner. Consumers should find a company
that they trust and use them for all of their HVAC needs. A technician who has a complete
service history will know that an HVAC system has had factory-authorized parts installed versus
after- market parts, which may affect the proper operation and UL listing of the equipment.

Keep in mind; it is best to schedule professional HVAC service before it is needed. Generally
speaking, maintenance on the cooling portion should be done once a year, during the spring. This
spring service call should include the following maintenance tasks:

 Ensure that the thermostat is functioning properly,

 Inspect the furnace filter,

 Inspect and clean the evaporator and coil,

 Inspect, clean, and adjust the blower motor,

 Inspect the condensate drain for blockage,

 Inspect and clean the condenser and coil,

 Inspect the fan motor and blades for damage and proper operation,

 Inspect all components, wiring, and controls to ensure that they are safe and working properly,

 Inspect refrigerant piping for leakage, repair any existing leak(s), measure and (if necessary)
balance the refrigerant level.

While most of these tasks are related to the mechanical operation of a central air conditioning
system and it is possible for a knowledgeable homeowner with the proper tools to complete such

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tasks, refrigerant within the system is dangerous to the ozone and as such is federally regulated.
Federal regulations govern an individual’s ability to purchase, dispose of, and handle refrigerant.
Balanced refrigerant levels within a system are essential to proper operation. An out-of-balance
system will operate less efficiently than a balanced system and will have higher energy costs and
a reduced lifetime.

11.4 Homeowner's Responsibilities

In comparison, a homeowner's responsibilities are somewhat limited in scope. However, this

doesn’t preclude the importance of completing them. “We often run into 'lack of filter
replacement' problems at our customers’ homes. Regular filter replacement is the single most
important thing a homeowner can do to help maintain their HVAC system,” says Chris
Theodorou. Every home owner should follow all these responsibilities for the longer life of
HVAC system.

 Inspect the furnace filter monthly, changing or cleaning it as needed. Turn off power to the
furnace. Clean the condensate drain line using a vinegar and water solution.

 Inspect the condenser (outside) and the area surrounding the unit. Using a carpenter’s level,
ensure that the condenser is sitting level. The condenser should be able to efficiently draw air
into the system. Remove any debris, keep the landscaping cut back at least 2' –3' from the
unit, and trim grass and weeds that surround it.

 Use a garden hose to gently spray off the exterior side of the condenser. Rinsing the condenser
clears any loose dirt, debris, or residue from the components and metal surfaces. For safety
reasons, disconnect power at the condenser prior to working around it.

 During the cold months, covering the entire condenser is not advised. Water trapped in the
interior of the condenser may cause the metal components to corrode. To prevent this top
opening can be cover with an appropriate material safely secured to the unit.

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 CHAPTER 12 BUDGETING & COST CONTROL TECHNIQUES IN
MAINTENANCE AND OPERATION

12.1 Maintenance Budgeting

All the big manufacturing units maintain their own Maintenance and Repair department. To
ascertain the exact cost of each maintenance or repair work, a series of service order accounts are
opened. Each service order will be given a distinct number, and will be debited with all
expenditure on material, labor or other direct charges for repair and maintenance. An addition is
also made for works and office indirect expenses on a suitable basis. The total will then be
included in factory overheads and is also used for maintenance planning, budgeting and control.
In case the repair work is done by an outside agency, there will be no difficulty in ascertaining
the exact cost of repair and the same will be included in factory overheads

Costs of no maintenance or inadequate maintenance are in the nature of opportunity cost. These
lost opportunities include lower rate of output, poor quality of products, wastage, defectives,
damage to equipment, reduction in the 2 Maintenance Resource Management and Costing useful
life of the equipment etc. These costs are not recorded in any of the accounting system and often
overlooked while exercising control over maintenance costs. A good maintenance policy should
incorporate both the maintenance cost and the cost of lost opportunity due to inadequate
maintenance.

12.2 Role of preventive maintenance in cost control

We can prevent breakdowns and lower HVAC maintenance costs with routine preventative
maintenance. Keeping your equipment in optimal condition prevents deterioration of parts and
prevents small problems from turning into big problems that cause system failure.

In preventive maintenance the technician inspects and test various parameters such as sir flow,
condition of refrigerant, heat exchanger, thermostats and many other components. Some tune-up
and proactive fixes can be done such as, replacing filters and any failing parts. With proper
cleaning of evaporator, condenser coils, drain lines and pans can reduce the overall maintenance
cost. With proper preventive maintenance anyone can definitely reduce the total cost of
maintenance.

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12.3 Replacement of HVAC equipment on time for cost control

Another important strategy for controlling HVAC maintenance costs, in addition to avoiding
problems with preventative maintenance, is planning for equipment replacement costs.

Commercial systems can last 20 years or more when properly maintained. However, no piece of
equipment lasts forever. We can save money by proactively replacing equipment that’s nearing
the end of its life (rather than waiting for it to fail). Here’s why:

 When there is an emergency breakdown, we have to act immediately and we don’t

have time to shop around for the best deal.
 We may pay more for installation in an emergency, due to the need to get the new
equipment up and running fast.

When we upgrade to new, more efficient systems, we also reduce your energy costs sooner.

That’s not even considering the possibility of lost business or work productivity, which can
easily happen when systems fail unexpectedly. Proactively replace aging equipment according to
a strategic plan, can budget for that expense instead of dealing with surprises.

12.4 Vetting commercial HVAC vendors for cost control

If the goal is to reduce total HVAC maintenance costs, choosing the right HVAC vendor is
critically important for commercial facilities. Here’s just one example: a vendor that acts as a
helpful business partner will work with you to identify, prioritize and budget for replacement
of aging equipment.

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CHAPTER 13 TECHNICAL DOCUMENTATIONS

Figure 15 Maintenance checklist

63
Figure 16 Maintenance Checklist II

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 CHAPTER 14 CONCLUSION & RECOMMENDATION

Central Air-conditioning system is the one of the most used AC systems. A detailed study on the
central AC, its components, and the maintenance practice was done to bring things on this paper.
The purpose of the report is to highlight the understanding of the topics such as preventive
maintenance technique, condition monitoring technique, FMEA, FTA, corrosion prevention
technique, CMMS, safety hazards etc. rather than the working and components of an engine.
Proper maintenance to the system can also help to reduce the overall maintenance cost for the
system.

These topics are much more advanced and broader than we think while studying in coursebook. I
found it very difficult to combine all these analyzes in one of her papers. A detailed summary of
all these analyzes in one paper would make the paper very long. In order to avoid this, this work
tries to explain these topics as simply and concisely as possible. These topics are so wide-ranging
that writing separate reports and research papers on these topics is very likely, interesting and
challenging. If you are looking for a broader and deeper understanding of a particular topic, I
encourage you to refer to specific papers/websites on the topic in the bibliography.

65
 CHAPTER 15 REFERENCE
[1] “MAINTENANCE ENGINEERING AND MANAGEMENT,” DEPARTMENT OF PRODUCTION
ENGINEERING. https://www.vssut.ac.in/lecture_notes/lecture1430512365.pdf (accessed Nov. 16, 2022).

[2] J. H. Spence, “AIR CONDITIONING-GENERAL,” 1959.

[3] “What is a Multi Split Air Conditioner? | mitsubishiacdealers.com.” https://mitsubishiacdealers.com/info/what-

is-multi-split (accessed Nov. 16, 2022).

[4] “How Does Ducted Air Conditioning Work?” https://www.crownpower.com.au/blog/how-does-ducted-air-

conditioning-work/ (accessed Nov. 16, 2022).

[5] T. Cielo, “8 Types of Air Conditioners: Choose the Best for Your Home,” 2022.
https://www.cielowigle.com/blog/types-of-air-conditioners/ (accessed Nov. 16, 2022).

[6] “air conditioning system: definition, functions, components - studentlesson.” https://studentlesson.com/air-

conditioning-system-definition-functions-components-types/#Components_of_an_air_conditioner (accessed
Nov. 16, 2022).

[7] “Central Air Conditioning | Department of Energy.” https://www.energy.gov/energysaver/central-air-

conditioning (accessed Nov. 16, 2022).

[8] “A/C Inspection Checklist – FJC Inc.” https://fjcinc.com/a-c-inspection-checklist/ (accessed Nov. 16, 2022).

[9] “What Preventive Maintenance On Your HVAC System Involves - Glasco Heating & Air Conditioning.”
https://glascohvac.com/air-conditioning/preventive-maintenance-hvac-system-involves/ (accessed Nov. 17,
2022).

[10] “How Corrosion Can Affect Your AC | Touchstone Heating Blog.”

https://www.touchstoneheatingonline.com/blog/how-corrosion-can-affect-your-ac/ (accessed Nov. 17, 2022).

[11] S. Nandi, H. A. Toliyat, and X. Li, “Condition monitoring and fault diagnosis of electrical motors - A review,”
IEEE Transactions on Energy Conversion, vol. 20, no. 4, pp. 719–729, Dec. 2005, doi:
10.1109/TEC.2005.847955.

[12] “6 Common Causes of Air Conditioner Failure - Air Specialist.” https://www.airspecialist.com/articles/6-

common-causes-of-air-conditioner-failure/ (accessed Nov. 17, 2022).

[13] “Six Reasons to Perform a Failure Analysis - Fluid Life.” https://www.fluidlife.com/blog-six-reasons-failure-

analysis/ (accessed Nov. 17, 2022).

[14] “Fault Tree Analysis - Six Sigma Study Guide.” https://sixsigmastudyguide.com/fault-tree-analysis/ (accessed
Nov. 17, 2022).

[15] “What’s a CMMS? Discover The Benefits, Use & Cost | Fiix.” https://www.fiixsoftware.com/cmms/ (accessed
Nov. 17, 2022).
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[16] “Yuman — CMMS the breath of fresh air for air-conditioners.” https://www.yuman.io/en/blog-post/37-cmms-
the-breath-of-fresh-air-for-air-conditioners (accessed Nov. 17, 2022).

[17] “8 HVAC Safety Hazards Every Technician Should Be Aware Of.” https://www.servicetitan.com/blog/guide-
to- hvac-safety (accessed Nov. 17, 2022).

[18] “7 Must-know Safety Tips for HVAC Technicians - InterCoast Colleges.” https://intercoast.edu/blog/hvac-
technicians-safety/ (accessed Nov. 17, 2022).

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 CHAPTER 17 APPENDIX

Some terms related to the Air conditioning system

A-coil — See evaporator coil.
accumulator — A device installed in the suction line of an air conditioner to prevent liquids from entering the compressor.
air balance — A term describing the distribution of air in an HVAC system. A balanced system has enough air distributed to match the amount required by all parts of
the system at any given time.
air changes per hour — The number of times the entire volume of air in a building is replaced via natural ventilation or air conditioning during one hour.
air diffuser — A distribution point where conditioned air is mixed with room air. Typically these are covered with some type of grille and located in the floor or
ceiling. air exchange rate — A measure of how quickly the air indoors is replaced by outside or conditioned air. The air exchange rate is often measured in air changes
per hour. air flow — The free movement of air.
air flow volume — The amount of air your air conditioner circulates through your home, typically measured in cubic feet per minute.
air handler — A moving part inside your home that propels air through the ductwork. A furnace or blower coil often serves this function.
air handling unit — See Air Handler.
air infiltration — The unintended entrance of air into a space via leakage, temperature differentials or wind.
air passages — Spaces through or within walls, floors and ceilings that allow conditioned air to move out of the
structure. all-in-one system — See Packaged Unit.
ambient air — Outdoor, unconditioned air.
blower — See Air Handler.
British thermal unit (BTU) — A measure of heat equivalent to the amount of energy required to raise one pound of water one degree Fahrenheit. The ability of an air
conditioner to extract heat is often expressed in BTUs.
British thermal units per hour (BTUH) — The number of BTUs per hour that an air conditioner can extract from a conditioned area.
building envelope — All the elements of the building that enclose the interior space, including walls, windows, doors and other materials.
capacity — The ability of an air conditioner to remove heat from an area.
charge — See Refrigerant Charge.
coil — See Condenser Coil.
compressor — The component of an air conditioner system that pressurizes the refrigerant, allowing it to flow through the system.
condensate pan — A pan located below the evaporator coil that catches the excess moisture that drops from conditioned air.
condenser — A unit that houses all the parts required to remove heat from the system. It is often placed outdoors.
condenser coil — The specific area inside an air conditioner where refrigerant is condensed into a liquid, releasing heat from the system.
condenser fan — The fan that circulates air over the condenser coil.
condensing unit — See Condenser.
conditioned air — Air that has been circulated through an air conditioner to remove heat and humidity
conditioned space — The area of a home where an air conditioner cools the air.
constant air volume system — An air conditioning system designed to provide constant air flow.
controller — A device controlling the air conditioner, such as a thermostat.
crankcase heater — A small heater installed on compressors to boil off liquid refrigerant that has combined with compressor oil. Not all air conditioners require a
crankcase heater, but most heat pumps do.
cycling — The process of an air conditioner turning on, processing some amount of air, and turning off.
damper — A physical plate that controls airflow through a duct or air diffuser.
dehumidifier — A device separate from an air conditioner that removes excess moisture from the air.
diffuser — See Air Diffuser.
drain pan — See Condensate Pan.
dry-charged unit — An air conditioner that is shipped without any refrigerant and charged after installation.
dual duct system — A climate control system with two ducts, one containing heated air and the other containing cooled air. Specific room temperatures are achieved
by mixing air from both ducts.
duct fan — A fan mounted inside the duct in order to increase conditioned air movement.
duct — A section of specially designed metal, fiberglass or plastic tubing that connects the air handler to the air diffusers throughout your home.
ductwork — A series of ducts that make up an entire household system.

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 Energy Star — A designation given by the Environmental Protection Agency to high-efficiency air conditioners that perform above and beyond the government’s
minimum standards.
evaporator coil — An a-shaped coil located inside the furnace or air handler that absorbs the heat from air passing over it.
expansion valve — A valve that deals out small amounts of refrigerants, allowing them to expand into a gas while releasing heat.
heat gain — The amount of cooled air required to maintain a desired indoor temperature, despite heat collected by the structure through external and internal sources.
heat pump — An outdoor unit that can both heat and cool indoor air in mild climates.
heat register — See Air Diffuser
horizontal flow — An air handler installed horizontally so that air moves from one side to the other and out into the ductwork. Horizontal flow units are typically
installed in attics or crawl spaces.
HVAC — An abbreviation meaning “heating, ventilation and air conditioning.”
indoor coil — See Evaporator Coil.
indoor / outdoor system — See Split System Air Conditioner
matched system — A system where all parts are matched for capacity and efficiency, creating a system that performs more efficiently, longer.
minimum outside air — A low limit on the amount of fresh air allowed into an air conditioning system.
outdoor coil — See Condenser.
outdoor unit — See Condenser.
packaged system — See Packaged Unit.
packaged unit — A unit that houses all the parts of your air conditioner. They’re typically installed on top of or beside a home.
plenum space — An air compartment that is part of the building’s structure and is connected to the ductwork.
programmable thermostat — A thermostat that has the ability to change the temperature in your home without your input, based on a pre-designed program of your
choosing.
R-22 refrigerant — The old standard for refrigerant. This type of refrigerant is being phased out in favor of R-410A.
R-410A refrigerant — A more environmentally friendly, chlorine-free refrigerant.
refrigerant charge — The act of adding refrigerant to a closed air conditioning system.
refrigerant lines — The copper tubing that connects the condensing unit to the evaporator coil.
refrigeration capacity — A measure of the cooling capacity of an air conditioner in BTUs or Tons.
return air — The air that is returned to the evaporator coil from inside the building.
return duct — The duct through which warm air is drawn into the air conditioning system to be cooled and blown out through the air diffusers.
rooftop unit (RTU) — See Packaged Unit.
Seasonal Energy Efficiency Ratio (SEER) — A measure of efficiency that describes the average number of BTUs of cooling created for every watt-hour of electricity
used by the air conditioning unit.
self-contained system — See Packaged Unit.
setback thermostat — See Programmable Thermostat.
single package — See Packaged Unit.
split system air conditioner — An air conditioner system where the compressor unit is located outside and the evaporator coil is located inside the home.
supply duct — The duct that returns conditioned air to individual rooms through the air diffusers.
temperature zones — Individual areas in a building where temperature can be controlled independently of other areas.
thermidistat — A unit that monitors both temperature and humidity and adjusts your cooling unit accordingly to maintain pre-determined levels.
thermostat — A small device typically located on a central wall that is used to control the indoor temperature.
ton — A unit of measurement for air conditioner units equivalent to 12,000 BTUs per hour.
two-stage cooling — An efficient method of cooling with two levels of operation — an energy saving level for most days and a higher energy-consumption level for
very warm days.
variable speed motor — The fan motor used to drive a two-stage cooling system.
vent — See Air Diffuser.
zone — See Temperature Zone.
zoning — An air conditioning system dividing the home into various areas to increase efficiency. For example — one zone is designated for the first floor and another
for the second floor of a home.

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