DJU31022

INTERMEDIATE AIR CONDITIONING & REFRIGERATION WORKSHOP

(PREVENTIVE MAINTENANCE)

NAME : NO MATRIC :
MUHAMMAD IMRAN BIN ZAINOL KAMAL 01DPU22F2011
NUR ALLIS ALLISA AQILLA BINTI RODZAN 01DPU22F2013

CLASS : DPU3
LECTURE NAME : ENCIK DIDI ASMARA BIN SALIM
 ASSESMENT :

CONTENT PAGE
Experiment outcomes
Theory
Apparatus/Equipments
Safety Precautions
Procedures
Results
Discussion
Conclusion
1.0 Experiment outcomes
At the end of the lab session students should be able:
i. To define preventive maintenance terminology
ii. To develop various maintenance tasks on major system components.
iii. To handle preventative maintenance for split unit air conditioning and water-cooled chiller.

2.0 Theory
Preventive maintenance can be described as maintenance of equipment or systems before
fault occurs. It can be divided into two subgroups, planned maintenance and condition-based
maintenance. The main difference of subgroups is determination of maintenance time, or
determination of moment when maintenance should be performed. While preventive
maintenance is generally considered to be worthwhile, there are risks such as equipment
failure or human error involved when performing preventive maintenance, just as in any
maintenance operation. Preventive maintenance as scheduled overhaul or scheduled
replacement provides two of three proactive failure management policies available to the
maintenance engineer. Common methods of determining what preventive or other failure
management policies should be applied are: OEM recommendation, requirements of codes
and legislation within a jurisdiction, what an expert thinks should ought to be done, or
maintenance that’s already done to similar equipment, and most important measured values
and performance indications. To make it simple preventive maintenance is conducted to
keep equipment working and/or extend the life of the equipment. Corrective maintenance,
sometimes called ‘repair’, is conducted to get equipment working again.
The primary goal of maintenance is to avoid or mitigate the consequences of failure of
equipment. This may be preventing the failure before it actually occurs which planned
maintenance and condition based maintenance help to achieve. It is designed to preserve
and restore equipment reliability by replacing worn components before they actually fail.
Preventive maintenance activities include partial or complete overhauls at specified periods,
oil changes, lubrication and so on. In addition, workers can record equipment deterioration
so they know to replace or repair worn parts before they cause system failure. The ideal
preventive maintenance program would prevent all equipment failure before it occurs.
3.0 Apparatus/Equipments
i. Test Pen

ii. Digital Multi-meter

iii. Manifold gauge

iv. Recovery machine

v. Micron gauge

vi. Vacuum pump

vii. Leak detector

viii. Charging scale

ix. Recovery tank

4.0 Safety Precautions
1. Make sure that your hands are dry before doing the wiring and testing on the electrical
circuits.
2. Do not touch the compressor discharge line with your bare hands.
3. Be careful not to get your hands or clothing caught in moving parts such as pulley, belts or
fan blades.
4. Wear goggle and gloves when attaching or removing gauges to transfer refrigerant or to
check pressures.
5. Observes all electrical safety precautions. Be careful at all times and common sense.

5.0 Procedures
5.1 Tools Inspection
a) Manifold Gauge Inspection
i. Suitability of manifold gauge with the refrigerant
ii. Check needle and calibrate if necessary
iii. Check manifold glass / screen condition
iv. Check hose rating, hose seal, valve nipple and condition
b) Leak Detector Inspection TEST
i. Check Leak Detector function and condition
c) Recovery Machine Inspection
i. Check filter and replace if necessary
ii. Check recovery machine manifold, valve and recovery unit condition
d) Vacuum Pump Inspection
i. Check Vacuum Pump - Oil function and condition
e) Micron Gauge Inspection
i. Check Micron Gauge function and condition
f) Charging Scale Inspection
i. Check Charging Scale function and condition
ii. Clamp On Meter Inspection
iii. Check Clamp On Meter function and condition
iv. Recovery Tank Inspection
v. Check Label (is it the same refrigerant)
vi. Tank Weight (Determine tank weight)
vii. Check tank condition (rust etc.)
viii. Purge recovery tank if not contaminated with
ix. Check tank valve / vacuum if empty
g) Thermometer
i. Check thermometer function and condition

5.2 Chiller System

1.Prepare the required equipment
2.Check the air handling unit, refrigeration cycle and cooling tower.
3.Record the data in the preventive maintenance checklist.
4.Turn ON the Chilled Water Pump, Condenser Water Pump, Cooling tower Fan
Compressor.
5.Let the system run for 10 minutes.
6.Record your Refrigeration Cycle System data in Preventive maintenance checklist.
7.Record your Air Handling Unit (AHU) System data in Preventive maintenance checklist.
8.Record your Cooling Tower System data in Preventive maintenance checklist.
9.Turn OFF all equipment.
10.Return all equipment and clean the working area.

5.3 Split Unit

i. Prepare the required equipment.
ii. Test run and inspection & record in Preventive Maintenance checklist.
iii. Perform recovery process.
a)Connection Procedure
1. Piercing valve / pliers - if no service valve (Oral)
2. Manifold gauge low pressure hose and high-pressure hose connect to AC unit
3. Manifold gauge vacuum hose connects to vacuum pump through micron gauge
4. Manifold gauge service hose connects to filter drier and inlet/suction Recovery
Machine
5. Connect hose from recovery machine outlet/discharge to recovery tank vapour
valve
6. Place recovery tank on weighing scale
7. Connect recovery machine safety cable (if applicable)
b)Recovery Procedure
1. On vacuum pump to minimize cross contamination hose (Minimum 1000
micron)
2. Open Manifold gauge valve
3. Turn knob Recovery Machine to "Recover"
4. Open inlet valve Recovery Machine
5. Open outlet valve Recovery Machine
6. Open recovery tank vapour valve
7. Press start and wait until inlet pressure gauge recovery machine reach zero and
cut off or switch OFF manually. (If applicable)
8. Close all manifold gauge valves
9. Close inlet valve Recovery Machine
10. Turn knob Recovery Machine to "Purge"
11. Press start and wait until inlet pressure gauge recovery machine reach zero and
cut off or switch OFF manually. (If applicable)
12. Close outlet valve Recovery Machine
13. Close recovery tank vapour valve
14. Turn off power supply recovery machine
15. Record quantity of recovery
c)Charging Refrigerant
1. Charging method (HCFC - vapour, HFC blend - liquid)
2. Make sure AC system is OFF.
3. Make sure all hoses are vacuum. Minimize cross contamination
4. Identify and set the amount of charge
5. Manifold gauge low side valve open, high side valve close - if charging vapour or3 TEST
RUNS and Manifold gauge high side valve open, low side valve close - ifcharging liquid
INSPECTION
6. Manifold gauge service valve "VAC" close
7. Manifold gauge service valve "REF" open
8. Place refrigerant tank on weighing scale
9. Check for leak using leak detector.
6.0 Results

2.1 Chiller system checklist

Chiller Model: Chiller Serial Number:

Completed by: Date:

AIR HANDLING UNIT

Need No
No. Component OK Comments
Attention Applicable

1. Supply Air Temp.

◦C

2. Return Air Temp.

◦C

3. Inspect Cooling Coil

4. Inspect blower wheel & belt

5. Clean or replace air filter

6. Check for leak on suction and discharge piping

REFRIGERATION CYCLE

Need No
No. Component OK Comments
Attention Applicable

1. Suction Pressure Psi

2. Discharge Pressure Psi

 3. Compressor Amps Amp

4. Inspect for refrigerant

5. Inspect for evaporator coil

6. Inspect for condenser coil

COOLING TOWER

Need No
No. Component OK Comments
Attention Applicable

1. Check and clean wet deck, remove all debris and

dispose of properly

2. Remove dirt and dust from all interior parts

3. Inspect and adjust motor, belt for proper operation

4. Check electrical wiring

5. Check for leak on suction and discharge piping

2.1 Split Unit checklist

AC Model : AC Serial No:

Completed by : Date :

INDOOR UNIT

No
No. Component OK Need Attention Comments
Applicable

1. Supply air temperature ◦C

2. Return air temperature ◦C

3. Inspect cooling coil

4. Inspect blower wheel

5. Inspect drain pan

6. Inspect control box

 OUTDOOR UNIT

No
No. Component OK Need Attention Comments
Applicable

1. Suction Pressure Psi

2. Discharge Pressure Psi

3. Compressor Amps Amp

4. Inspect for condenser oil

5. Clean dirt, leaves and debris from inside

cabinet

6. Inspect fan motor and fan blades for wear

and tear.

7.0 Discussion
i. What the purpose to cleaning the filter in indoor unit?
To maintain clean air in the room, and ensure the unit operates smoothly.
ii. What will happen to the system if suction pressure is higher than the discharge pressure?
If the suction pressure is higher than the discharge pressure in a system, it would likely
indicate a significant problem or malfunction. This scenario could lead to issues such as
decreased efficiency, reduced flow rates, or even system failure due to the abnormal
operating conditions. It's essential to identify and address the root cause promptly to prevent
further damage to the system.
iii. What will happen to the chiller system if preventive maintenance is not done in a timely
manner?
Higher risk of breakdowns: Neglected components are more prone to mechanical failures
and malfunctions, increasing the likelihood of unexpected breakdowns and costly repairs.
Poor indoor air quality: Dirty filters and coils can lead to poor indoor air quality as the
system circulates contaminants throughout the building, potentially causing health issues for
occupants.
iv. List the possible problems that will happen to the air conditioner and how to solve the
problem.
Regular Maintenance:
Schedule regular maintenance for your air conditioner, preferably before the start of the
cooling season. This includes cleaning or replacing the air filter, checking and cleaning the
coils, checking coolant levels and lubricating moving parts. Regular maintenance helps
ensure the system operates efficiently and reduces the possibility of breakdowns.
8.0 Conclusion
Your conclusion should be related to your practical and theoretical understanding on the
related topic.
In conclusion, preventive maintenance is essential for ensuring the optimal performance,
efficiency, and longevity of chiller systems. Regular inspections, cleaning, and servicing of
components help to identify and address potential issues before they escalate into costly
repairs or system failures. By investing in preventive maintenance, building owners and
operators can minimize downtime, reduce energy consumption, improve indoor air quality,
and ultimately prolong the lifespan of their chiller systems. Overall, preventive maintenance
is a proactive approach that not only saves money in the long run but also ensures the
continued comfort and functionality of the building environment.