Service and Maintain Package-Type Air-Conditioning/Commercial Refrigeration Equipment

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COMPETENCY- BASED LEARNING MATERIAL

Heating, Ventilation, Air-conditioning and

Sector:
Refrigeration

Qualification Title: RAC SERVICING NCIII PACU/CRE

Unit of Competency: SERVICE AND MAINTAIN PACU

Module Title: SERVICING AND MAINTAINING PACU

SANTA ROSA MANPOWER TRAINING CENTER

LM SUBD. BRGY. MARKET AREA CITY OF STA. ROSA, LAGUNA
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HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module in Servicing and Maintaining PACU/CRE. This

module contains training materials and activities for you to complete.

This unit of competency Servicing and Maintaining PACU/CRE

contains knowledge, skills and attitudes required for RAC SERVICING NC III.

You are required to go through a series of learning activities in order to complete

each learning outcome of the module. In each learning outcome are Information
Sheets, Self-Check, Task Sheets and Job Sheets. Follows these activities on your
own.If you have questions, don’t hesitate to ask your facilitator for assistance.

The goal of this course is the development of practical skills in supervising

work-based training. Tools in planning, monitoring and evaluation of work-based
training shall be prepared during the work shop to support in the implementation of
the training program.

This module is prepared to help you to acquired competency, in Servicing and

Maintaining PACU/CRE .

This will be the source of information for you to acquire knowledge and skills in
this particular competency independently and at your own pace, with minimum
supervision or help from you facilitator.

Remember to:

 Work through all the information and complete the activities in each section.
 Read information sheets and complete the self-check. Answer keys are included
in this package to allow immediate feedback. Answering the self-checks will help
you to acquire the knowledge content of this competency.
 Perform the task sheets and job sheets until you are confident that your
conforms with the performance criteria checklist that follows the sheets.
 Submit output of the Task Sheets and Job Sheets to you facilitator for the
evaluation and recording in the Accomplishment Chart. Outputs shall serve as
you portfolio during the Institutional Competency Evaluation.
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QUALIFICATION :RAC SERVICING NCIII PACU/CRE

UNIT OF COMPETENCY : SERVICE AND MAINTAIN PACU/CRE

MODULE TITLE : SERVICING AND MAINTAINING PACU/CRE

INTRODUCTION
This course designed is to enhance the knowledge, skills and attitudes to safety
install package-type air -conditioning unit, components as well as accessories based on
manufacturer’s recommendations. It also includes site survey, installation of electrical
and piping systems.

LEARNING OUTCOMES:

Upon completion of this module, the trainees/students must be able to:

LO 1. Check and adjust air-conditioning and refrigeration components, controls and
operating condition.
LO 2. Maintain lubrication system in PACU /CRE
LO 3. Maintain refrigerant system in PACU /CRE
LO 4. Maintain secondary heat transport equipment in PACU / CRE
LO 5. Maintain air distribution system in PACU /CRE
LO 6. Maintain electrical system

ASSESSMENT CRITERIA

1. Work instructions are read interpreted to determine job requirements.

2. Appropriate manufacturers manual is selected to guide maintenance procedure for
PACU/CRE.
3. Tools and equipment are selected in accordance with job requirements
4. Personal Protective Equipment [PPE] is selected in line with job requirements.
5. Evaporator /condenser coil are cleared in accordance with manufacturers maintenance
manual.
6. Refrigerant piping are checked for condition, leak, insulation, and tightness of
support /brackets
7. Operating condition and electromechanical controls/ setting is in accordance with
manufacturers operations /service manual.
8. Air-conditioning and refrigeration components are checked and adjusted as per
manufacturers operation / service manual.
9. Correct maintenance procedures are applied according to standard operating
procedures.
10. Lubrication system variables and components were checked and adjusted to meet
operational specifications
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11. Oil levels, properties and circulation balances were checked and adjusted to meet
operational specifications
12. Oil leaks were detected and rectified to ensure operational efficiency
13. Recovered refrigerant in the tank must be labeled prior to recycling
14. Pressure drops across strainer, filters, and filter drier are checked and recorded.
15. Refrigerant leaks are detected and rectified to secure operational efficiency
16. Refrigerant system variables and contaminated are checked and adjusted to meet
the operational efficiency
17. Air distribution system components are checked and airflows are balanced
18. Outdoor air supply systems are checked and maintained to meet operational and
regulatory requirements
19. Humidifier, equipment is checked, serviced, and sanitized to meet operational and
regulatory requirements
20. Electrical wiring are checked for ground, continuity, open in accordance with standard
operating procedures
21. Electrical components, controls and devices are checked for operation and functions in
accordance with standard operating procedures.
22. Wiring connections and panels are checked for firmness and tightness in accordance
with standard operating procedures

CONDITIONS:

The students/trainees must be provided with the following:

Equipment Tools
 Water pressure washer  Set of wrenches
 Audiovisual equipment  Set of pliers
 PACU Unit  Set of screw drivers
 Fin comb
Instrument  Oiler
 System analyzer
 Multi tester Supplies and materials
 Electronic Leak Detector  Refrigerants
 Thermometer  Soap solution
 Refrigerant Identifier  Markers
 Rags
 Electrical tapes
Learning Materials
 Coil cleaner
 LEs on PACU
 LEs on Maintenance methods
Personal Protective Equipment
and procedures  Goggles
 Audiovisual materials on  Gloves
maintenance  Working clothes
 Maintenance schedule  Safety shoes
 Manufacturer’s manual  Ear muff/plug
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METHODOLOGIES:
 Self-paced instruction
 Film viewing
 Direct laboratory experience
 Group discussion
 Industry visit
 Industry immersion
 E-learning

ASSESSMENT METHODS:
 Interview
 Written exam
 Observation with questioning
 Demonstration with questioning
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Check and adjust air-conditioning

and refrigeration
LEARNING OUTCOME NO. 1 components, controls and
operating condition.

Contents :
 Maintenance and Inspection of Refrigeration and Air-Conditioning Unit.

 Procedure for Service and Maintenance Activities” and “Cleaning Air Filters.

 Check and Adjust Air-Conditioning and Refrigeration Components, Controls

and Operating Condition.

 Procedures in Dismantling, Inspecting and Reassembling Service Valves.

Assessment Criteria:
 Work instructions are read interpreted to determine job requirements.
 Appropriate manufacturers manual is selected to guide maintenance
procedure for PACU/CRE.
 Tools and equipment are selected in accordance with job requirements
 Personal Protective Equipment [PPE] is selected in line with job
requirements.
 Evaporator /condenser coil are cleared in accordance with manufacturers
maintenance manual.
 Refrigerant piping are checked for condition, leak, insulation, and tightness
of support /brackets
 Operating condition and electromechanical controls/ setting is in
accordance with manufacturers operations /service manual.
 Air-conditioning and refrigeration components are checked and adjusted as
per manufacturers operation / service manual.
 Correct maintenance procedures are applied according to standard
operating procedures.
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CONDITIONS:
Trainees/ Students must be provided with the following
EQUIPMENT
 Water pressure washer
 Audiovisual equipment
 PACU Unit

INSTRUMENT
 System analyzer
 Multi tester
 Electronic Leak Detector
 Thermometer
 Refrigerant Identifier

LEARNING MATERIALS
 LEs on PACU
 LEs on Maintenance methods and procedures
 Audiovisual materials on maintenance
 Maintenance schedule
Manufacturer’s manual

TOOLS
 Set of wrenches
 Set of pliers
 Set of screw drivers
 Fin comb
 Oiler

SUPPLIES AND MATERIALS

 Refrigerants
 Soap solution
 Markers
 Rags
 Electrical tapes
 Coil cleaner

PERSONAL PROCTECTIVE EQUIPMENT

 Goggles
 Gloves
 Working clothes
 Safety shoes
Ear muff/plug

METHODOLOGIES :
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 Self-paced instruction
 Film viewing
 Direct laboratory experience
 Group discussion
 Industry visit
 Industry immersion
 E-learning

ASSESSMENT METHOD
 Interview
 Written exam
 Observation with questioning
 Demonstration with questioning

Learning Experiences
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INFORMATION SHEET #1
Maintenance and Inspection of Refrigeration and Air-Conditioning Unit

In any operating refrigeration and air-conditioning unit, it is most important to provide

planned maintenance and inspection of its functioning parts to keep the units operating at its
peak efficiency.

If a unit failure occurs due to improper maintenance during the warranty period, the
manufacturer will not be liable for the cost incurred to return the unit to satisfactory operation. It
is the responsibility of the owner to assure that prescribed operating and maintenance
requirements of the units are performed as listed below.

I. Daily Requirements (Check the following):

1. Control center
 Gauges
 Indicator lights
2. Condenser and cooler units
 Temperature differential
 Pressure differential
3. Refrigerant level in cooler
4. Compressor oil level
5. Voltage
6. Verify proper water treatment

II. Weekly (Check and record the following):

1. Compressor
 Oil level
 Oil pressure
 Oil temperature
 Refrigerant suction temperature
 Refrigerant discharge temperature
2. Condenser
 Refrigerant pressure
 Refrigerant temperature
 Refrigerant high-pressure liquid temperature
 Refrigerant system air device
 Water inlet pressure
 Water inlet temperature
 Water outlet pressure
 Water outlet temperature
 Water flow rate
3. Cooler/Evaporator
 Refrigerant pressure
 Refrigerant temperature
 Refrigerant level
 Water inlet pressure
 Water inlet temperature
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 Water outlet pressure

 Water outlet temperature
 Water flow rate
4. Compressor Electric Motor
 Line voltage
 Line current
 Bearing lubrication
5. Purging Unit
 Purger pressure
6. Control Center

III. Monthly
1. Check purging unit operation, purge air and non-condensable gas if necessary.
2. Check electrical and electronic pressure and temperature controls including their safety
cut-in points and operating parameters.
3. Check, clean and tighten circuit breakers and starters controls including their terminals
and components.
4. Check and lubricate compressor motor bearing.
5. Check vibration of equipment.
6. Perform external leak test if necessary.
7. Verify proper water treatment.
8. Maintain cleanliness of equipment and its surrounding.

IV. Quarterly
1. Submit compressor lubricating oil test analysis report.
2. Check and recommend for any painting to minimize corrosion and deterioration.
3. Check and recommend for any modulation of component requirement that requires
repair or replacement.

V. Semi-annually
1. Change compressor lubricating oil
2. Change and inspect compressor oil filter element.
3. Change motor cooling refrigerant filter element.
4. Oil return system.
 Clean nozzles of oil for foreign particles
 Change filter drier dehydration or element
5. Purging unit
 Inspect and clean all valves and orifices
 Drain and flush oil refrigerant from the purger shell cylinder
 Change filter drier dehydration and foul gas strainer

VI. Annually
1. Meg and test compressor motor winding
2. Condenser and cooler
 Inspect and clean water strainer from foreign particles
 Inspect and clean tubes and end sheets (mechanical only)
 Drain and refill with water
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Note: For additional information, refer to code of practice for RAC part 2.2 section 3 page 15.
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SAMPLE LOG SHEET FOR SERVICE AND MAINTAIN PACU/CRE

INSPECTION AND MAINTENANCE SCHEDULE

9. Check water level

12. Tighten loose bolts

1. Inspect for clogging

10. Check for leakage

4. Lubricate (grease)
5. Check oil seals
6. Check oil level

8. Change oil, at least

13. Clean
14. Repaint
condition11. Inspect general
and dirt7. Check oil for water
noise or vibration2. Check for unusual
screw3. Inspect keys and set

FAN D S R R

MOTOR D S Q S S R

GEAR REDUCER D S W W M S S R R

DRIFT W R
ELIMINATORS

FILL W Y R

BASIN D W Y S

WATER W D Y R S
DISTRIBUTION

STRUCTURAL Y Y Y R
MEMBERS

CASING W Y R R

SUCTION W W
SCREEN

BLOW DOWN D

D – daily, W – weekly, M – monthly, Q – quarterly, S – semi-annually, Y – yearly, R – as required

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SAMPLE LOG SHEET

Date: _________________________

Job Name: ___________________________________ Address:

______________________________________
System Model No.: ____________________________ Compressor Serial No.:
___________________________
SYSTEM DESIGN OPERATING CONDITIONS

Volts ____________ Phase ____________ Hertz

Motor ___________ Speed _____________
FLA _____________
Temperature In F ____________ Out F _____________ GPM
______________________
Cooler
Pressure Drop ___________ Ft. System Refrigerant
_____________________________
Temperature In F ____________ Out F _____________ GPM
______________________
Condenser
Pressure Drop ___________ Ft. System Refrigerant
_____________________________
Data By SYSTEM DATA LOG
AM AM AM AM
Time
PM PM PM PM
Barometric Pressure “HG. “HG. “HG. “HG.
Suction Press. (PSI) (“HG.)
Compr.

Suction Temp. F
Disch. Press. (PSI) (“HG.)
Disch. Temp. F
Pressure (PSI), (Refrigerant)
Actual Disch. Temp. F
High Press. Liquid Temp. F
Condenser

Sub-cooled Liq. Temp. F

Inlet Temp. F
Outlet Temp. F
Water Press. Drop (PSI) (“HG.)

Flow

Pressure (PSI), (Refrigerant)

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Actual Disch. Temp. F
Inlet Temp. F
Cooler

Outlet Temp. F
Water Press. Drop (PSI) (“HG.)

Flow

RPM
Motor

Volts
Amps
KW or Rev./Sec’s.

Remarks; Meter info. (Constants, size, etc.): _____________________________

________________________________________________________________
________________________________________________________________
________________________________________________________________
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JOB SHEET #1
Procedure for service and maintenance activities for PACU/CRE such as:

- Mini split
- Wall mounted
- Floor mounted
- Unitary ducted
- Split ducted
- Cassette model
- Commercial refrigeration

Tools and Equipment:

Tools: Equipment:
- Set of pliers - System analyzer with hoses
- Set of screwdrivers - VOA clamp meter
- Adjustable wrench 8” - Multi-tester
- Wrench, open ½” x 9/16” - Pocket thermometer 2 pcs.
- Wrench, open 3/8” x 7/16” - Pressure washer
- Wrench, Ratchet ¼” x 3/8”
- Allen wrench (metric) 1 set Supplies:
- Paint brush 1”
Components to be serviced: - Contact cleaner
- Air filter - Laundry brush (hard)
- Evaporator coils - Liquid soap
- Control switch - Rags
- Drain lines
- AHU panels
- Condenser coils
- ACCU pan blade and motor
- Service valves
- Compressor terminals
- Magnetic contactor
- ACCU panels
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Procedure (Regular Servicing):

1. Turn OFF the circuit breaker.

2. Clean and check AHU.

a. Remove air filters and clean with water and soap.

3. Check drain line for clogs.

4. Return air filter properly.

5. Clean AHU panel with soft cloth and water.

6. Clean and check the ACCU.

a. Remove fan grille and electrical panel cover.
b. Check and tighten the following:
- Electrical control terminals
- Compressor terminals
- Fan motor terminals
c. Clean electrical components with paint brush

7. Clean and check the ACCU.

a. Remove fan grille and electrical panel cover
b. Check and tighten the following:
- Electrical control terminals
- Compressor terminals
- Fan motor terminals
c. Clean electrical components with paint brush

8. Switch ON the circuit breaker

9. Check unit’s operating data (Run unit for at least 15 min. before taking data.)
a. Suction line temperature
b. Ambient temperature
c. Power supply voltage
d. Compressor current draw
e. Overall current draw
f. Air in/out temperature at AHU
g. Air in/out temperature at ACCU
h. Room temperature
(Note: the suction pressure will only be taken if the unit is not cooling well after cleaning
of air filters. Otherwise, it will have to be taken to determine refrigerant charge.)

10. Clean ACCU panels with soft cloth and water.

11. Accomplish the Service Attendance Report and have it signed by the owner of his/her
authorized representative.
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Procedure (General Cleaning)

1. Switch off circuit breaker

2. Clean and check AHU

a. Remove air filters and clean with water and soap
b. Remove panel then check and clean the following:
- Electrical control terminals
- Blower motor terminals
- Blower wheels
c. Clean electronic control with paint brush
d. Flush drain line with pressurized water
e. Check for any signs of refrigerant leaks
f. Clean AHU coil with laundry brush
g. Return air filter and panel properly
h. Clean AHU panels with soft cloth and water

3. Clean and check the ACCU

a. Remove fan grille and electrical panel cover.
b. Check and tighten the following:
- Electrical control terminals
- Compressor terminals
- Fan motor terminals
- Fan blade and motor mounting
c. Clean electrical components with paint brush
d. Clean condenser coil using pressure washer and laundry brush.
e. Return fan grille.

4. Switch ON the circuit breaker

5. Check unit’s operating data. (See step #8 and 9 of Regular Servicing Procedures)

6. Return electrical panel cover.

7. Clean the ACCU panels with soft cloth and water.

8. Accomplish the Service Attendance Report and have it signed by the owner or his/her
authorized representative.
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JOB SHEET #2
CLEANING AIR FILTERS

 Filters Air filters

Option 1: Active carbon filter/Photo-catalyst filter
Option 2: Active carbon filter/Electrostatic filter
 Air filters eliminate dust and lint
 Optional active carbon filter/Photo-catalyst filter effectively eliminates odor and
cigarette smoke in the room air.
 Optional Active carbon filter/Electrostatic filter is particularly effective in eliminating
odor and microscopic dust.

Life Time of Filters

 The life of above filters varies according to the amount of cigarette smoke, room size and
the operating time.
 Air filters can be cleaned with a vacuum cleaner or rinsed under running water after
using a month.
 The life time of optional Active carbon filter is about 2 years and that of optional
Electrostatic filter is about 3 months. These filters cannot be recycled.
 The life time of optional Photo-catalyst filter is about 2 years. This filter can be washed
under running water and can be refreshed by exposing under direct sunlight. Exposure
time is 6 hours after using for 3 months.

Note: Additional information for air filter.

Refer to Unit of competency: Service and Maintain Window-Type Air-
Conditioning/Domestic Refrigeration Units.
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CARE AND MAINTENANCE

Cleaning the Filters and Front Panel

 Turn off the unit and pull out the power plug.
 Clean the air filters once a month.

1. Lift the front panel and pull 3. Clean the filters with a 3. Rinse the filters under
the air filters downwards. vacuum cleaner. running water and dry
them completely, and then
refit them correctly into
their guides.

Refreshing the Optional Photo-catalyst filter

1. Lift the front panel and put 2. Blow off the dust from the 3. Expose under direct
the optional photo-catalyst filter with fresh air or wash sunlight for 6 hours and
filter downward. the filter under running refit correctly into its guide.
water.

Washing the Front Panel

Note:
 Turn off the unit and pull out the power plug.
 Clean the front panel if it becomes dirty and spotted.
 Front panel is removable.
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1. Lift the front panel up to 2. Rinse the panel under 3. Refit it correctly.
the top of the unit, then running water and dry it Installation procedure is
separate the front panel completely in a shaded reverse to the removal
from the unit. area. procedure.
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Cleaning the Main Unit

 Use only a damp soapy towel.  Do not pour water onto the unit and do not
use petrol, solvents or abrasive powder
which may result in damage to the unit.

Note:
 When cleaning the unit, first turn it off and pull out the power plug.

After-Season Care

1. Clean the filters and refit them into the unit. 2. If the unit to be switched off for an extended
period, run the unit on FAN only for two
hours to dry inside of the unit.

3. Clean the indoor and outdoor unit and wrap

the outdoor unit with a protection cover.
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INFORMATION SHEET #2
Check and Adjust Air-Conditioning and Refrigeration Components, Controls and
Operating Condition

This material will guide you in performing the following operations:

 obtain the operating data of the equipment;

 check head pressure or suction pressure;
 check the refrigerant charge in the system;
 check the motor for excessive temperature;
 check for leaks in the suction valve and discharge valve;
 check the condition and lubrication of the bearings;
 check the amount of lubrication in the motor and refrigeration system;
 check the shaft seals for leaks;
 check the compressor, condenser and evaporator for excessive low or high temperature;
 check the condenser cooling water temperature flow rate; and
 check the condition of belts and couplings.

The following equipment and instrument will be used for the above operations:

Quantity Unit Description

1 unit Available refrigerating unit
1 unit Gauge set
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INTRODUCTION:

Refrigeration machinery may not require major regular maintenance when small problems are
detected and corrected before they become big problems. The reliability of the system can be
maintained through periodic inspection by a qualified refrigeration man. His services must be
utilized and his recommendation must be acted upon.

Shown below is a typical refrigeration system with a refrigeration man doing visual inspection as
a means of preventive maintenance or doing a maintenance check-up of the system.

SERVICING EQUIPMENT

Some compressors are

equipped with suction
and discharge pressure
gauges which indicate
evaporator and
condensing pressures
respectively. However,
most compressors do
not have permanently
mounted pressure
gauges and in such
cases a particular unit
known as a GAUGE
MANIFOLD is used. The
service manifold is one
of the most versatile
instruments that the field
serviceman has utilized
to determine the
operating conditions of
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the refrigeration system.
The manifold is connected to the suction service valve and the discharge service valve with
flexible lines. The actual connection shall be explained in time latter pages.
The service valves on the other hand, are fitted to the suction amid discharge ports of the
compressor and their construction is discussed in the following section. See illustration on
figure above for the location of service valves.

COMPRESSOR SERVICE VALVES AND FITTINGS

Before gauges and service Nomenclature of service valve assembly

cylinders can be titled to the
system or any part removed
from a system, a knowledge
of the construction and
functioning of the valves is
essential. See figure.
There are three main service
valves:

1. Suction service valves

(SSV)
2. Discharge service valves
(DSV)
3. Liquid receiver service
valves (LRSV)
1. Flare nut 6. Seal cap
2. Union 7. Valve Body
3. Spindle 8. Gauge plug
4. Gland washer 9. Washer packing
5. Gland nut 10. Seal cap washer

The suction and discharge service valves have a front and a back seating arrangement, so
that the gauge manifold may be fitted to the system, while the liquid receiver service valve
usually has one seat.

The various positions of the valve spindle on both the suction and discharge service valves are
as follows:

Back Seated - this is when the spindle is turned

fully backwards closing the gauge
port.
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Mid-seated - in this position the spindle can be
turn mid way of the valve allowing
the gauge port line connection
and compressor connection open.

Front seated - this is when the spindle is turned

fully forward thus closing the line
connection.

SAFETY PROCEDURES IN HANDLING SERVICE VALVE

1. Always slacken off (loosen) gland packing nut before attempting to turn the valve stem.
2. Always use a ratchet spanner or key to suit the size of the valve stem.
3. NEVER FORCE the valve against its seat; this may score it or “freeze” the stem and seat
together.
4. Give the valve stein a drop of refrigeration oil occasionally.
5. Always back seat the service valve spindle before removing the gauge plug.
6. When service work is completed the gauge plug must be replaced, the gland nut tightened
and the sealing cap, complete the sealing washer inserted, replace on the service valve
tightened.

VALVE WRENCH AND SPANNERS

Service valve is the access point to refrigeration system. It serves as a key accessory in
servicing operation. Being one of the most important accessories in refrigeration system, care
should be taken in consideration. To handle the valve carefully, special access tools are being
used. These are:

a. Valve ratchet wrench

This is a special tool used mainly in servicing

operation. It is design for the purpose of
accessing service valve. The wrench suit to
the valve stem and fit it snugly to avoid
slippage that could wear or damage it.
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b. Adjustable wrench

This tool is not new to us, this is a universal

tool commonly used by a mechanic. The jaw
of this wrench can be adjusted to fit the size of
nut and/or flare cap. In servicing operation this
used particularly on opening of service valve
cap and service port cap.

THE COMBINATION GAUGE MANIFOLD

The combination gauge manifold is a necessary instrument for the serviceman, enabling him to
check and service refrigeration system. The gauge manifold is usually fitted to the compressor
service valves to obtain high and low side pressure in the system, and may be used for nearly
all service operations, such as adding or removing refrigerant, purging off air or excess
refrigerant, and by-passing pressure from high to low side of the system.

The combination gauge manifold should be given proper care, the gauges protected from
vibration and the threaded or flared ends should be provided with protective covers, it is
important to prevent entry of moisture and dirt into the hoses and manifold when not in use and
so avoid contaminating the refrigeration system. The gauges themselves should be checked
periodically so that so that accurate readings are taken at all times. A routine check before
using the compound gauge should be to see that the needle reads zero when the gauge is
open to the atmosphere.

CONSTRUCTION OF THE MANIFOLD

Basically the gauge manifold consists of compound amid

high pressure gauges mounted oil a manifold with hand
valves to isolate the common connection, or open it to either
side as desired. The construction of the valves allows full
flow of refrigerant to the gauge at all times.

Gauge manifold set

Flexible hoses
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The two types of gauges are incorporated into the manifold,
these are:

1. Low Pressure Gauge:

The compound gauge indicates pressures above and

also those below atmospheric pressures (vacuum). This
is used to measure the low pressure or evaporator side Compound gauge
of the system and is connected to the suction service
valves.
2. High Pressure Gauge:

This gauge is used on the high pressure or condenser

side of the system and is connected to the discharge
service valves.

Pressure gauge

CARE IN HANDLING GAUGE MANIFOLD

1. Always blank-off (cover) the manifold lines when not in use to prevent entrance and
contamination of air.

2. Inspect the rubber of flexible hose before and after using it. If indication of wearing is
detected replace it at once.

3. Wipe-off oil and grease after using the gauge manifold. Remaining oil in it would catch dust
and forms heavy dirt. It is very hard to remove and unsafe to use.

4. Calibrate the gauge regularly before using.

`
JOB SHEET #3
DISMANTLING, INSPECTING, AND REASSEMBLING SERVICE VALVES

TOOLS AND MATERIALS

Discharge line valve Ratchet wrench, 1/4 in.

Suction tine valve Graphite packing
Liquid line valve Packing gland
Service valve wrench, 1/4 in. Packing nut wrench
Adjustable end wrench

PROCEDURES

A. Two-way Service Valve

1. Obtain a two-way suction line valve from the instructor.
2. Remove the end cap with an adjustable wrench. Record your observations.
3. Remove the packing gland nut with the packing nut wrench.
4. Remove the valve stem using the 1/4-in, ratchet wrench.
5. Lay out the parts on a flat surface in the order of removal.
6. Proceed to clean all parts with dry rags.
7. Make a list of the parts in the table below and indicate the function of each part.
8. Reassemble the parts in their proper order.

B. One-Way Service Valve

Repeat steps 1 through 8 in port A.

C. Liquid Line Valve

Repeat steps 1 through 8 in part A.

Operating Data

These are the basics used by a refrigeration man in troubleshooting a system.

An example of operating data of a motor is shown below:

1. Motors are identified from the information

in the rating plate. This includes:

- Maker’s name or trade mark.

- Type of supply, e.g., 3-phase, 38-0 V,
50 cycles.
- Rated power, e.g., 5 Hp.
- Rating, e.g., continuous operation.
- Speed, e.g., 1450 rev/mm.
- Serial number of motor.
- Frame reference number.
- Additional information.

Typical Rating Plate

`
Check Head or Suction Pressures

2. Install the gauge manifold set, as shown.

NOTE:

Refer to L.E. “Gauge and Manifold Set” if

necessary.

Head Pressure Test

3. Head pressure should not exceed 60 psi.
(4.20 kg/cm2), as shown.

4. If head pressure exceeds 60 psi (4.20

kg/cm2), it is possible that the condenser is
clogged and needs cleaning. Clean the
condenser as shown.

Refer to the L.E. on “Cleaning, Removing

and/or Replacing Condensers” if
necessary.

Check the Refrigerant Charge in the System

5. A popular method to check for refrigerant

charge is to mount a glass sight gauge in
the liquid line, as shown.
`
6. Bubbles indicate that there is insufficient
refrigerant.

7. Add refrigerant.

NOTE:

Refer to L.E. “Charging the System with

Refrigerant” if necessary.

8. Checking the Motor for Excessive

Temperature

NOTE:

Do not use your hand to check the

temperature of the motor.

9. Use a thermometer and check the reading

against the allowable temperature shown
on the name plate.
`
10. The temperature of the motor should not
rise more than 40ºC (72ºF) over room
temperature.

Checking for Leaks in the Suction Valve and Discharge Valve

To test for leaks on the low pressure side oi a

compressor, such as at the gaskets, at the
suction service valve, or at the crankshaft seal,
one may use one of two methods:

11. Close the suction service valve and draw

as high a vacuum on the compressor as
possible. Then turn the discharge service
valve all the way in.

12. Keep the compressor running. If the head

pressure gradually rises, it means that air
is being drawn into the low side off the
system.

13. A better way is to balance the pressures in

the crankcase and turn the discharge
service valve all the way in, as shown.
`
14. Remove the discharge service valve gauge
plug and connect a 250 mm length of
copper line, as shown.

15. Immerse the copper line into a glass bottle

partly filled with oil, as shown.

16. If the tube discharges gas continuously as

shown by air bubbles it means air is being
admitted to the low side of the compressor.

17. If there are no leaks, the bubbling will stop

immediately after the compressor is
started.
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SELF-CHECK #1

CALL YOUR INSTRUCTOR who will observe you perform maintenance check-up.

Acceptability
Instructor’s checklist
Yes No
1. Obtaining operating data of the equipment ______ ______
2. Checking the head and suction pressure ______ ______
3. Checking the refrigerant charge in the system ______ ______
4. Checking motor for excessive temperature ______ ______
5. Checking for leaks in the suction valve and discharge valve ______ ______
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Learning Outcome # 2 : Maintain Lubrication System in PACU/CRE.

Content :
 Check the Condition and Lubrication of the Bearings.

Assessment Criteria:

 Lubrication system variables and components were checked and adjusted to meet
operational specifications
 Oil levels, properties and circulation balances were checked and adjusted to meet
operational specifications
 Oil leaks were detected and rectified to ensure operational efficiency
 Recovered refrigerant in the tank must be labeled prior to recycling

CONDITIONS:
The students/trainees must be provided with the following:

Equipment Tools
 Audiovisual equipment  Set of wrenches
 Oil pump  Set of pliers
 PACU  Set of screw drivers
 Set of Allen wrenches
 Oiler
Instrument
 Refractometer Personal protective
Equipment
 Goggles
Learning Materials
 Gloves
 LEs on PACU
 Working clothes
 LEs on Maintenance
 Safety clothes
methods and procedures
 Safety shoes
 Audiovisual materials on
lubrication system  Ear muff/plug
 Manufacturer’s manual

Supplies and materials

 Refrigeration oil
 Soap solution
 Markers
 Rags
 Oil testing kits
 Lubrication oil
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METHODOLOGIES:
 Self-paced instruction
 Film viewing
 Group discussion
 Industry immersion
 E-learning

ASSESSMENT METHODS:

 Interview
 Written exam
 Direct observation
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LEARNING EXPERIENCES

LEARNING OUTCOME NO. 2: Maintain Lubrication System in PACU/CRE.

Learning Activities Resources

1. Read the information sheet “Checking the  Information Sheet #3

Condition and Lubrication of the Bearings”.

2. Answer the Self-Check #2.  Self Check #2

3. Ask instructor if you can proceed to the

next learning outcome.

INFORMATION SHEET #3
Checking the Condition and Lubrication of the Bearings

1. An increase iii temperature particularly at

the bearing housing section of the
equipment is an indication that the bearing
is excessively starved of lubrication.

This can be checked by feeling with the

hands. A more accurate means of checking
would be to use a thermometer.

2. A damaged bearing is indicated by

excessive noise while the motor is running.
Most often, this is accompanied by an
increase in temperature.
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Checking the Shaft Seals for Leaks

3. A noisy seal will soon become a leaky one

if not attended to.

It may be remedied by the usual process of

lapping the seal, or it may sometimes be
repaired by tapping the seal box lightly with
a hammer.

4. A leaky seal may be detected by the usual

test for leaks (ammonia for sulfur dioxide).

SELF-CHECK #2

CALL YOUR INSTRUCTOR who will observe you perform maintenance check-up.

Acceptability
Instructor’s checklist
Yes No
1. Checking for leaks in the suction valve and discharge valve ______ ______
2. Checking the condition and lubrication of the bearing ______ ______
3. Checking the shaft seals for leaks ______ ______
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Learning Outcome # 3 : Maintain Refrigeration System in PACU/CRE.

Content :
 Poor Condensation in PACU/CRE.

Assessment Criteria:

 Pressure drops across strainer, filters, and filter drier are checked and recorded.
 Refrigerant leaks are detected and rectified to secure operational efficiency
 Refrigerant system variables and contaminated are checked and adjusted to meet the
operational efficiency

CONDITIONS:
The students/trainees must be provided with the following:

Equipment Tools
 Audiovisual equipment  Set of wrenches
 Oil pump  Set of pliers
 PACU  Set of screw drivers
 Set of Allen wrenches
 Oiler
Instrument
 Refractometer Personal protective
Equipment
 Goggles
Learning Materials
 Gloves
 LEs on PACU
 Working clothes
 LEs on Maintenance
 Safety clothes
methods and procedures
 Safety shoes
 Audiovisual materials on
lubrication system  Ear muff/plug
 Manufacturer’s manual

Supplies and materials

 Refrigeration oil
 Soap solution
 Markers
 Rags
 Oil testing kits
 Lubrication oil
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METHODOLOGIES:
 Self-paced instruction
 Film viewing
 Group discussion
 Industry immersion
 E-learning

ASSESSMENT METHODS:

 Interview
 Written exam
 Direct observation

LEARNING EXPERIENCES

LEARNING OUTCOME NO. 3: Maintain Refrigeration System in PACU/CRE.

Learning Activities Resources

1. Read the information sheet “Poor  Information Sheet #4

Condensation in PACU/CRE”.

2. Answer the Self-Check #1.  Self Check #1

3. Ask instructor if you can proceed to the

next learning outcome.

INFORMATION SHEET #4
Poor Condensation in PACU/CRE
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To determine what is responsible for a poor condensing condition proceed, as follows.

1. Install a gauge manifold, as shown. Refer

to L.E. on “Gauge and Manifold Set”, if
necessary.

2. Determine head pressure. The head

pressure should be 165-205 psig
1.14 x 10-4 Pa to
1.14 x 10-4 Pa at 100ºF

NOTE:

If the head pressure registered is more

than the range mentioned; then the system
has too much refrigerant, too much oil or
has a corroded interior.

Checking the compressor, condenser and the evaporator for excessive low or high
temperature.

3. Compressor

Compressors are checked by using a

thermometer, as shown. Temperature
range should be from 65ºF to 115ºF.
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4. Condensers

Condensers whether air cooled or

water cooled are installed to remove
heat. The condensers will fail to do its
job if the heat transfer surfaces are
inefficient.

Evaporators

5. Install a. thermometer on the

evaporator tube, as shown.

6. A reading of between 5ºF to 15ºF (-

15ºC to -45ºC) should be registered.

NOTE:

If reading does not reach the range, it

means a lack of refrigerant. Add
refrigerant. Refer to L.E. “Charging the
system with Refrigerant”, if necessary.

Checking the Condenser Cooling Water Flow Rate

7. Too much water flow will give a very

satisfactory refrigeration.
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8. Less water flow clue to leaky valves or
water lines gives unsatisfactory
refrigeration.

9. Adjust valve to control the flow rate of

water by turning the valve stem
clockwise or counterclockwise, as
shown.
10. Install the water flow meter or gauge
to determine the flow of water, as
shown.

Checking the Condition of Belts and Coupling

11. Fan belts need periodical checking for

its tension, as shown. Amount of sag
should not exceed 1/2” (12mm), as
shown.
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CALL YOUR INSTRUCTOR who will observe you perform maintenance check-up.

Acceptability
Instructor’s checklist
Yes No
1. Checking the compressor, condenser and evaporator for ______ ______
excessive low or high temperature
2. Checking the condenser cooling water and flow rate ______ ______
3. Checking the condition of belts and couplings ______ ______

Learning Outcome # 4 : Maintain Secondary Heat Transfer Equipment in PACU/CRE.

Content :

1. Cooling Tower and Evaporative Condenser.

2. Test the Efficiency of Compressor

3. Charge Oil in the Compressor

4. Evacuate the System

5. Charge Refrigerant in the System

6. Test Leaks in the System

7. Remove and Replace Filter Drier

8. Remove and Replace Oil Separator

9. Remove and Replace or Clean Thermostatic Expansion Valve Strainer

10. Service Commercial Refrigerating System

Assessment Criteria:

 Liquid properties are adjusted to meet specified standard

 Follow-up action is arranged in accordance with workplace procedures
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LEARNING EXPERIENCES

LEARNING OUTCOME NO. 4: Maintain Secondary Heat Transfer Equipment in PACU/CRE

Learning Activities Resources

1. Read the information sheet “Cooling Tower and Evaporative  Information Sheet #5
Condenser”.

2. Read and perform the procedures in the job sheet “Test the  Job Sheet #4
Efficiency of Compressor” and answer the questions. Write your
answers on a piece of paper and have them checked by your
instructor.

3. Read and perform the procedures in the job sheet “Charge Oil  Job Sheet #5
in the Compressor” and call your instructor to check your work.

4. Read and perform the procedures in the job sheet “Evacuate  Job Sheet #6
the System” and call your instructor to check your work.

5. Read and perform the procedures in the job sheet “Charge  Job Sheet #7
Refrigerant in the System” and call your instructor to check your
work.

6. Read and perform the procedures in the job sheet “Test Leaks  Job Sheet #8
in the System” and call your instructor to check your work using
the listed evaluation criteria.

7. Read and perform the procedures in the job sheet “Remove and
 Job Sheet #9
Replace Filter Drier” and call your instructor to check your work
using the listed evaluation criteria.

8. Read and perform the procedures in the job sheet “Remove and
 Job Sheet #10
Replace Oil Separator” and answer the questions. Write your
answers on a piece of paper and have them checked by your
instructor.

9. Read and perform the procedures in the job sheet “Remove and
Replace or Clean Thermostatic Expansion Valve Strainer” and.  Job Sheet #11
and call your instructor to check your work using the listed
evaluation criteria

10. Read and perform the procedures in the job sheet “Service
Commercial Refrigerating System” and answer the questions.  Job Sheet #12
Write your answers on a piece of paper and have them checked
by your instructor.
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11. Ask instructor if you can proceed to the next learning outcome.

INFORMATION SHEET #5
Maintain Secondary Heat Transfer Equipment

COOLING TOWER AND EVAPORATIVE CONDENSER

Heat from water cooled may be transferred to the surrounding through a cooling tower or an
evaporative condenser.

1. A cooling tower contains apparatus which sprays the condenser water through a blast of air
(some design rely on the wind created by spraying itself; others use fans). Some of the
water evaporates and loses the latent heat of vaporization. The remaining water dries to the
bottom and is returned to the condenser foil reuse. Chemicals may be needed to control
rust, algae fungus and the organism that causes legionnaires disease, which grows inside
the cooling tower. During operation, a cooling tower receives enough condenser heat to
keep it from freezing. The system must be able to empty itself of water when not in use to
prevent freezing.

2. An evaporative condenser also uses evaporation to remove heat. In this device, the
condenser water flows through a heat exchanger which is under a spray or drip of water.
Fan blow air across the condenser during operation. Build up of scale is visible in this
device.

Shell and Tube or Coil

In a shell and tube condenser is a large cylinder with a water manifold at each end. Water
recirculates through the large cylinder. Hot refrigerant vapor enters the inlet manifold and flows
through the cooling tubes and exits the discharge manifold.

A shell and coil is also a cylinder with two manifolds but the refrigerant flows through coiled
tubes instead of straight ones. Due to their shape, the coil must be cleaned with chemicals not
brushes.

Tube-Within-a-Tube

In this model, the outer tube contains refrigerant and the inner tube contains water. The two
fluids flow in opposite direction to the incoming cold water contacts the refrigerant that is just
about to flow to the receiver. This ensures the greatest temperature reduction in the refrigerant.
The wall between the two fluids may be shaped to increase its area and the rate of heat
transfer. The tube-within-a-tube type has too little space to store refrigerant and cannot serve
as a liquid receiver. Consequently, the tube-within-a-tube type is easy to overcharge which
reduces the space available for heat transfer and can cause erratic cooling.
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WATER TREATMENT

All air-conditioning systems using water-cooled condensers require some form of water
treatment. This treatment is necessary because water (from any source such as wells, lakes,
and rivers) contains impurities in the form of minerals, gases, organic matter, algae, and
bacterial slime. These impurities act on the condenser water system in the following ways:

 Minerals cause the formation of scale on the metal surfaces.

 Guns In the atmosphere, such as carbon dioxide and sulfur dioxide, form acids when
they come into contact with the water. These acids eventually attack and corrode the
metal surfaces.
 Algae attach themselves to the surfaces of the system. Since algae are living plants,
they grow until the passages of the system are closed. Bacteria form slime and clog the
system in much the same way as algae.

Most of the Impurities found in water can be neutralized by chemicals which are prepared to
perform a specific function. For example, specific chemical compounds can suspend minerals,
dissolve scale, neutralize acids, coat the surface of the metal with a protective film, or attack
and kill algae and bacteria.

Some of the chemical compounds used to remove scale or neutralize acids can be harmful
to wood and to certain metallic and composition materials used in valves, valve diaphragms,
and cooling tower fill. Care must be exercised when these chemical compounds are used in
condensers and cooling towers. It is recommended that a water treatment specialist be
consulted for each system requiring some form of water treatment.

HARD AND SOFT WATER

Water is classified as hard or soft depending upon the amount of solid impurities contained
In the water. In general, water containing less than 200 parts per million (ppm) of mold material
is considered to be soft water. Hard water contains solids in amounts greater than 200 parts per
million (ppm). In terms of grains of hardness, 100 ppm to 200 ppm is roughly equivalent to 6 to
11 grains of hardness per gallon of water; 200 ppm to 300 ppm is equivalent to 12 to 17 grains
of hardness pergallon of water; and 300 ppm to 400 ppm is equivalent to 18 to 24 grains of
hardness per gallon of water.

CONTROLLING SCALE

Scale formation is controlled by compounds called scale inhibitors. Some minerals tend to
accumulate and become more concentrated as the water in the system evaporates. An inhibitor
holds these mineral solids in suspension in the water. If the inhibitor is used in the water and a
water bleedoff is provided in the system, the suspended solids flow from the system through the
bleed pipe. Thus, the solids do not accumulate and the concentration of solids is maintained at
a minimum level. The amount of bleedoff can vary from four gallons per hour for five-ton tmits to
360 gallons per hour far 100-ton units. For each unit size, the bleedoff also varies according to
the hardness of the water.
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Based on the specifications determined by a water treatment specialist, one water scale
treatment can maintain the amount of solids in the water at a safe level for three months or
more.

Removing scale through the condenser only.

REMOVING SCALE

To remove accumulated scale from a system, the services of a water treatment specialist
should be obtained. The specialist can determine the type of scale present. A suitable chemical
compound and the quantity of this compound necessary to remove the scale can then be
recommended. In most cases, the chemical should not be allowed to pass through the cooling
tower.
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Unless otherwise specified by the water
treatment specialist, the chemical should pass
through the condenser only, figure 1. This
precaution is recommended because most
scale removers are acid compounds that can
damage the materials in the cooling tower.
(However, the acid may be mild enough that
the water treatment specialist considers it to
be harmless to the materials in the cooling
tower.)

If the scale removing solution is harmless

to the materials in the cooling tower, the
solution can be added to the system at the
points shown in figure 2 for a forced-draft
tower. Part A in the figure is the tower
distributor plate. Part B is the tower sump, and
Part C is the water tank. For natural-draft
tower, figure 3, the solution is added at the
sump (Part B).
Figure 2. Forced-draft tower.
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It is a good practice to clean the sump
before the scale remover is added. This action
is recommended because the sludge in the
sump Is likely to absorb some of the cleaning
strength of the remover.

CORROSION

Corrosion in a system can occur in the

following ways:

 Acids are caused by gases from the

atmosphere dissolving in the water.
These acids gradually increase in
strength until they begin to attack and
etch the metal surfaces in the system.

Figure 3. Natural-draft tower

 One of the metals used in the system is dissolved by the action of electrolysis resulting
from the connection of two unlike metals. The two dissimilar metals set up an electric
current with the result that one metal dissolves and goes into solution. Some
combinations of dissimilar metals react faster than other combinations.

 Oxygen enters the water from the atmosphere resulting in pitting of the metal surfaces in
the system.

CORROSION CONTROL

Corrosion can be controlled in the water system by the addition of chemically blended
polyphosphates or other similar compounds. The polyphosphate compound deposits a film over
the entire surface of the metal. This compound also protects the metal surfaces from some of
the milk acids that form from atmospheric gases.

Electrolysis can be prevented by following a few general rules.

 If dissimilar metals are joined in the system, the metals should be electrically insulated
from each other.

 If copper and steel are used in the system piping, large surfaces of copper and small
surfaces of steel result in rapid corrosion of the steel. Small areas of copper and large
areas of steel cause the steel to corrode, but at a rate which is much slower titan for the
previous case. A similar corrosive action will result when brass and steel are combined.
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CONTROLLING ALGAE AND SLIME

Algae and slime are controlled by the use of toxic compounds commonly called algaecides.
Chlorine is an algaecide. Since one type of algae vows best in daylight and mater flourishes in
darkness, one type of algaecide may be suitable and effective for indoor cooling tower
installations. Another type of algaecide may be more effective hr outdoor installations where the
tower ii exposed to daylight. In all instance, a water treatment specialist should be consulted to
determine the algaecide that is likely to produce the best results. Algae treatment usually lasts
one month or more depending upon the conditions of the water and the atmosphere around the
tower.

All algaecide compounds are toxic; therefore, the skin and eyes should be protected when
these compounds are handled.

The most important rule to be followed regarding water treatment or water treatment
problems is to obtain the services of a reputable water treatment specialist.

SUMMARY

 Cooling towers are designed to operate on the principle of -

1. natural draft where natural air currents cool the circulated water; or,
2. forced draft in which a fan blows or draws air through the tower to cool the circulated
water.
 In forced-draft towers, the discharge air should blow in the same direction as the
prevailing wind.

 To install a forced-draft tower:

1. Locate the tower
2. Prepare a foundation
3. Install the Ian motor and belts
4. Install the water piping and pump
5. Connect the fan motor and water pump wiring

 To install a natural-draft tower:

1. Locate the tower
2. Prepare a foundation
3. Install the water piping and pump

 Water treatment is required in systems using water-cooled condensers because:

1. Minerals in the water cause scale formation on metal surfaces.

2. Atmospheric gases form acids in the water; these acids corrode the metal surfaces.
3. Algae and bacteria clog the system passages.

 Hard water contains relatively large amounts of solid impurities; soft water has relatively
small amounts of impurities.
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 Scale formation is controlled by inhibitors. Some systems are designed so that the solids
suspended by the inhibitor can be removed.
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JOB SHEET #4
Test the Efficiency of a Compressor

General Instruction:

The compressor is the heart of a refrigeration system. The system efficiency depends mainly on
the perfect working of a compressor. So it is an essential part for the servicemen to test the
compressor efficiency before he proceeds to any repairing work. This worksheet will guide the
trainees to test the efficiency of a commercial compressor.

Tools, Equipment and Materials:

1. Gauge manifold set

2. Charging lines
3. Ratchet wrench
4. Adjustable wrench
5. Double ended spanner set
6. Soap and brush
7. Refrigeration oil
8. Clean cloth
9. Black tape

Procedure:

1. Prepare system
a. Loosen the service valve system cover by open ended spanner.
b. Check that the service valve stems are all the way out, i.e., backseated.
c. Remove the dead plugs from the half union at the gauge port of the service valve.

2. Connect gauge manifold in the system

a. Connect the compound gauge to the low pressure gauge port opening by means of a
charging line.
b. Connect the pressure gauge to the high pressure gauge port opening by means of
another charging line.
c. Slowly front seat the suction service valve stem.
d. Check oil level in the compressor.
e. Short the electrical terminals of the dual pressure cutout.

Caution: Check that the shorting wire should not touch the body of the dual pressure cutout.

3. Check pressure at low side of the system.

a. Run the compressor for some time and note the readings in the compound gauge
which should be 28”—30’ Hg.
b. Stop the unit and keep an eye on the compound gauge.
c. If the reading remains constant it is sure that there are no leaks in the compressor.
d. The vacuum should stand constant for 24 hrs.
e. Check seal for any leakage of oil.
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4. Check pressure at high side of the system
a. If the suction side is O.K. then slowly front seat the discharge service valve stem.
b. Allow dry air to suck through the suction service valve or place a clean cloth soaked
with compressor oil in the suction gauge port opening.
c. Built up a pressure of about 250 P.S.I.G. in the high side of the compressor.
d. Test leaks by applying soap sud to all joints in the high side of the compressor.
e. See that the pressure remains constant in the high side of the compressor.
f. If the discharge pressure decreases and the Suction pressure increases as recorded
in the gauge, it indicates that the reeds are leaky.

5. Test efficiency
a. Release the high side pressure till it is 150 P.S.I.G.
b. in the compressor and check the amount of vacuum the compressor will draw and the
time it takes.
c. Determine the vacuum the compressor can produce against a 150 P.S.I.G. head
pressure. It should not be less than 20” Hg.
d. Check leaks at all joints including seal.
e. Remove gauge manifold set and charging lines.
f. Plug the gauge port openings.
g. Connect the dual pressure cutout properly.

QUESTIONS:

1. Why is it necessary to test the efficiency of a compressor?

2. Why is it advisable to test leak of the low side of the compressor by compressor oil?
3. What would happen when the discharge reed of a compressor is leaky?
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JOB SHEET #5
CHARGE OIL IN THE COMPRESSOR

Tools, Materials and Equipment Needed:

Equipment: Tools:
 PACU/CRE  Ratchet wrench
 System analyzer  Adjustable wrench
Materials: PPE:
 Refrigeration oil of correct grade  gloves
 Clean cloth  goggles
 ¼ flared copper tube

Procedures:

1. Check oil level of the unit through the oil

level sight glass

Oil level
too low

2. Install gauge manifold set in the system

and purge the charging lines

3. Frontseat the suction service valve.

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4. Replace center charging line of the gauge manifold with flared copper tube.

5. Start the unit, when the low side gauge

manifold reached 25-28 inches of
mercury, stop the unit.

6. Place the tube into a container of

refrigeration oil. Open the low side hand
valve of the manifold and charge oil into
the compressor.

7. Close low side hand valve and check oil

in the compressor through the oil level
sight glass of the compressor.

Note: If oil level seems to be low,

charge the correct amount of oil
by repeating the procedures Oil at its
above. proper level

8. Remove gauge manifold from the system and let the system run in normal operation.

Caution: Be careful not to spill oil from the system

9. Perform housekeeping.
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10. Have your instructor check your work.

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JOB SHEET #6
EVACUATE THE SYSTEM

Definition:

Evacuation/Vacuuming is the removal of any gases not recommended for a system or

vessel.

Methods of Evacuation:

A. Deep Evacuation

It involves reducing the pressure in the system to about 50 to 250 microns. It

utilizes two stage vacuum pumps.

B. Triple Evacuation

It is accomplished by
evacuating a system to a low
vacuum, about 1 to 2 mm, and the
allowing a small amount of
refrigerant to bleed into the system
three (3) times. It utilizes single
stage vacuum pump.

Objectives: At the end of this practice the learner/trainee will be able to:
o Evacuate the system

Tools, Materials and Equipment Needed

Equipment: Instrument:
 PACU/CRE  Vacuum gauge with adapter
 System analyzer
 Vacuum pump

Tools:
 Pliers
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 Screw drivers
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Procedures:

1. Remove discharge and suction

service valve cap.

2. Midseat discharge and suction service

valves.

3. Remove service port cap of discharge

and suction service valve
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4. Connect gauge manifold into the

system and center connection of the
manifold to the vacuum pump.

5. Turn on the vacuum pump. Open both

hand valves and evacuate the system
long enough or as required.

6. If evacuation is completed, close both

hand valves of the gauge manifold
and turn off the vacuum pump.
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7. Observe the pointer that it should not

deflect back to 0 psig. at the compound
gauge. (Note: If the pointer deflects
back to zero psig or less, it indicates
that a leak is present in the system.)

8. Set-up the system for charging.

9. Perform housekeeping
10. Have your instructor check your work.
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JOB SHEET #7
CHARGE REFRIGERANT IN THE SYSTEM (VAPOR CHARGING)

Objectives: At the end of this practice the learner/trainee will be able to:
o Vapor charge a PACU/CRE system

I. Tools, Materials and Equipment Needed

Equipment: Tools:
 PACU/CRE  Adjustable wrench
 System analyzer  Ratchet wrench
  Screw driver
Instruments: PPE:
 Charging/Weighing scale  Goggles
 Thermometer  Gloves
 Clamp ammeter

II. Procedures

The correct amount of refrigerant must be charge in a PACU/CRE system to obtain a

maximum efficiency of the system. The desired temperature and proper functions of the
controls depends on the correct amount of refrigerant charge. This job sheet will guide you to
charge refrigerant in a PACU/CRE system.

1. Check system under vacuum, it

should be between 28 to 30 inches
of mercury.
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2. Connect the service cylinder to the

center charging line of the manifold.

Note: Place the cylinder on upright position in

a weighing scale. Record the weight of the
refrigerant cylinder. Purge the refrigerant
hoses.

3. Turn the suction and discharge

service valve on a backseat position
and crack a bit to note down the
suction and discharge pressure.

4. Open the service cylinder valve and

charge refrigerant until the pressure
in the gauge shows above 50-55
psig.
5. Start the compressor and operate it
until enough refrigerant is charge in
system. Control the low side
pressure by opening and closing the
low side hand valve of the gauge
manifold.
Caution: Never allow the system to
run in vacuum.

6. Close refrigerant cylinder valve and

check both suction and discharge
pressure. When pressure seems to
be steady, note down the weight of
the refrigerant cylinder.
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7. Check the cabinet temperature,

running current and operation of
pressure control.

8. Perform housekeeping.

9. Have your instructor check your

work.
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JOB SHEET #8
TEST LEAKS IN THE SYSTEM

Objectives: At the end of this activity, the learner/trainee should be able to:
o Test leak the system
o Practice safety precaution and proper housekeeping

Materials, Tools and Equipment:

Materials:
o Match - ½m
o Clean cloth - 1 pc
o Compressor oil of the same specification
o Soap suds
Tools
o Adjustable wrench - 1 set
o Ratchet wrench - 1 set
o Double ended spanner - 1 set
o Small paint brush - 1 set
o Charging lines - 1 pc
Equipment
o Halide torch
o Service cylinder containing R12
o Service cylinder containing nitrogen - 1 cylinder
Instrument
o Gauge manifold - set

Personal Protective Equipment

o Goggles
o Mask
o Gloves

* - Item is optional
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Procedure:

Make sure that before you perform this activity, you are wearing appropriate personal
protective equipment.

1. Prepare the system

a. Install gauge manifold set into the

system.

b. Place high and low compressor

valve to cracked off to back seat
position.

c. Place high and low side manifold

shut off valve in closed position.

d. Note down the pressure in the system to determine the refrigerant in the system.

Caution: See that a minimum of 50-55 P. S. I. G. is needed for leak test.

If the system pressure is below than 50-55 P. S. I. G. or new piping system, it needs to be
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charged first (follow steps e to i).
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e. If there is no refrigerant in the

system then attach the center line
of the gauge manifold to a
refrigerator cylinder.

f. Open the refrigerant in the system

service cylinder valve, and charge
the refrigerant into the system till
the pressure reads 50-55 P. S. I.
G. in the low side and high side
gauge.

See that the solenoid valve is energized is energized to pass refrigerant throughout the system.

g. Close the hand valve of the gauge

manifold.
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h. Close the service valve of the

refrigerant cylinder.

2. Prepare the leak detector

a. Open valve and light gas torch.
b. Adjust for low flame which burns about 1/2 “ above the reactor plate.
c. Let it burn until the reactor plate, a copper element, turns to a cherry red color.
d. Lower flame or even with the reactor plate.

3. Check for leaks in the system by moving the search hose under all joints and
connections in the system including the compressor shaft seal. Be sure to check below
every joint because R12 and R22 refrigerants are heavier than air.

Caution:
a. A halide torch must only be used in a well ventilated area
b. It must never be used in places where explosive gases are present.
c. Never inhale the vapors or fumes from halide torch, they are poisonous.

4. Observe for the change in color of the flame of halide torch.

a. Yellow flame means there is no leak on the part where the search is pointing
b. Green flame means, there is a small amount of leak to where the search hose is
pointing
c. Dark blue or violet flame means there is a large amount of leak to where the
search hose is pointing

5. If the location of the leak cannot be detected, use the soap suds method to pinpoint the
actual location of leak.

6. Let your instructor check your work

7. Perform house keeping

Evaluation:

While performing the activity it is important for you to assess your performance following
the criteria below:

 Joints are checked for leaks

 Actual location of leaks are pinpointed
 Safety practices and proper housekeeping are employed in the conduct of activity
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JOB SHEET #9
REMOVE AND REPLACE FILTER DRIER

Objectives: At the end of this activity, the learner/trainee should be able to:
o Pump down the unit
o Recover refrigerant
o Replace filter drier
o Leak test the unit
o Charge the unit
o Practice safety and proper housekeeping

Materials, Tools and Equipment:

Materials:
o Filter drier - 1 pc
o Refrigerant -
Tools
o Wrenches - 1 set
Instrument
o System analyzer - 1 set
o Thermometer - 1 set
o Ammeter -
o Leak detector -
Equipment
o Vacuum pump - 1 unit
o Recovery/recycling Machine - 1 unit

Personal Protective Equipment

o Goggles
o Globes
o Mask
* - Item is optional

Introduction:

The filter drier is a device used in a refrigerant line to remove moisture. It is a practice to
replace filter drier, every time that a system is to be re-charged with refrigerant. It is also a
must to replace the filter drier with the same specification in order to eliminate the presence
of contaminants and moisture within the system.
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Procedure:

Make sure that before you perform this activity, you are wearing appropriate personal
protective equipment.

1. Pump down the unit. See to it that the service valve in the liquid receiver is front
seated.

2. Recover remaining refrigerant from

liquid line, evaporator and suction
line.

3. Remove defective filter drier.

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4. Install appropriate and new set of

filter drier.

5. Purge the system and test for leak.

Make sure that after purging the
liquid receiver valve is returned to
close position.

6. Vacuum the unit till the gauge

reading reach perfect vacuum
(approximately 29 inch of mercury)

7. After vacuuming close the two valves

of the system analyzer.
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8. Disconnect the center hose from the

vacuum pump and transfer to
refrigerant tank cylinder.
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9. Open refrigerant cylinder valve and
purge the center hose. Then after
purging make sure that the fittings
are tightened.

10. Open all valves to its normal

operation

11. Run the unit and observe its

operation. Add refrigerant if needed.

12. Have your job checked by your

instructor
13. Perform proper housekeeping

Evaluation:

While performing the activity it is important for you to assess your performance following
the criteria below:

 The liquid receiver service valve is front seated properly with the use of proper tools and
equipment before replacing the filter drier
 The remaining refrigerant is recovered before replacing filter drier
 Filter drier has been replaced with the same specs
 The system is ensured to be leak-free
 The unit is charged with refrigerant when needed
 Safety and proper housekeeping is employed during the activity.
 JOB SHEET #10
REMOVE AND REPLACE OIL SEPARATOR

Objective:

The trainees will be able to:

 Remove and replace oil separator.

General Instructions:

The purpose of an oil separator in the refrigerating unit is to separate oil from the refrigerant
vapor. The oil is highly miscible (soluble with refrigerant) at higher temperature and pressure. It
also serves as a muffler in reducing pulsations to prevent the condensation of the refrigerant
vapor in the oil separator, it should be insulated. This worksheet will guide the trainees to
remove and replace an oil separator in a Commercial Refrigeration system.

Tools, Equipment and Materials:

1. Gauge manifold set.

2. Charging lines.
3. Adjustable wrench.
4. Double ended spanner set.
5. Ratchet wrench.
6. Halide torch.
7. Match box.
8. Goggles.
9. Clean cloth.
10. Service cylinder containing F-12.
11. New oil separator of same capacity.
12. Thermometer.

Procedure:

1. Prepare the system

a. Install gauge manifold set in the
system.
 b. Purge the charging lines.

c. Check suction and discharge

pressure of the system.

2. Check the system

a. Run the Unit about 10-15 minutes.
b. Observe the cooling effect in the
evaporator.
c. Check the oil level of the
compressor.
Oil at its
proper level

3. Pump down the system

a. Close the receiver service shut off valve.
b. Energize the solenoid valve to open the liquid line passage.
c. Short the electrical terminals of the dual pressure cutout.
Caution: Check the shorting wire should not touch the body of the dual pressure cutout.
d. Run the unit until the compound gauge shows about 2 P.S.l.G. and stop the unit.
e. Wait for some time and see that if the pressure in the compound gauge rises or not.
f. If the pressure rises, start the unit again until the pressure in the suction side comes
to 2 P.S.I.G. and then stop the unit.
Caution: Do not run the unit below 0 P.S.I.G.

g. Repeat the process from 3(d) to 3(f) until a steady pressure one or two P.S.I.G. is
obtained in the suction side.
 h. Close suction and discharge mainports.
i. Close the hand valve after the oil separator.
4. Remove oil separator
a. Open the discharge line flarenut connections of the oil separator.
Caution: If the pressure seems to be more, open the flarenut slowly.
b. Open the flare connection of the oil separator with the crank case.
Caution: Place a bucket underneath the oil separator to collect oil to be drained from it.
c. Open both the flarenuts at the two ends of the oil separator and remove the oil
separator from the system.
Caution: Do not tilt the oil separator as the oil may come out from the oil separator.
d. Place the oil separator in a safe place.
5. Replace oil separator
a. Connect the oil separator to the flarenuts on the discharge line and tight them
properly.
b. Connect the bottom connection of the oil separator with the crank case and tight it
properly.
Caution: Check that the oil separator is properly insulated.
c. Place the oil separator in such a way that it does not produce strains on the
discharge
Caution: Check that the oil separator is vertically connected.
d. Open the receiver service valve a bit and allow the refrigerant to flow.
e. Open suction and discharge mainports.
f. Purge from the outlet of the oil separator.
Caution: Wear goggles while purging.
g. Now open tile receiver service shut off valve and allow the liquid to flow in the system
h. Open the hand valve after the oil separator in the discharge line.
i. Connect the dual pressure cutout properly.
j. Run the unit and cheek suction and. discharge pressures.
k. Charge refrigerant, if necessary.
l. Check oil level in the compressor.
m. Check the cabinet temperature after running at least for one hour.
 1. Outlet connection
2. Inlet connection
3. Separator
4. Filter
5. Fastening strap
6. Ball float
7. Needle
8. Nozzle
9. Oil pipe connection

Figure 5.

n. Check the operation of the dual pressure cutout.

o. Check leaks by the halide torch after stopping the system.
p. Remove gauge manifold and charging lines and plug the gauge part openings.
q. Close the system covers.

QUESTIONS

1. Why is it necessary to insulate the oil separator properly?

2. What happens if the accumulation of oil in the oil separator is too much?
3. What happens when the float valve of the oil separator collapses?
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JOB SHEET #11

REMOVE, REPLACE OR CLEAN THERMOSTATIC EXPANSION VALVE STRAINER

Objectives: At the end of this activity, the learner/trainee should be able to:
1. Install system analysis
2. Pump down the unit
3. Recover refrigerant
4. Remove and reinstall expansion valve
5. Page and link list
6. Add refrigerant
7. Observe system operation
8. Observe safety and wear PPE

Materials, Tools and Equipment:

Materials:
o Expansion Valve
o Refrigerant
Tools
o Wrench
o Flaring tools
Instrument
o Multi-tester
o System analyzer
o Thermometer
o Ammeter
o Leak detector
Equipment
o PPE
o Vacuum pump
o Recovery/recycling Machine

* - Item is optional

Introduction:

Automatic expansion Valve - A refrigerant control valve that maintains a constant

pressure in an evaporation system. These valves are hermetic and cannot be
disassembled for inspection and cleaning. If found defective or inoperative. It is possible
sometimes to adjust the valve until the obstruction is dislodged. The usually work best when
the system is running. If it leaks around the spring housing it will have to be replaced. The
bellows have been permanently damaged.
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Procedure:
Make sure that before you perform this activity, you are wearing appropriate personal
protective equipment.

1. Install system analyzer

2. Pump down the unit

3. Recover remaining refrigerant from liquid

line, evaporator and suction line.
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4. Remove expansion valve and replace it

with a new set (the same specification)

5. Purge the system and test for leak.

6. Run the unit and observe its operation.

Make some adjustment on the valves if
needed. Add refrigerant

7. Have your job check by your instructor

8. Perform proper housekeeping

Evaluation:

While performing the activity it is important for you to assess your performance following
the criteria below:

a. Install system analyzer on suction and discharge valves of the system.

b. Pump down the unit thru liquid receiver service valve.
c. Recover remaining refrigerant thru the use of recovery machine.
d. Remove expansion valve.
e. Reinstall new expansion valve.
f. Purge the system and leak test.
g. Observe system operation by taking data
h. Add refrigerant to the system
i. Perform house keeping.
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j. Wear PPE
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JOB SHEET #12

SERVICE COMMERCIAL REFRIGERATING SYSTEM

Objective:

The trainees will be able to:

 Service commercial refrigerating system.

General Instructions:

The inherent construction of a refrigerating system is such that any trouble in the system
will be accumulative, i.e., one trouble will cause another. It is, therefore, essential that
refrigerating system should be completely checked over periodically for efficient working of
the system. This worksheet will guide the trainees to service the commercial systems in a
systematic way.

Tools, Equipment and Materials:

1. Gauge manifold set

2. Charging lines
3. Adjustable wrench
4. Double ended spanner set
5. Ratchet wrench
6. Halide torch
7. Match box
8. Clean cloth
9. Amprobe
10. Voltmeter
11. Spirit level
12. Thermometer
13. Wire brush
14. A small blower
15. One packet mild detergent.

Procedure:

1. Inspection
a. Check the proper installation.
b. Check that the cabinet is not exposed to direct sun light.
c. Check the proper ventilation.
d. Check that the machine is very close to an electrical outlet.
e. Check the proper level of the cabinet as well as the machine.
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CHECKLIST

2. Check and service YES NO

a. All electrical connections are checked according to circuit

diagram so that there should not be any chance of
leakage of electricity.
b. The compressor is checked for any noise.
c. The belt is taken out from the motor and compressor
pulley.
d. The condition of the belt is checked for dryness or
wearing out.
e. The end bearings of the motor are carefully checked.
f. The pulley alignment and the end play are carefully
checked.
g. Motor bearing is lubricated properly.
h. Unit is thoroughly cleaned.
i. The fan and motor pulley are checked for proper
tightness.
j. The line voltage is checked using voltmeter.
k. The current drawn by the motor is checked using an
amprobe.
l. The belt around the motor and compressor pulley is fixed.
m. The belt is checked for alignment and proper tightness.
n. The oil level in the compressor is checked.
o. The seal of the compressor is checked for oil and
refrigerant leakage.
p. The leakage of the entire system is checked by halide
torch.
q. The condenser externally.
r. The suction pressure is checked.
s. The discharge pressure is checked.
t. The cabinet temperature is checked.
u. The operation of the dual pressure cutout is checked.
v. The door gasket is checked for proper tightness.
w. The door binges are lubricated and the latches aid are
adjusted if found necessary.
x. The condition of suction, discharge and liquid lines are
checked.
y. The noise and vibration of the unit is checked and
rectified by using a suitable method.
z. The cabinet is cleaned both internally and externally.

Caution: Refrigeration oil should never be used to lubricate motor bearings.

QUESTIONS

1. What happens if the belt of the compressor and motor is misaligned?

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2. What would happen if the seal is leaking of excessive oil?
3. What happens to the “hot gas” as it enters into the evaporator?

Learning Outcome # 5 : Maintain Air Distribution System in PACU/CRE.

Contents :
 Belt Inspection and Analysis

 Electric Motors

 How to Service Motor Properly

Assessment Criteria:

 Air distribution system components are checked and airflows are balanced
 Outdoor air supply systems are checked and maintained to meet operational and
regulatory requirements
 Humidifier, equipment is checked, serviced, and sanitized to meet operational and
regulatory requirements

Resources:

 Refrigeration and air conditioning technology book

 Carrier owner’s manual
 Learning Element
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CONDITIONS:
The students/trainees must be provided with the following:

Tools and Equipment Supplies and materials

 Acetylene equipment  Refrigerants
 Electronic leak detector  Strainer
 1 unit transport  Filters
 Halide detector  Filter drier
 Refrigeration ratchet  Soap suds
 Adjustable wrench  Acetylene gas (contents)
 Gauge manifold  Oxygen tank
 PACU Learning Materials
Personal Protective  Learning element
Equipment  Service manual
 Goggles
 Gloves
 Working clothes
 Safety shoes
 Gas mask

METHODOLOGIES:
 Self-paced instruction
 Film viewing
 Direct laboratory experience
 Group discussion
 Industry visit
 Industry immersion
 E-learning

ASSESSMENT METHODS:

 Interview
 Written exam
 Observation with questioning
 Demonstration with questioning
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LEARNING EXPERIENCES

LEARNING OUTCOME NO. 5: Maintain Air Distribution System in PACU/CRE

Learning Activities Resources

1. Read and perform the procedures in the job sheet “Belt  Job Sheet #13
Inspection and Analysis” and answer the questions.

2. Read information sheet “Electric Motors”.  Information Sheet #6

3. Read and perform the procedures in the job sheet  Job Sheet #14
“How to Service Motor Properly” and answer the
questions.

JOB SHEET #13

BELT INSPECTION AND ANALYSIS

Tools:

1. Allen wrench
2. Adjustable wrench
3. Steel rule
4. Spirit level
5. Screwdriver

Follow this procedure to inspect a belt:

1. Shut down the power switch and tag it: “Down for maintenance. Do not turn the power
on”. Lock the switch open.

2. Remove the guard and inspect it for wear or damage. Clean grease and debris from the
guard to ensure good ventilation.

3. Notice the temperature. A belt that is too hot to touch just after the drive is shut down has
problems. Find and correct the source of overheating before returning the drive to
service.

4. Inspect the belt. Mark a starting point and work your way around, looking for cracks,
nicks, frays, cuts, or unusual or uneven wear. Replace belts wit excessive wear, cuts, or
missing teeth.
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5. Check alignment by removing the belt and laying a straight edge along the outside edges
of both pulleys (see below). Misalignment will increase the chances for premature wear
instability and turnover.

6. Inspect other parts of the drive: motor and pulley mounting, and housing.

ALIGNING A BELT

To prevent premature wear and failure, belt drives must be in proper alignment, with the
shafts parallel and the pulleys in the same plane. If your inspection reveals a misalignment,
corrective action is indicated. A heft can have either angular misalignment and/or parallel
misalignment. (Misalignment can also result from a pulley that is damaged or improperly
mounted.)

1. Angular misalignment can be detected by a long straight edge; a tape measure, string, or
straight board can be substituted on a long drive (see Figure 16). In general, pulley
alignment should be within 1/10 inch per foot (8.4 mm per meter) of the span between
the pulleys. Correct a misalignment by loosening the mounting bolts and rotating one
piece of equipment until both shafts are aligned. Then tighten the mounting bolts and
check for parallel misalignment.

2. To check for parallel misalignment, use a square to show that each shaft is at 90º to the
straightedge. Correct by loosening pulley mounting screws and sliding the pulley until
both edges of both pulleys line up to the straightedge.

Figure 16. Belt alignment.

INSTALLING AND TENSIONING A BELT

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Belts must be properly installed and tensioned for good performance. Overtight belts will
cause compressor seals to leak, and bearings and belts to wear prematurely. Loose belts will
slip, heat up, and fail. New belts will stretch slightly, so manufacturers recommend they be
installed somewhat tighter than normal. Always check and retension a new belt after 4 to 24
hours of operation.

After performing the inspections suggested above, use this procedure to replace and
tension a belt

1. Check the number on the belt to order a replacement. If the number is illegible, measure
the length (along the outside) before removing it from the drive. (Check the belt section
later or use a gauge on the sheave to find the section.)

2. Loosen the motor mount and slide the motor toward the compressor to slack off the belt.

3. Remove the old belts without prying them.

4. Install the proper size belt. All belts should be replaced on a multiple drive to ensure that
they pull equally.

5. Slide the motor back into position to tighten the belt.

6. Check and adjust alignment using the above procedure. Check tension by deflecting the
bell at the midpoint between the pulleys. (Rotate multiple-belt drives by hand to seat
them in the grooves and even out the tension before checking tension.) Although belt
tension gauges are available, most mechanics deflect the belt manually and check that
the belt moves a little without having excess slack. Use this rule of thumb: a force of 10
pounds (4.5 kg) should deflect a belt about ½ inch (1.3cm).

7. Tighten motor mounting bolts to the proper torque.

8. After 4 to 24 hours of operation, recheck and readjust the tension.

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Figure 17. Fan motor mounting.

ADUSTING THE FAN SPEED

The fan motor is usually equipped with an

adjustable pitch pulley, figure 18. This pulley
can be adjusted to vary the fan speed to
obtain a range of air quantities. To obtain the
desired fan speed, adjust the fan motor pulley
according to the following procedure.

1. Remove the belt from the fan motor

pulley after loosening the motor (as
outlined in the section Adjusting Fan
Belt Tension).

Figure 18. Adjustable speed motor pulley

2. Loosen the setscrew in the movable flange of the pulley. Screw the movable flange in
toward the fixed flange as far as possible. In this position, the pulley gives the maximum
fan speed.

3. Each half-turn of the adjustable flange away from the fixed flange reduces the fan speed.
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CAUTION: Under no circumstances should the flange be screwed more than six turns from
the fixed flange. Before tightening the setscrew, insure that the setscrew is over the
nearest flat surface of the pulley hub.

4. Replace the belt and adjust the belt tension as outlined in the following section. It is not
possible to measure the fan speed accurately while the front panel is removed from the
unit. Such fan speed measurement should not be necessary if the preceding instructions
have been followed.
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INFORMATION SHEET #6
ELECTRIC MOTORS

Introduction

Electric motor converts electrical energy to magnetic energy and then to kinetic energy. The
rotation is caused by repeated attractions and repulsions between electromagnets located in
the motor housing and induced magnets rotating on the armature (rotor).

Practically every motor used in a commercial cooling system operates on alternating current
because the wavelike magnetic field of alternating current (AC) induces a current in conductors
whether or not they are moving in relation to each other (see figure below).

Electric motors have basic parts: the stator (housing or field) and the rotor (armature) which
spins on a shaft inside the housing. When electricity passes through the stator winding, they
become an electromagnet whose field strength rises and falls with the AC waves. This induces
current in the rotor, causing it to become a magnet. The rotor would not rotate if the opposite
poles were positioned next to each other, so motors are designed so the magnetic fields can
never rest in this condition. Due to magnetic attraction and repulsion, the rotor tends to spin,
and as it does, the magnetic field shifts position to cause the attraction or repulsion to continue.

As the AC waves increases in strength during the start of each half of its cycle, the induction
of magnetism in the rotor lags slightly. The time the rotor is fully magnetized, the stator is
already starting to change polarity due to the change in the AC wave, so the field can never line
up with north opposite south.
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LUBRICATION AND CLEANING OF MOTOR

Tools: Equipment Supplies

1. Oiler  B R
2. Grea lower ags/cloth
se gun  G
3. Scre rease/oil
w driver
4. Adju
stable wrench

Procedure for Lubrication of Motor – Sleeve Bearing

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Procedure for Cleaning of Motor – Sleeve Bearing

Procedure for Lubrication of Motor – Ball and Roller Bearing

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Procedure for Cleaning of Motor – Ball and Roller Bearing
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JOB SHEET #14

HOW TO SERVICE MOTOR PROPERLY

Tools and Equipment

1. Screwdriver
2. Clamp ammeter
3. Megger
4. Feeler gauge
5. Speedometer/tachometer
 ASSESSMENT INSTRUMENT

EVIDENCE PLAN

Competency HVAC/R NC II
Standard:
Unit of Service and Maintain PACU/CRE Equipment
Competency:
Ways in which evidence will be collected:

Question/Interview
[tick the column]

Demonstration
The evidence must show that the candidate …
1. Identified and removed parts/components of PACU/CRE
X X
equipment in accordance with standard procedures.
2. Checked and inspected all controls/wiring as per schematic
X X
diagrams are in line with SOP.
3. Cleaned parts and components in accordance with standard
X X
procedures.
4. Checked refrigerant circuits for condition, leak, insulation and
X X
tightness of support brackets.
5. Applied correct servicing maintenance procedures in
mechanical and electrical parts of PACU/CRE equipment as X X
per SOP/manuals.
6. Applied proper housekeeping. X X
7. Demonstrated compliance with safety regulations applicable
to worksite operations. X X
8. Selected and used appropriate processes, tools and X X
equipment to carry out tasks.
9. Wear appropriate PPE X X
10. Communicate effectively with other where applicable to
X X
ensure safe and effective work operations.

NOTE: *Critical aspects of competency

Date Developed: Document No.

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Prepared Date:
by:
Checked Date:
by:

Date Developed: Document No.

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DEMONSTRATION

Candidate name:
Assessor name:
Unit of competency: Service and Maintain PACU/CRE Equipment
Competency standards: HVAC/R NC II
Date of assessment:
Time of assessment:
Instructions for demonstration
Prepare the tools and equipment needed, and have the demonstration in servicing and
repairing clutch system.
OBSERVATION  to show if evidence is
demonstrated
During the demonstration of skills, did the candidate: Yes No N/A
1. Identified and removed parts components of PACU/CRE
equipment in accordance with standard procedures.
2. Checked and inspected all control/wiring as per schematic
diagrams are in line with SOP
3. Cleaned parts and components in accordance with SOP.
4. Checked refrigerant circuits for condition, leaks, insulation
and tightness of support bracket.
5. Applied correct servicing and maintenance procedures on
mechanical and electrical parts of PACU/CRE equipment as
per SOP/manual.
6. Applied proper housekeeping.
7. Demonstrated compliance with safety regulations applicable
to worksite operations.
8. Selected and used appropriate equipment to carry out tasks.
9. Wear appropriate PPE.
10. Communicate effectively with others to ensure safe and
effective work relations.

The candidate’s demonstration was:

Satisfactory  Not Satisfactory 

Date Developed: Document No.

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SELF CHECK 2.2-1
DIRECTION Read the question carefully answer true or false

_______ 1. Correct piping helps to prevent damage to the compressor.

_______ 2. In the refrigeration system, compressor is designed to pump
only refrigerant in vapor form.
_______ 3. Liquid refrigerant that enters to the compressor is good for
the compressor
_______ 4. All piping used must be thoroughly clean and dry.
_______ 5. All lubrication in the compressor is essential to overcome
friction.

ANWSER KEY:
1. True
2. True
3. False
4. True
5. True

Date Developed: Document No.

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 TASK SHEET 2.2-1

Title: Installing Suction and Discharge Lines for Packages Air

Conditioning Unit and Commercial Refrigeration
Equipment

Perfomance The learner/trainee should be able to:

Objectives: o Determine the number and type of fittings used in piping
installation
o Determine the total length and size of pipe to use
o Layout pipe for installation
o Perform pipe joint using acetylene
o Practice safety and proper house keeping

Materials
o Copper tube ¾ “0D x 30ft, 3/8 “0D x - 4 pcs
20ft
o Installation plan - 1 pc
o Silver rod - 15 pcs
o Silver flux - 1 quart
o Elbow ¾ “0 - 6 pcs
o Sand paper - 3 pcs
Tools
o Push pull rule - 1 pc

Date Developed: Document No.

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 o Steel meter - 1 pc
Equipment
o Acetylene - 1 set
o Electric drill - 1 set
o Hole saw - 1 unit
Instrument
o Leak Detector - 1 unit
Personal Protective Equipment
o Safety glass -
o Gloves -
o Safety shoes -

Procedure:

1. Prepare tools and

acetylene equipment

2. Based on the working

drawing, determine the
number of elbow
couplings, diameter of
pipes to be used

Date Developed: Document No.

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 See working
plan at the back for larger view

3. Based on the working

drawing and actual
location, determine length,
diameter of pipe and no. of
pipes to be use

4. Based on working drawing

Date Developed: Document No.

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5. Measure the pipe to be cut
from coupling to elbow as
shown

6. Cut the pipe according to

the length as shown

7. Insulate the pipe as shown

Date Developed: Document No.

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8. Perform joint as shown

Note: Put 2 to 3 P.S.I.

nitrogen while brazing to
prevent oxidizing of a pipe

9. Clamp the tubes and pipe

securely. Install brackets
and support if necessary.
10. Based on the working
drawing install the
discharge line.

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11. Based on the working
drawing install filter drier
and sight glass

12. Based on the working

drawing install the suction
line.

13. Execute flushing for

refrigeration piping

Note: Isolate filter drier, sight

glass, AHU and ACCU

Date Developed: Document No.

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14. Leak test the unit

15. Vacuum the unit. When

there is no leak, the
system the system is now
ready for charging.

Performance Criteria Checklist 2.2-1

Name: ____________________________ Date: _______________

Date Developed: Document No.

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 CRITERIA
YES NO
Did you….

LO2. Install PACU/CRE piping system

1. Size of piping and fitting used is based on 
working drawing/installation plan

2. The system is ensured to be leak-free

3. Fittings used is based on working drawing/ 

installation plan


4. Length of pipes are based on working
drawing/installation plan

5. Layout of pipes is based on working 

drawing/installation plan

6. Joints and connections are based on working

drawing/installation plan and standard operating
procedure

7. Piping system is securely mounted with the use

of clamp, brackets and supports

8. Safety and proper house keeping is

implemented

Date Developed: Document No.

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Comments/Suggestions:

Trainer: _________________________________Date: _____________________

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Title: Insulate Copper Tubing

PerformanceObjectives: The learner/trainee should be able to:

o Select insulator for appropriate for the
application
o Insulate copper tube prior to installation in
the system
o Insulate copper tube that is already installed
in the system
o Practice safety precaution and good
housekeeping

Materials
o polyethylene tape - 1 roll
o Insulator - 1 roll
o Copper tubing - 1 roll
Tools
o Cutter - 1 pc
o Pull-push rule - 1 pc

Date Developed: Document No.

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Procedure:.

1. Select the appropriate

insulator based on the
diameter of copper tubing

2. Measure the required

length of insulator

Date Developed: Document No.

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3. Cut the insulator

4. Insert one end of the

copper tubing to the
insulator. Continue doing
this until the insulator
covers the entire tube.
This is done before the
tube is connected to the
line.

5. For existing lines, or when

it is impractical to insulate
before installing the tubing,
the insulation can be slit by
a utility knife and snapped
over the tubing.

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6. Apply adhesive to both
ends of the insulation or to
all the seams when the
insulation has been slit. Do
not use tape, nor stretch
the insulation because the
wall thickness may be
reduced or adhesive may
fail to hold and reduce the
effectiveness of the
insulation.

7. Some insulation work

requires application of
polyethylene tape

8. Inspect your work, and

then when you think its
good enough, let your
instructor check it.

Date Developed: Document No.

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Performance Criteria Checklist 2.2-2

Name: ____________________________ Date: _______________

CRITERIA
YES NO
Did you….

LO2. Install PACU/CRE piping system

1. Size of insulator used is appropriate for the 
tube.

2. Insulator covers all copper part of the tube

3. Ends of the insulators are applied with 

adhesive

4. Ties applied to hold the insulator in place is not
too tight (no thinning of insulator walls caused
by ties)

5. Polyethylene tape is applied when needed 

6. Safety and proper housekeeping is employed

in the conduct of activity

Comments/Suggestions:

Trainer: _________________________________Date: _____________________

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 Different Leak Testing Methods

Piping in the refrigerant and air conditioning unit is a leak- free

system. A leak in refrigerant line is dangerous for the following
reason:

1. Lost of refrigerant in the units.

2. Leak may allow contaminants and moisture into the system,
which may result damage to the unit.
3. Some refrigerant are hazardous to healt and environment, and
environment, therefore it should always be enclosed in the
refrigerant piping system.

Any loss of refrigerant may be accompanied by air and moisture

getting into the refrigeration system. Air is contaminant because it can
cause oil to break down directly, which leads to refrigerant breakdown.
Moisture is also harmful in the system because it can “cause freeze-ups”
in the expression value and assist in the formation of harmful acids.

A good indicator of a leaky refrigeration and air conditioning piping

system is that their evaporator is frosting. Some oil leaks may also be
present on the joints and pipes. If pressure gauge is installed on the
system, a drop on the pressure is noticed for leaky system. To ensure
that the unit is leak-free, it will be pressure tested and vacuum tested.

Pressure testing method involves pressurizing the system with

nitrogen or nitrogen mixed w/ refrigerant and then checking for outward
leakage.

There are several techniques which can be used for pressure

testing like:

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 1. Bubble test method
This method
consists of brushing
soap solution on each
pressurized joint (about
30-50 psi, nitrogen or
refrigerant) and
observing any bubbles
formed. This is a good
method of pinpointing
the location of leaks in a
suspected area
remember, the
appearance of oil at any
connection or part of
refrigeration system
usually indicate the
location of a leak. Clean
the system of both soap
solution and oil at the
completion of testing.

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 2. Using halide torch
technique
This method
requires the system
to be pressurized
(30-50 psi, mixture
of nitrogen and
refrigerant or pure
refrigerant). It relies
on the color of the
flame of the torch.

 Light blue frame-

No amount of
refrigerant
burning.
 Green flame-
Minimal amount
of refrigerant
burning
 Dark blue or
violet- Large
amount of
refrigerant
burning

3. Using electronic
leak detector

Using
electronic leak
detector method is
similar w/ halide
torch technique,
only it uses
electronic leak
detector, use sound
to indicate leak in
the system.

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 - Low sound- no
refrigerant near
the sensor.
- Rapid sound-
refrigerant is
present near the
sensor.

Vacuum testing method is done after pressure testing the unit. The
system will be evacuated to a very low vacuum approximately 1000
microns( 29.87 in. hg) sealed then left for at least 30 minutes while
monitoring the vacuum. If the pressure reading increases then the
system has a leak, it should be leak tested again

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SELF CHECK 2.3.1
DIRECTION read questions carefully write the answer on the space
provided

________ 1. The method of brushing soap solution to each joints.

________ 2. This method requires the system to be pressurirized and
relies on the color of the flame of the torch.
________ 3. The method which uses sound to indicate leak in the
system.

________ 4. Testing method is done after pressure testing the unit.

________ 5. Which contaminant is harmful to the refrigeration piping
system.

ANSWER KEY:
1. Bubble test method
2. Halide torch technique
3. Electronic leak detector method
4. Vacuum testing method
5. Airam moisture

Leak Testing Using Halide Torch

Date Developed: Document No.
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Title:

PerformanceObjectives: The learner/trainee should be able to:

o Test leak the system
o Practice safety precaution and proper
housekeeping

Materials:
o Match - ½m
o Clean cloth - 1 pc
o Compressor oil of the same
specification
o Soap suds
Tools
o Adjustable wrench - 1 set
o Ratchet wrench - 1 set
o Double ended spanner - 1 set
o Small paint brush - 1 set
o Charging lines - 1 pc
Equipment
o Halide torch
o Service cylinder containing R12
o Service cylinder containing nitrogen - 1
cylinder
Instrument
o Gauge manifold - set

Personal Protective Equipment

o Goggles
o Mask
o Gloves

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Procedure:
Make sure that before you perform this activity, you are wearing
appropriate personal protective equipment.
1. Prepare the system

k. Install gauge
manifold set into the
system.

l. Place high and low

compressor valve in
cracked position.

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 m. Place high and
low side manifold
shut off valve in
closed position.

n. A nitrogen
pressure of 150
PSI at the low
side and 300 PSI
at the High side

o. If there is no
refrigerant in the
system then
attach the center
line of the gauge
manifold to a
refrigerator
cylinder.

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 p. Open the
refrigerant in the
system service
cylinder valve,
and charge the
refrigerant into
the system till
the pressure
reads 50-55 P.
S. I. G. in the low
side and high
side gauge

Note make sure that the

solenoid valve is
energized to allow
refrigerant to pass
throughout the system.
When the sight glass and
pressure gauge reading
q. When the
solenoid valve is
energized, cause
the hand valve of
the gauge
manifold
r. Close the service
valve of the
refrigerant
cylinder.

2. Prepare leak detector

a. Open valve and
light gas torch

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 b. Adjust for low
flame which burns
about ½ above the
reactor plate
c. Let it burn until
the reactor plate,
a copper
element, turns to
a cherry red
color.
d. Lower flame or
even with the
reactor plate

3. Check for leaks in the

system by moving the
search hose under all
joints and connections
in the system including
the compressor shaft
seal. Be sure to check
below every joint
because R12 and R22
refrigerants are
heavier than air.

a. A halide torch must

only be used in a
well ventilated area
b. It must never be
used in places where
explosive gases are
present
c. Never inhale the
vapors or fumes from
halide torch, they are
poisonous.

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4. Observe for the change
of color of the flame of
halide torch
a. Yellow flame means
there is no leak on
the part where the
search is pointing
b. Green flame
means, there is a
small amount of
leak to where the
search hose is
pointing
c. Dark blue or violet
flame means there
is a large amount of
leak to where the
search hose is
pointing
5. If the location of the
leak cannot be
detected, use the soap
suds method to
pinpoint the actual
location of leak.
6. Let your instructor
check your work
7. Perform house
keeping

Date Developed: Document No.

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 Performance Criteria Checklist 2.3-1

Name: ____________________________ Date: _______________

CRITERIA
YES NO
Did you….

LO2. Install PACU/CRE piping system

1. Flame color can be interpreted 

Comments/Suggestions:

Trainer: _________________________________Date: _____________________

Leak Testing Using Electronic Leak

Date Developed: Document No.
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Title:
Detector

PerformanceObjectives: The learner/trainee should be able to:

o Test leak the system
o Practice safety precaution and proper
housekeeping

Materials:
o Clean cloth - 1 pc
o Compressor oil of the same
specification
o Soap suds
Tools:
o Adjustable wrench - 1 set
o Ratchet wrench - 1 set
o Double ended spanner - 1 set
o Small paint brush - 1 set
o Charging lines - 1 pc
Equipment:
o Service cylinder w/ appropriate - 1
refrigerant cylinder
o Service cylinder containing nitrogen - 1
cylinder
Instrument:
o Electronic leak detector - 1pc
o Gauge manifold - set
Personal Protective Equipment
o Goggles
o Mask
o Gloves

Procedure:
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 s. Install gauge
manifold set into
the system.

t. Place high and low

compressor valve
in cracked
position.

u. Place high and low

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 side manifold shut
off valve in closed
position.

v. Note down the

pressure in the
system to
determine the
refrigerant in the
system.

Caution: See that

a minimum of 50-
55 P. S. I. G. is
needed for leak
test.

If the system pressure is

below than 50-55 P. I. S.
G. or new piping system, is
installed it needs to be
charged first (follow steps e
to h).

w. If there is no
refrigerant in the
system then attach

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 the center line of
the gauge
manifold to a
refrigerant
cylinder.

x. Open the
refrigerant in the
system service
cylinder valve, and
charge the
refrigerant into the
system till the
pressure reads
150HGHG P. S. I.
G. in the low side
and high side
gauge.

Note: Make sure that

the solenoid valve is
energized to allow
refrigerant to pass
throughout the
system. Where the
sign glass and the
pressure gauge
reading.
y. When the solenoid
valve is energized,
cause the hand
valve of the gauge
manifold.

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 z. Close the service
valve of the
refrigerant
cylinder.
2. Turn on the electronic
leak detector

3. Check for leak by

moving the search
nozzle under and
around all joint
connections in the
systemincluding
compression shaft seal.

4. Observed the change in

sound of the electronic
leak detector

a. Beeping sound indicates

no leak
b. Continous beeping
sound indicates
leak
5. If the location of the leak
cannot be detected, use
the soap suds method to

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 pinpoint the actual
location of leak.

6. Let your instructor check

your work
7. Perform house keeping

Performance Criteria Checklist 2.3-2

Name: ____________________________ Date: _______________

CRITERIA
YES NO
Did you….

LO2. Install PACU/CRE piping system

1. The sound produced by the leak detector 
can be interpreted

Comments/Suggestions:

Trainer: _________________________________Date: _____________________

Date Developed: Document No.

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InformationSheet

Condensate Drain Piping

When the evaporation is installed, provision must be made

for the condensate that will be collected in the air conditioning cycle. An
air conditions in a climate with average humidity will collect about 3 pints
(pt) of condensate per hour of operation for each ton of air conditioning.
A 3-ton system will condense about 9 pt per hour of operation. This is
more than a gallon of condense per hour or more than 2x gal in a 24
hour operating period.
A trap in drain line will hold some water and keep air from
pulling into the unit from the transition point of the drain

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Some location call for the condensate to be piped to a dry well, a dry
well is a hole in the ground filled with stones and gravel. The condensate
is drained into the well and observed into the ground.

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 Title: Install Condensate Drain Piping

PeferomanceObjectives: , The learner/trainee should be able to:

o Install condensate drain piping using PVC
pipe

Materials:
o PVC pipe (10 ft) - 1 pc
o Contact contact - 1 quart
o Rags - 1 pc
o PVC elbow 90°elbow - 3 pc
o P-trap - 1 pc
Tools
o Hack saw - 1 pc
o Sand paper - 1 pc
o Flat file - 1 pc
Equipment
o Electric drill - 1 unit
Instrument
o -

Personal Protective Equipment

o Goggles

Date Developed: Document No.

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Procedure:
Make sure that before you perform this activity, you are wearing
appropriate personal protective equipment.

1. Prepare tools and materials

2. Count all the elbows to be

used base on the working
plan

(See working drawing for larger view)

3. Lay out the PVC pipe from

fittings to fitting s are shown

4. Cut the end square with

plastic tubing, using a
hacksaw.

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5. Remove the burr inside and
out of the pipe with knife or
half round file

6. Clean the pipe end. Apply

contact cement to both the
outside of the pipe and the
inside the fitting.

7. Insert the pipe all the way

into the fitting. Turn
approximately one-quart
turn to spread the contact
cement and allow it to set
dry for a minute.
8. Install PVC pipes according
to the lay out.

Date Developed: Document No.

RAC SERVICING NC III August 08, 2019
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