Repair, Maintenance&

Overhauling of 2TON
Air Contioner
 Institute Code 0964
A CAPSTONE PROJECT PLANNING REPORT
On

Repare, Maintenance&
Overhauling of 2 TON Air Conditioner

SUBMITTED BY
Name of Candidates Enrollment No
Yash Barshe 23112120564
Swaraj Patil 23112120563
Sanyog Koli 2209640159
Saumya Samudre 2209640156
Aditya Dasnur 2109640107

UNDER GUIDANCE OF

Mr. Mayuresh Naikwade

MECHANICAL ENGINEERING DEPARTMENT

Maharashtra State Board of Technical Education, Mumbai

(Autonomous) (ISO-9001-2008) (ISO/IEC27001:2013)

Mechanical Engineering Department

Academic Year: 2024-2025
 CERTIFICATE

This is to certify that Mr. Yash Barshe, Swaraj Patil, Sanyog Koli, Saumya
Samudre, Aditya Dasnur . From Institute Saraswati Institute of Technology having
Enrollment No 23112120564,23112120563,2209640159,2209640156,2109640107

has completed Project planning Report having title Repare,Maintenance&

Overhauling of 2 TON Air Contioner
Individually/ in a group consisting of 5 Candidates under the guidance of the
Faculty Guide. Mr Mayuresh Naikwade

Name & Signature of Guide - Mr.Mayuresh Naikwade

Name & Signature of HOD – Mr.Jaslok Pandey

 Institute Vision

To excel in the field of technology by creating technocrats with value-based

professionalism.

Institute Mission:

M1: - To Provide technical expertise to fulfill the needs of industry.

M2: - To Impart ethical values and professional responsibilities.
M3: - To Achieve excellence in academics.
 MECHANICAL ENGINEERING DEPARTMENT

VISION
“To incorporate technical & professional skills in Mechanical Engineers to fulfill
industrial & social needs”.
MISSION
To educate, guide, and mentor the students for academic excellence.
To develop technical skills and discipline among the students as per the
requirement of the industry.
To impart ethics & social values by arranging social activities..

MECHANICAL ENGINEERING DEPARTMENT

PROGRAMME OUTCOMES-Program Outcomes (POs)
PO 1. Basic and Discipline specific knowledge: Apply knowledge of basic mathematics,
science, engineering fundamentals and automobile engineering to solve the mechanical
engineering problems.
PO 2. Problem analysis: Identify and analyse well-defined engineering problems using
codified standard methods in mechanical engineering.
PO 3. Design/ development of solutions: Design solutions for well-defined mechanical
engineering problems and assist with the design of systems, components or processes to
meet specified needs.
PO 4. Engineering Tools, Experimentation and Testing: Apply modern mechanical
engineering tools and technique to conduct standard tests and measurements.
PO 5. Engineering practices for society, sustainability and environment: Apply
mechanical engineering technology in context of society, sustainability, environment and
ethical practices
PO 6. Project Management: Use engineering management principles individually, as a
team member or a leader to manage projects and effectively communicate about well-
defined mechanical engineering activities.
PO 7. Life-long learning: Ability to analyze individual needs and engage in updating in
the context of technological changes.

MECHANICAL ENGINEERING DEPARTMENT

 PROGRAMME EDUCATIONAL OBJECTIVES

PEO 1. Provide socially responsible, environment friendly solutions to Mechanical engineering

related broad-based problems adapting professional ethics.
PEO 2. Adapt state-of-the-art Mechanical engineering broad-based technologies to work in
multidisciplinary work environments.
PEO 3. Solve broad-based problems individually and as a team member communicating
effectively in the world of work

PROGRAMME SPECIFIC OUTCOMES

PSO 1. Modern Software Usage: Use latest Mechanical engineering related softwares for
simple design, drafting, manufacturing, maintenance and documentation of mechanical
engineering components and processes.
PSO 2. Equipment and Instruments: Maintain equipment and instruments related to
Mechanical Engineering.
PSO 3. Mechanical Engineering Processes: Manage Mechanical engineering processes
by selecting and scheduling relevant equipment, substrates, quality control techniques,
and operational parameters
 Acknowledgements
We would like to thank to all the people who give their guidance in the
completion of this project and Mr. Mayuresh Naikwade (Project Co-Ordinator)
for giving us the opportunity to work under guidance and help us gaining the
experience of major project making. Our sincere thanks to our (internal project
guide), Mr. Mayuresh Naikwade Sir for giving us valuable inputs and ideas
right from the selection of our project till its successful completion.

We thank Mr. Jaslok Pandey (HOD Mechanical Department) for her ongoing
support and encouragement in every aspect. Last but not the least, the entire
staff of Department of the Mechanical Engineering for guiding our thoughts and
vision.

The successful completion of our project would not have been possible without
the dedicated support from all the mentors and guides.
 ABSTRACT

Maintenance is crucial for efficient and effective operation of air conditioners.

Neglecting maintenance can lead to reduced airflow, increased energy
consumption, and even system failure. Key maintenance tasks include:

- Cleaning or replacing air filters

- Inspecting and cleaning condenser coils

- Checking and refilling refrigerant levels

- Lubricating moving parts

- Ensuring proper drainage

- Scheduling professional servicing

Air conditioner maintenance is essential to maintain a comfortable and healthy

indoor environment while minimizing costs and maximizing system efficiency.
 Content

1. Introduction...........................................................................................................
1.1 Introduction
1.2 Application Requirement......................................................................
2. Literature Survey..................................................................................................
2.1 Literature Survey...................................................................................
2.2 Problem Statement................................................................................
2.3 Specification.........................................................................................
3. Proposed Detail.....................................................................................................
3.1 Proposed Methodology……….............................................................
3.2 Action Plain..........................................................................................

4. References...............................................................................................................
 Introduction
1.1 Introduction
 Title: Air Conditioner Maintenance: Ensuring Efficient Cooling and
Energy Savings
 Introduction:
Air conditioners are a crucial aspect of modern life, providing comfort and
relief from extreme temperatures. However, like any mechanical equipment,
they require regular maintenance to function efficiently and effectively.
Neglecting air conditioner maintenance can lead to reduced airflow, increased
energy consumption, and even system failure, resulting in discomfort, increased
energy bills, and costly repairs.
The purpose of his project is to emphasize the importance of air conditioner
maintenance and provide a comprehensive guide on maintenance tasks,
benefits, and best practices. This report will cover the essential maintenance
tasks, the consequences of neglecting maintenance, and the advantages of
regular maintenance, including improved indoor air quality, energy savings,
extended system lifespan, and enhanced cooling performance.
By highlighting the significance of air conditioner maintenance, this project
aims to promote a culture of regular maintenance among users, ensuring optimal
performance, energy efficiency, and extended lifespan of air conditioning
systems.

Page-1
 Literature Review
2.1 Literature Survey

Numerous studies and publications have emphasized the importance of air

conditioner maintenance, highlighting its impact on energy efficiency, indoor
air quality, and system reliability. Key findings include:

1. Energy consumption can be reduced by 10-20% through regular maintenance.

2. 2. Dirty air filters can increase energy consumption by 20-30%.
3. Regular maintenance can extend system lifespan by 5-10 years.
4. Indoor air pollution can be reduced by 50-90% through proper maintenance.
5. Maintenance neglect can lead to a 10-20% decrease in system performance.
6. Regular cleaning of condenser coils can improve efficiency by 10-15%.
7. Refrigerant leaks can increase energy consumption by 10-20%.
8. Proper maintenance can reduce repair costs by 10-20%.

Page-2
 Problem Statement
The 2-tonne air conditioner is not cooling effectively and has
increased energy consumption. It has not been maintained regularly
and is showing signs of wear and tear. The goal is to repair, maintain,
and overhaul the unit to restore its performance, improve energy
efficiency, and extend its lifespan.

 Objective:

To fix any faults, clean the system, replace worn-out parts, and ensure the air
conditioner works efficiently and reliably.

 Scope of Work:

1. Inspection: Check for faults, leak, and performance issues.

2. Repairs: Fix or replace broken components (compressor, fans, etc.).
3. Cleaning: Clean filters, coils, and other parts for better airflow.
4. Overhauling: Restore key parts like the compressor and ensure accurate temperature
control.
5. Testing: Verify cooling performance and check energy usage.

Page-3
 Methodology
Repair, maintenance, and overhauling of a 2-ton air conditioner (AC) require a
systematic approach to ensure the system works efficiently and extends its
lifespan. Below is a detailed methodology for the proper care and repair of a 2-
ton AC unit:

1. Preparation Phase: Safety and Tools

 Safety Precautions: Always disconnect the power supply before performing any work on the
AC unit. Wear appropriate safety gear like gloves, goggles, and hearing protection.
 Required Tools and Materials:
o Screwdrivers, wrenches, and pliers
o Coil cleaner, cleaning brushes, and microfiber cloths
o Refrigerant gauge and manifold set
o Vacuum pump
o R-22 or R-410A refrigerant (depending on the unit)
o Multimeter for electrical testing
o Thermometer to check air temperature
o Duct tape or sealing foam (for leakage testing)
o Replacement parts (filters, capacitors, contactors, thermostats, etc.)

2. Routine Maintenance
a. Cleaning the Air Filters:

 Frequency: Every 1–3 months.

 Method: Remove the air filters from the unit. Wash them with warm water and mild soap.
Allow them to dry completely before reinserting them. If the filters are damaged, replace
them.

b. Cleaning the Evaporator and Condenser Coils:

 Frequency: Every 6 months.

 Evaporator Coil: Use a coil cleaner or a soft brush to remove dirt and debris from the
evaporator coil. Ensure the coil is dry before reassembly.
 Condenser Coil: Remove debris from the condenser coils using a brush, compressed air, or
vacuum. You can apply coil cleaner for a more thorough cleaning. Avoid using excessive
pressure that might damage the coils.

c. Cleaning the Drain Line and Pan:

 Frequency: Every 6 months.

 Method: Use a wet/dry vacuum to remove debris from the drain line. Ensure there’s no
clogging in the drain pan. Use a mixture of bleach and water to clear the drain tube to
prevent mold and algae growth.

d. Checking the Refrigerant Levels:

  Frequency: Annually or if the cooling performance is suboptimal.
 Method: Using a refrigerant manifold gauge, check the pressure readings on both the high
and low-pressure sides. If the levels are low, the system may have a leak, or there may be
insufficient refrigerant. Recharging the system with the proper type of refrigerant may be
necessary.

e. Inspecting and Cleaning the Blower and Fan:

 Frequency: Every 6 months.

 Method: Clean the blower assembly using a soft brush and remove any debris. Inspect the
fan blades for damage and replace them if necessary. Lubricate the fan motor bearings if
needed.

 Frequency: Annually.
 Method: Ensure that the thermostat is properly calibrated by comparing its reading with a
reliable thermometer. Replace the batteries if necessary. If the thermostat is faulty,
recalibration or replacement may be required.

3. Repair Procedures
a. Refrigerant Leak Detection:

 Method:

o Visually inspect all refrigerant lines and joints for signs of oil or refrigerant leakage.
o Use an electronic leak detector or UV dye to identify the source of the leak.
o If a leak is found, it must be sealed before recharging the system with refrigerant.

b. Replacing Damaged Components:

 Compressor: If the compressor is faulty (no cooling, high energy consumption, unusual
sounds), it may need to be replaced. Ensure the refrigerant is recovered before removing
the compressor.
 Capacitor: A faulty capacitor (often indicated by a failure to start the compressor or fan
motor) should be replaced. Match the new capacitor with the old one in terms of rating
(voltage and microfarad).
 Contactor: If the contactor fails (intermittent operation, no cooling), replace it with the
correct part. Ensure all connections are tight and secure.

c. Electrical System Troubleshooting:

 Method:

o Check the circuit breaker to ensure it’s not tripped.

o Test all electrical connections with a multimeter to check for continuity.
o Ensure that the motor windings, thermostat wiring, and capacitor connections are
intact.

d. Fan and Motor Issues:

  Method: If the fan or motor is malfunctioning (e.g., not spinning, making noise), it should be
inspected for debris, lubrication issues, or wear. If the motor is defective, replacing it may be
necessary.

4. Overhaul Procedures

If the unit is older or suffering from multiple issues, an overhaul may be necessary to restore
it to full functionality.

a. Comprehensive Cleaning:

 Remove the unit’s cover and carefully clean both internal and external components.
 Thoroughly clean or replace the air filters, coils, and drain systems.
 Check all wiring and components for corrosion or wear.

b. Compressor Overhaul:

 In case of a compressor failure, a complete overhaul may involve disassembling and cleaning
the internal components.
 The refrigerant should be evacuated before compressor servicing.

c. Refrigerant Recharging:

 After detecting leaks, fixing them, and replacing the compressor or other components, the
system should be recharged with the appropriate type and quantity of refrigerant. Always
use a vacuum pump to evacuate air and moisture from the system before recharging.

d. System Testing:

 Once repairs are done, power on the system and check the operation of the compressor,
fan, and thermostat.
 Measure the air temperature coming out of the vents to ensure it matches the desired
settings.

5. Post-Overhaul System Checks

 Cooling Performance: Monitor the temperature drop at the air vent and ensure the AC is
cooling effectively.
 Air Flow: Check airflow from the vents and make sure there is no blockage or restriction.
 Noise Levels: Ensure there are no unusual noises indicating mechanical failure.
 Energy Efficiency: Observe the system's performance and check if energy consumption is
within expected limits
Fig.5.1. Output body(Compressor) and Digital Clamp Meter

Fig.5.2. Air Conditioner in Not working

Condiotioner
Fig.5.3. Sealing the Copper pipe by Heating
 Page-5

Action Plan
Sr no. Nature of work Date of planned Date of completion
1 We started searching not working parts
of Air conditioner to replace them new 03/09/2024 11/09/2024
parts.

2 We discussed about costs and

purchased the new parts for Air 12/09/2024 18/09/2024
contioner e.g. Compressor, Fan,
Output body,
R-410A liquid, Copper
Pipe,Polyethylene Foam,PVC
Insulation Tape,etc.

3 We replaced new parts with the faulty

parts (Parts which are not in working 19/09/2024 21/09/2024
condition)

4 We installed the copper pipe at the Air

Conditioner and Polyethylene Foam 22/09/2024 26/09/2024
and taped with PVC Insulation Tape
around it
5 We replaced the Compressor, Fan,
Outside blades of AC and All output 27/09/2024 01/10/2024
body of Air Conditioner.

6 We checked the Air conditioner and it

was leaking from input then add more 02/10/2024 08/10/2024
foam and then we add more PVC
Insulation Tape which is moisture
resistance.
7 We installed and assemble the Air
Conditioner in the Department of 09/10/2024 11/10/2024
Mechanical engineering.
 Page-6

References
1. ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning
Engineers). (2019). HVAC Systems and Energy Efficiency.
2. ENERGY STAR. (n.d.). Air Conditioner Maintenance.
3. EPA (United States Environmental Protection Agency). (2020). Indoor Air
Quality and Air Conditioner Maintenance.q
4. DOE (United States Department of Energy). (2018). Condenser Coil
Cleaning and Air Conditioner Efficiency.
5. NIST (National Institute of Standards and Technology). (2019). Building
Maintenance and Air Conditioner Performance.
6. AHRI (Air-Conditioning, Heating, Refrigeration Certification Board). (2020).
Refrigerant Leaks and Air Conditioner Performance.
7. NAHB (National Association of Home Builders). (2019). The Benefits of
Regular Air Conditioner Maintenance.
8. HVAC&R Research (Journal). (2018). The Importance of
Maintenance for Air Conditioners.
9. IEEE (Institute of Electrical and Electronics Engineers). (2019). Electrical
Aspects of Air Conditioner Maintenance.
10. Building Services Engineering Research and Technology (Journal). (2020).
Air Conditioner Maintenance and Energy Efficiency.
Name of Program: Mechanical Engineering
Name: Yash barshe, Swaraj Patil, Sanyog Koli, Saumya Samudre, Aditya
Dasnur
Semester: Fifth
Course Title and Code: Capstone Project-Planning
Title of Capstone Project: Repair, Maintenance & Overhauling of 2TON
Air Conditioner

A. POs addressed by the Capstone Project

a) Basic and Discipline of specific knowledge.
b) Design / Development of model
c) Engineering Tools, Experimentation and Testing.
d) Engineering practices of society, sustainability, and environment.
e) Project Management.

B. COs addressed by the Capstone Project

a) Implement the planned activity individually as a team.
b) Select, collect and use required information knowledge to to built the model as
per design
c) Ensure quality in product.
d) Communicate effectively and confidently as a member and leader of team.
e) Consider the ethical issues related to the project.
f) Access the impact of society.

C. Other Learning Outcomes Achieved Through This Project

1) Unit Outcomes (Cognitive Domain)

a. Learned about the fabrication work and designing of model
b. Gained knowledge about the automotive engineering
c. Performed every step together which gave us the team spirit and unity towards
the captstone project

2) Practical Outcomes
 Learned the engineering skills and development of an individual. Learned
the proper management of time and other arrangements for the project.

Enrollment Student Name Problem Punctuali Project Executio Project presentation P.A
No Indentificatio ty and Diary n of plan report Marks
n/ project overall during including (25)
Title contributi fifth documentati
on semester on

25 mark
10 marks 5 marks 5 marks 5 marks

23112120564 Yash Barshe

23112120563 Swaraj Patil

2209640159 Sanyog Koli

2209640156 Saumya Samudre

2109640107 Aditya Dasnur

Name and Signature Of Project Guide:

Mr. Mayuresh Naikwade