Troubleshooting Window-Type Air-Conditioning - Domestic Refrigeration Systems

COMPETENCY BASED LEARNING MATERIAL
Sector:
HEATING, VENTILATING, AIR-CONDITIONING AND REFRIGERATION (HVAC/R)
Qualification:
RAC Servicing NC II
Unit of Competency:
Troubleshoot and Repair Domestic Refrigeration
and Air-Conditioning (DomRAC) Systems
Module Title:
Troubleshooting Window-Type Air-Conditioning/
Domestic Refrigeration Systems
Technical Education and Skills Development Authority

East Service Road, South Superhighway, Taguig, Metro Manila
Introduction:
The unit of competency “Troubleshoot Window-Type Air-conditioning and
Domestic Refrigeration Systems” contains the knowledge, skills and attitudes
required in a Refrigeration and Air-conditioning course. This is one of the core
modules for National Certificate level II (NC II).
Summary of Learning Outcomes:
On completion of this module you should be able to:
 Plan and prepare for troubleshoot.

 Identify and repair faults / troubles
 Perform refrigerant recovery / recycling and retrofitting / conversion on
domestic refrigeration and air conditioning unit
 Test-run repaired unit
Assessment Criteria
To be able to verify that you are competent enough in this module you must be
able to demonstrate the performance criteria while troubleshooting and repairing
electrical and mechanical system including recovery / recycling retrofitting/
conversion of window-type air-conditioning and refrigeration system.
 Appropriate wiring diagrams, charts and manuals are read and interpreted
 Tools, materials and equipment needed are prepared in line with job
requirements
 Manufacturer's nameplate rating are properly identified
 Correct testing procedures in the components are applied
 Components faults and problems are identified and diagnosed
 Remedial action is undertaken on the identified faults and problems
 HVAC code of practice and safety guidelines on troubleshooting and repair

of electrical system are properly applied
 Test unit pressure and temperature are performed in accordance to work

instructions
 Completed report on trouble shooting and repair of electrical system are

accomplished
Code No. Date: Developed Date: Revised Page #

Troubleshooting Window Type Air-
conditioning/Domestic Refrigeration System 1 of 287
 Refrigeration cycle is explained
 Mechanical parts and functions are identified and described
 Troubleshoot and repair procedure of mechanical system are performed in

accordance with work instructions
 Operating procedures are performed in accordance to unit's manual

procedures
 HVAC code of practice and safety guidelines in troubleshooting of

mechanical system are properly applied
 Test unit pressure and temperature are performed in accordance to work

instructions
 Work documentation is prepared and submitted as per prescribed

procedure
 Good housekeeping and safety practices is applied in line with job

requirements

Conditions:
The trainee must be provided with the following
Equipment Tools
 R\R machine  Wrench set
 Nitrogen equipment  Tubing tools set
 Oxy acetylene  Pinch Off pliers
 Vacuum pump  File
 Screw driver set
Instruments  Service ratchet
 Multi-tester  Soldering iron
 Gauge Manifold  Wire crimper
 Thermometer  Pliers set
 Electric leak Detector  Wire stripper
 Weighing scale  Crimping pliers
 Clamp ammeter
 Megger Personal Protective Devices
 Vacuum meter  Goggles
 Gloves
Supplies and Materials  Gas mask
 Refrigerant  Safety shoes
 Electrical wire  Working clothes
 Electrical tape
 Terminal end connector Learning Materials
 Access valve  LEs/CBLM on window AC &
 Copper tube Domestic Refrigeration
 Filter/drier, braze type  Text books/Manuals
 Silver rod  Catalogue
 Brazing flux  Brochure
 Rags  Work instructions
 Capillary tube
 Aluminum rod
 Soldering lead
 Wire harness tire
 Filter drier
 Flare fittings
 Refrigerant hose gasket
 Nitrogen gas
 Access valve cap

Reference Materials:
 Althouse A. D., Turnquist C.H., Bracciano A. F. MODERN REFRIGRATION

AND AIR CONDITIONING, 1992. The Goodheart-Wilcox Company, Inc.
 Institute of Integrated Electrical Engineers. PHILIPPINE ELECTRICAL

CODE, PART 1 2000 Edition. June 2002. Bookman Inc.,
 CODE OF PRACTICE FOR REFRIGERATION AND AIR CONDITIONING

(Philippine Setting. June 2004. Department of Environment and Natural
Resources (DENR)

About this Competency Based Learning Material
Welcome to the Module on “Troubleshooting and Repairing Window-Type
Air-conditioning and Domestic Refrigeration Systems”. This module contains
training materials and activities for you to complete.
In going through this module, you will follow the “Learning Activity Sheet”.
This Learning Activity Sheet will guide you through different “Instruction Sheets”
that will assist you in performing different learning activities towards the
attainment of the learning outcome.
The instruction sheet may be in a form of:

 Information Sheet - This type of sheet supplies will supply you with
information needed to be able to perform certain
activities.
 Job Sheet - This instruction sheet is designed to guide you

how to do a complete piece of work that will
contribute to the attainment of the learning
outcome.
 Operation Sheet - This instruction sheet will guide you in

performing single basic task, operation or
process in a job.
 Assignment Sheet - The assignment sheet is a guide used to

enhance (follow-up) what you have learned in
the information sheet, job sheet or operation
sheet.
 Work Sheet - Work sheets are the different forms that you will
be filling up in certain activities that you will be
performing.

This procedure will be repeatedly done until you have completed all the
learning elements in this Competency Based Learning Module or until such time
that you are ready to take the final assessment for this module. You may skip
some learning activities if you are competent enough for the said task.
At the end of this module is a Learner’s Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you
in providing further details to your trainer or an assessor. A Record of
Achievement is provided for you by your trainer to accomplish once you
complete the module.
Upon completion of this module, ask your trainer to assess you. You will be
given a certificate of completion as proof that you met the standard requirements
(knowledge, skills and attitude) for this module. The assessment could be made
in different methods, as prescribed in the competency standards.
If you have questions, please don’t hesitate to ask your technical

instructor/tool subject instructors for assistance. Your facilitator will always be
available to assist you during the training.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills covered in
this module because you have:
 been working for some time
 already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular
skill or skills, talk to him/her about having them formally recognized so you don’t
have to do the same training again. If you have a qualification or Certificate of
Competency from previous trainings show it to your trainer. If the skills you
acquired are still current and relevant to this module, they may become part of
the evidence you can present for RPL. If you are not sure about the currency of
your skills, discuss this with your trainer.

Symbols
These symbols are located in the left margin of the module. It illustrates action
which should be taken or resources to be used at the particular stage in this module.
Learning
Optional Activity
Outcome
Resources Practice
Reading Activity Self Check
Use Computer Answer Key
Competency
View Video
Assessment
Listen to Audio
Safety
Tape
Work Sheet

Reading Activity 1 p.24
Read: Information Plan and Prepare Troubleshooting

Sheet 1:
o This is an informative sheet that discuss about planning and preparing
troubleshooting.
Practice Activity 1 p.41
Perform: Job Sheet 1: Troubleshooting Refrigeration/Air

conditioning Unit
o This is a practice activity that will enhance your knowledge and skills in
troubleshooting
o After performing this activity, let your instructor check your work for
further comments and improvements.
Read: Information Hermetic Motor Compressor

Sheet 2:
o This is an informative sheet that discuss the basic principles and
operation of hermetic motor compressor
Self-Check p.45
Do: Self-Check 1
o This is to self-evaluate what you have learned about the basic

principles and operation of hermetic motor compressor.
o After answering the questionnaire, you can check your answer with the
answer key on the following page.

Perform: Assignment Sheet Identifying Hermetic Compressor

1: Terminal
o This is a practice activity in identifying hermetic compressor terminal

through the given resistances.
Self-Check p.48
Do: Self-Check 2
o This is to self-evaluate what you have learned about identifying

hermetic compressor terminal through the given resistance.
answer key on the following page
Perform: Operation Sheet 1: Determining Hermetic Compressor

Terminal Using Multimeter
o This is a practice activity in determining hermetic compressor terminal

through the use of multimeter.
o After performing the practice activity, ask your instructor to check your
work.
Read: Information Hermetic Compressor Electrical

Sheet3: Connection
o This is an informative sheet that discusses about different types of

hermetic compressor electrical connection.

Self-Check p.55
Do: Self-Check 3
o This is to self-evaluate what you have learned about the Different types
of hermetic compressor electrical connection
answer key located at the following page.
Perform: Operation Sheet Connecting Hermetic Compressor

2: (Permanent Split Capacitor Motor)
o This is a practice activity in connecting compressor circuit using PSC

type of compressor motor.

3: (Capacitor Start Capacitor Run Motor)
o This is a practice activity in connecting compressor circuit using CSCR


4: (Capacitor Start Induction Run Motor)
o This is a practice activity in connecting compressor circuit using CSIR



5: (Resistance Start Induction Run Motor)
o This is a practice activity in connecting compressor circuit using RSIR

Perform: Operation Sheet Testing Compressor Motor Winding

6:
o This practice activity will enable you to determine the common defects
of hermetic compressor motor such as grounded, shorted and open
winding.
Perform: Job Sheet 2: Replace Compressor Motor
o This practice activity will enable you to determine the common defects
of hermetic compressor motor such as grounded, shorted and open
winding.
Read: Information Fan motors

Sheet 4:
o This is an informative sheet that discusses about operating principles of
fan motors, standard color coding and standard terminal leads brought
out.

Perform: Operation Sheet Identify Fan Motor Terminals

7:
o This practice activity will enable you to identify fan motor terminals
through color coding, determining untagged terminals of fan motor and
checking conditions of fan motor.
Read: Information Identifying Capacitors

Sheet 5:
o This is an informative sheet that discusses about operating principles,
types of capacitor used in refrigeration and air conditioning system. It
also deals with connecting capacitors to suit for the capacitance needed
during emergency repairs.
Self-Check p.84
Do: Self-Check 4
o This is to self-evaluate what you have learned about the capacitors.
Perform: Operation Sheet 8: Testing capacitor using ohmmeter

(Running and Starting Capacitor)
o This practice activity will show how to determine defective capacitor

using multimeter.

Perform: Job Sheet Replace Capacitor

3:
o This practice activity will show how to replace defective capacitor from
the unit.
o After this activity, have your instructor check your work.
Read: Information Selector Switch

Sheet6:
o This is an informative sheet that discusses about operating principles of
selector switch used in air conditioning unit.
Perform: Operation Sheet 9: Checking Selector Switch
o This activity will show how to check selector switch. It also deals with
identifying selector switch terminals.
Read: Information Electrical Controls: Current and

Sheet 7: Potential Relays
o This is an informative sheet that explains about operating principles and

connections of current and potential relay in the refrigeration and air
conditioning units.

Self-Check p.102
Do: Self-Check 5
o This is to self-evaluate what you have learned about current and

potential relays.
Perform: Operation Sheet Checking Current Relay (Coil Type)

10:
o This activity will show how to identify defective current relay.
Perform: Operation Sheet Checking Potential Relays

11:
o This activity will show how to identify defective potential relay.
Read: Information Overload Protector

Sheet 8:
connections of overload protector in the refrigeration and air
conditioning units.

Self-Check p.113
Do: Self-Check 6
o This is to self-evaluate what you have learned about overload

protectors.
Perform: Operation Sheet Checking Overload Protector

12:
o This activity will show you how to check overload protector..
Read: Information Sheet Temperature Control Switch

9: (Thermostat)

connections of thermostat in the refrigeration and air conditioning units.
Self-Check p.122
Do: Self-Check 7
o This is to self-evaluate what you have learned about thermostat.

Perform: Operation Sheet Checking Thermostat

13:
o This activity will show you how to check thermostat.
Read: Information Defrost Timers

Sheet10:
connections of defrost timers in the refrigeration units.
Self-Check p.132
Do: Self-Check 8
o This is to self-evaluate what you have learned about operation of semi

automatic defrost timer.
Read: Information Sheet Operation of a Semi-Automatic Defrost

11: Timer
o This is an informative sheet that explains about operation of a semi

Self-Check p.136
Do: Self-Check 9
o This is to self-evaluate what you have learned about operation of semi


Perform: Operation Sheet Testing Defrost Timer

14:
o This activity will show you how to test defrost timer.
Perform: Job Sheet 4: Replace Defrost Timer
o This activity will show you how to replace defective defrost timer.
Perform: Operation Sheet Test Air Swing Motor

15:
o This activity will show you how to replace defective air swing motor.
Perform: Job Sheet 5: Replace Air Swing Motor
o This activity will show you how to replace defective air swing motor.

Perform: Operation Sheet Checking Door Switch

16:
o This activity will show you how to check door switch.
Perform: Operation Sheet Checking Service Cord/Plug

17:
o This activity will show you how to check service cord/plug.
Perform: Operation Sheet Continuity Test Air conditioning Unit

18: (Power Cord)
o This activity will show you how to troubleshoot the unit by means of
continuity testing.
Read: Information Sheet Oxyacetylene

12:
o This is an informative sheet that discuss about soldering and brazing
equipment such as oxyacetylene.

Perform: Operation Sheet 19: Setting-up Oxyacetylene Equipment
o This Practice activity that will teach you how to set-up oxyacetylene
equipment.
Perform: Operation Sheet 20: Perform Brazing and Soldering
o This Practice activity that will show you how perform brazing and
soldering.
Perform: Assignment Sheet 2: Soldering and Brazing Tube

Fittings
o This practice activity that will enhance your knowledge and skills in
brazing and soldering.
Read: Information Sheet Evaporator

13:
o This is an informative sheet that discuss the basic principles and
operation of evaporator

Read: Information Sheet Condenser

14:
o This is an informative sheet that discusses about different types of
condensers.
Read: Information Sheet Identifying Cleaning and Rinsing

15: Solvents
o This is an informative sheet that discusses about cleaning and rinsing

solvents used in evaporator and condensers
Self-Check p.178
Do: Self-Check 10
o This is to self-evaluate what you have learned about cleaning and

rinsing solvents.
o After answering the questionnaire, ask your trainer for the answer key.
Perform: Job Sheet 6: Cleaning, Removing and/or

Replacing the Evaporator
o This practice activity will show you how to clean, remove and replace
evaporator.
Perform: Job Sheet 7: Pressure Washing Finned Evaporator
o This practice activity will help you how to pressure wash finned
evaporator

Perform: Job Sheet 8: Straightening Bent Fins
o This practice activity will show some techniques in straightening bent

fins.
Perform: Job Sheet 9: Cleaning Condensers
o This is a practice activity that will show how clean condensers.
Perform: Job Sheet 10: Determining Defective Compressor

(Stuck-up and Loss Compression)
o This activity will show how to determine loss compression and stuck-up
compressor motor.
Perform: Job Sheet 11: Determining Leaky Refrigeration/Air

conditioning System
o This activity will show how to determine leaky refrigeration/air

conditioning system.

Perform: Job Sheet 12: Determining Clogged

Refrigeration/Air conditioning
System
o This Practice activity that will show you how determine clogged
refrigeration/air conditioning system.
Read: Learning Outcome

Information Sheet 16: The Importance of Recovery/Recycling of Refrigerants
Self Check p.211
Do: Self-Check.11
• Check your work with the Answer Sheet
Read: Information Sheet 17: Identify refrigerants
Read: Information Sheet 18: Identify refrigerant using identifier
Self Check p.224
Do: Self-Check. 12

Practice: Job Sheet 13 - Identify Refrigerant Using Portable Identifier

• Ask permission from instructor
• Prepare equipment, tools and materials
• Observe safety practices
• Maintain cleanliness
Practice: Job Sheet 14 - Identify Refrigerant Using Pressure Temperature
Method
• Ask permission from instructor
• Prepare equipment, tools and materials
• Observe safety practices
• Maintain cleanliness
Read: Learning Outcome

Study: Information Sheet 19: Assess Unit for Retrofit
Viewing Video Program

View: Ask instructor to assist you setting up the video program
• Video: Back to the Future—Working Safely with Hydrocarbons
Optional Activity
Call Instructor: Discuss other options to attain objectives
• Ask instructor short lecture and demonstration in retrofitting.
Self Check p.264
Do: Self-Check. 14

Information Sheet 1
Plan and Prepare for Troubleshooting.
Test Unit & Troubleshooting Procedures
Troubleshooting Procedures
There is a close relationship between the terms troubleshooting & servicing.

Troubleshooting is often referred to as analysis of the problem. This analysis is generally
guided by a chart provided by the manufacturer of the equipment. Servicing is the manual
labor needed to correct the problem that was identified in the troubleshooting sequence.
One of the key requirements for service technicians is to follow standard procedure;
the example is as follows;
1. Obtain from the owner a description of the problem,

2. From the problem identified by the owner, determine the possible cause of the
problem,
3. Identify a specific remedy for the problem.
Using standard procedure will save time, money and frustration. Most charts
have three (3) basic columns, heading are;
a. Problem (trouble, complaint)

b. Possible Cause (probable cause, have gas checked….)
c. Remedy (Repair, you may need to…..)
When using the troubleshooting charts, it is important that the technician follow the
chart on a step-by-step basis.
Upon arrival at the location, the technician should become familiar with the system in
questions. The system should be visually inspected and all components and wiring
examined for any evidence of malfunction, the technician should then consider
examination of the system’s electrical wiring & component diagram.
When responding to service call the technician must always approach the problem in
a logical sequence.
 The first step in troubleshooting is to ask the owner/user or operator about the
problem, then inspect, check and test the system using troubleshooting
instrument. Your ability to think the problem of a cooling system is a great asset
in troubleshooting.

 Your five (5) senses can tell a lot about what is going on a system.
Look: for vibration, gauge reading, current and voltage reading, leaks, broken
or loose parts.
Listen: for compression knocks, valves opening or closing, switches clicking at
the right time.
Feel: feel temperature changes, pipes that are hot when they should be cool, or
vice versa.
Smell: for burned wire insulation, hot parts or belts slipping.
Taste: for food that has spoiled due to vacuum temperatures.
Owner’s Description of Problem
 The first column of the troubleshooting chart normally lists the problem. This
column would be the complaint given to the service technician by the owner –
usually in general terms.
 The technician logins troubleshooting by carefully listening to the owner’s
complaint.
Checking Possible Cause
 The next step would be for the technician to check the possible cause column
& to analyze this listing in terms of the major components of the system.
 After a through investigation of the possible cause’s column, the technician
proceeds to identify the parts of the system listed as the possible cause of the
problem or symptom. The technician should then be able to determine a
specific cause or malfunction & to identify the specific faulty part.
Suggested Remedy
 The final column on the troubleshooting chart may have a heading of remedy.
This is the third (3rd) step when using troubleshooting chart. The technician will
perform the appropriate task for this column. The actual procedure will vary
depending upon the specific remedy selected, the type of part or device being
checked & the specific system. Basic service & safety procedures are always
followed as the technician repairs the system.

Information Sheet
Trouble Probable Cause Suggested Remedy

Complaint Cause Repair
Problem Have You Checked You May Need To
Problem Possible Cause Remedy

F. Unit operates 1. Shortage of refrigerant 1. Fix leak, add charge.
long or 2. Control contacts stuck 2. Clean contacts or
continuously or frozen closed. replace control.
3. Refrigerated space 3. Determine fault and
has excessive load or correct.
poor insulation
4. System inadequate to 4. Replace with larger
handle load system.
5. Evaporator coil iced 5. Defrost.
6. Restriction in 6. Determine location
refrigeration system and remove.
7. Dirty condenser 7. Clean condenser.
8. Filter dirty 8. Clean or replace.
Troubleshooting Chart
 Servicing must always accomplished through the use of the proper tools,
gauges, electrical analyzing equipment & other necessary equipment.
 The use of troubleshooting charts is relatively simple. The technician must
understand it is a helpful map which leads from step 1 – Problem, step 2 –
Possible Cause, & step 3 – Remedy.
 One must be very careful to utilize the specific troubleshooting chart the
manufacturer of the equipment being serviced. Troubleshooting charts vary,
depending upon the purpose of the equipment & the particular manufacturer.
The troubleshooting chart is broken down into the basic columns; Complaints,
Possible Cause & Repair.

HERMETIC REFRIGERATION SYSTEM DIAGNOSIS
1. GENERAL
Each complaint is followed by probable causes and suggested repairs. To isolate the
possible cause, proceed in a systematic manner to determine the faulty component. This
guide does not cover all possible troubles and deficiencies that may occur under
conditions of operation.
2. ELECTRICAL CHECK:
A. Compressor Does Not Run-
1. Check power at outlet receptacle. Your compressor is designed to operate (see
serial no. and data plate) on 115-60-1 with a voltage range of 126.5 – 103.5. Your
240/220-50-1 will operate within range of 264-198.
2. Check thermostat for proper setting and continuity. Make sure control setting is
not in an “Off” position. Continuity may be verified by following instructions on the
individual compressor motor circuits.
3. Look for obvious loose or broken wiring.
4. Following systematically the instruction listed on the compressor motor circuitry,
check the relay, overload, and if employed, the start capacitor for continuity.
Replace any components found faulty with the recommended service parts.
3. TROUBLESHOOTING AND SERVICE CHART
COMPLAINT POSSIBLE CAUSE REPAIR

A. Compressor will not 1. Line disconnect switch 1. Close start or disconnect
start – no hum open. switch.
2. Fuse removed or blown 2. Replace fuse.
3. Overload protector tripped 3. Refer to electrical diagram.
4. Control stuck in open 4. Repair or replace control.
position.
5. Control off due to cold 5. Relocate control.
location.
6. Wiring improper or loose. 6. Check wiring against
diagram.
B. Compressor will not 1. Improperly wired. 1. Check wiring against
start – hums diagram.
2. Low voltage to unit. 2. Determine reason and
correct.
3. Starting capacitor 3. Determine reason and
defective. replace.
4. Relay failing to close. 4. Determine reason and
correct, replace if
necessary.
5. Compressor motor has 5. Replace compressor.
winding open or shorted.
6. Internal mechanical trouble 6. Replace compressor.
in compressor.

C. Compressor will not 1. Improperly wired 1. Check wiring against
start – hums but diagram.
trips on overload 2. Low voltage to unit. 2. Determine reason & correct.
protector. 3. Relay failing to open. 3. Determine reason & correct,
replace if necessary.
4. Run capacitor defective. 4. Determine reason & replace
5. Excessively high discharge 5. Check discharge shutoff,
pressure. possible overcharge.
6. Compressor motor has a 6. Replace compressor.
winding open or shorted.
7. Internal mechanical trouble 7. Replace compressor.
in compressor (tight).
D. Compressor starts 1. Additional current through 1. Check wiring diagram, check
and runs, but short overload protector. for added fan motors,
cycles on overload pumps, etc., connected to
projectors. wrong side of protector.
2. Low voltage to unit. 2. Determine reason and
correct.
3. Overload protector 3. Check current, replace
defective. protector.
4. Run capacitor defective. 4. Determine reason and
replace
5. Excessive discharge 5. Check ventilation, restriction
pressure. in cooling medium, restriction
in refrigeration system.
6. Check for possibility of
6. Suction pressure too high. misapplication, use stronger
unit
7. Compressor too hot – return 7. Check refrigerant charge (fix
gas hot. leak), add if necessary.
8. Compressor motor has a 8. Replace compressor.
winding shorted.
E. Unit runs ok, but 1. Overload protector 1. See D
short cycles. 2. Thermostat 2. Differential set too close –
3. High pressure cut-out due widen.
to:
a. Insufficient air. 3a. Check air to condenser
–correct.
b. Overcharge. 3b. Reduce refrigerant
charge.
c. Air in system 3c. Purge
4. Low pressure cut-out due to:
a. Undercharge 4a. Fix leak, add refrigerant.
b. Restriction in 4b. Replace device
expansion device.

F. Units operates long 1. Shortage of refrigerant. 1. Fix leak, add charge.
or continuously 2. Control contacts stuck or 2. Clean contacts or replace
frozen control.
3. Refrigerated space has 3. Determine fault and correct.
excessive load or poor
insulation
4. System inadequate to 4. Replace with larger system.
handle load.
5. Evaporator coil iced. 5. Defrost.
6. Restriction in refrigeration 6. Determine location and
system. remove.
7. Dirty condenser. 7. Clean condenser.
8. Filter dirty 8. Clean or replace.
G. Start capacitor open, 1. Relay contacts not operating 1. Check and replace.
shorted or blown properly
2. prolonged operation on start 2a. Determine reason and
cycle due to: correct.
a. low voltage to unit 2b. Replace.
b. Improper relay 2c. Correct by using pump
c. Starting load too high down arrangement if
necessary
3. Excessive short cycling 3. Determine reason for short
cycling (E above) & correct.
4. Improper capacitor. 4. Determine correct size and
replace.
H. Relay defective or 1. Incorrect relay 1. Check and replace.
burned out 2. Incorrect mounting angle 2. Remount relay in correct
position.
3. Line voltage too high or too 3. Determine reason and
low correct.
4. excessive short cycling 4. Determine reason (see E)
and correct.
5. Relay being influenced by 5. Remount rigidly.
loose vibrating.
6. Incorrect run capacitor 6. Replace with proper
capacitor.
I. Space temperature 1. Control setting too high. 1. Reset control.
too high 2. Inadequate air circulation. 2. Improve air movement.
J. Suction line frosted 1. Evaporator fan not running. 1. Determine reason and
or sweating. correct.
2. Overcharge of refrigerant. 2. Correct charge.
K. Liquid line frosted or 1. Restriction in dehydrator or 1. Replace part.
sweating strainer
L. Unit noisy 1. Loose parts or mounting. 1. Find and tighten.
2. Tubing rattle 2. Reform to be free of contact.
3. Bent fan blade causing 3. Replace blade.
vibration. 4. Replace motor.
4. Fan motor bearings worn.
TROUBLESHOOTING CHART
TROUBLE COMMON CAUSE REMEDY

1. Unit will not run  Blown fuse  Replace fuse
 Low voltage  Check outlet with voltmeter,
should check 115V plus or
minus 10 percent.
 If circuit overloaded, either
reduce load or have
electrician install separate
circuit.
 If unable to remedy any other
way, install auto transformer.
 Broken motor or temperature  Jumper across terminals of
control control. If unit runs and
connections are all tight,
replace control.
 Broken relay.  Check relay, replace if
 Broken overload. necessary.
 Broken compressor  Check overload, replace if
necessary.
 Check compressor, replace if
necessary.
 Defective service cord.  Check with test light at unit; if
no circuit and current is
indicated at outlet, replace or
repair.
 Broken lead to compressors,  Repair or replace broken
timer or cold control leads or cold control.
 Broken timer.  Check with test light and
replace if necessary.
2. Refrigerator section  Repeated door openings  Instruct user.
too warm  Overloading of shelves,  Instruct user.
blocking normal air
circulation in cabinet
 Warm or hot foods placed in  Instruct user to allow foods to
cabinet. cool to room temperature
before placing in cabinet.
 Poor door seal.  Level cabinet, adjust door
seal.
 Interior light stays on.  Check light switch; if faulty,
replace.
 Refrigerator section airflow  Turn control knob to colder
control. position. Check airflow
heater.
 Check if damper is opening
by removing grille. With door
open, damper should open. If
control inoperative, replace
control.
 Cold control knob set at too  Turn knob to colder position
warm a position, not
allowing unit to operate
often enough.
 Freezer section grille not  Reposition grille.
properly positioned.
 Freezer fan not running  Replace fan, fan switch, or
properly defective wiring.
 Defective intake valve.  Replace motor compressor.
 Air duct seal not properly  Check and reseal or put in
sealed or positioned. correct position.
3. Refrigerator section  Refrigerator section airflow  Turn control knob to warmer
control too cold knob turned to coldest position.
position.
 Airflow control remains  Remove obstruction.
open.
 Broken airflow control.  Replace control.
 Broken airflow heater.  Replace heater.
4. Freezer section and  Fan motor not running.  Check and replace fan motor
refrigerator section if necessary.
too warm.  Cold control set too warm or  Check and replace if
broken. necessary.
 Finned evaporator blocked  Check defrost heater
with Ice. thermostat or timer, either
one 0f these could cause this
condition.
 Shortage of refrigerant.  Check for leak, repair,
evacuate and recharge
system.
 Not enough air circulation  Relocate cabinet or provide
around cabinet. clearances to allow sufficient
 Dirty condenser or circulation.
obstructed condenser ducts.  Clean the condenser and
the ducts.
 Poor door seal  Level cabinet, adjust door
seal
 Too many door openings  Instruct customer.
5. Freezer section too  Cold control knob  Turn knob to warmer position
cold improperly set.
 Cold control capillary not  Tighten clamp or reposition.
properly clamped to
evaporator.
 Broken cold control  Check control. Replace if
necessary.
Chart lists some common hermetic system troubles. Their causes, and suggested remedies
Installing and Servicing Small Hermetic Systems
TROUBLESHOOTING CHART

6. Unit runs all the time  Not enough air circulation  Relocate cabinet or provide
around cabinet or air proper clearances around
circulation is restricted cabinet -remove restriction
 Check and make necessary
adjustments.
 Poor door seal  Explain to customer that
heavy loading causes long
running time.
 Freezing large quantities of  Undercharge or overcharge
ice cubes or heavy loading -check, evacuate and
after shopping recharge with proper
 Refrigerant charge. charge.
 Ventilate room as much as
possible.
 Room temperature too  Check control; if it allows
warm. unit to operate all the time,
 Cold control. Check if light goes out,
replace control.
 Defective light switch.  Replace switch if necessary.
 Excessive door openings  Instruct customer
7. Noisy operation  .Loose flooring or floor not  Tighten flooring or brace
firm. floor.
 Tubing contacting cabinet-  Move tubing.
or other tubing
 Cabinet not level.  Level cabinet.
 Drip tray vibrating  Move tray -place on styro
foam pad if necessary.
 Fan hitting liner or  Move fan
mechanically grounding.
 Compressor mechanically  Replace compressor
grounded mounts.
8. Unit cycles on  Broken relay.  Replace relay.
overload  Weak overload protector.  Replace overload protector.
 Check outlet with voltmeter.
 Low voltage Underload voltage should
be 115V plus or minus 10
percent. Check for several
appliances on same circuit
or extremely long or under-
sized extension cord being
used.
 Poor compressor  Check with test cord and
also for ground before
replacing.
9. Stuck motor  Broken valve  Replace motor compressor.
compressor.  Insufficient oil.  Add oil; if unit still will not
operate, replace motor
compressor.
 Overheated compressor  If compressor faulty for any
reason, replace motor
compressor.
10. Frost or ice on  Broken timer.  Check with test light and
finned evaporator replace if necessary.
 Defective defrost heater  Replace heater.
 Defective thermostat  Replace thermostat.
11. Ice in drip catcher  Defective drip catcher  Replace heater
heater
12. Unit runs all the  Ice builds up on the  Check door gaskets -
time, temperature evaporator replace if necessary.
normal  Control bulb on thermostat  Place control bulb in,
not in contact with the contact evaporator surface.
evaporator surface.
13. Freezer runs all the  Faulty thermostat.  Check thermostat -test and
time. Temperature replace if necessary.
too cold
14. Freezer runs all the  Ice buildup in insulation  Remove breaker strips, stop
time. Temperature unit, melt ice and dry
too warm insulation, seal outer shell
leaks and joints and -,. then
assemble.
15. Rapid ice buildup on  Leaky door gasket  Adjust door hinges. Replace
the evaporator door gasket if cracked,
brittle or worn.
16. Door on freezer  Faulty electric; gasket  Use alternate gasket heater
compartment, heater. or install new one.
freezes shut.  Faulty gasket seal.  Inspect and check gasket. If
worn, cracked or hardened,
replace it.
17. . Freezer works then  Moisture in refrigerator  Install drier in liquid line
warms up
18. Gradual reduction in  Wax buildup in capillary  Use capillary tube cleaning
freezing capacity. tube tool or replace capillary
tube.

DOMESTIC AND LIGHT COMMERCIAL SYSTEMS
The "Troubleshooting and Service Chart" is quite self-explanatory; however, a

discussion of some of the complaints, possible causes, and repair solutions may be of some
additional assistance.
COMPLAINT "A" is Compressor will not start. No hum. Possible causes are:
1. Switch open. Rather obvious, but maybe it would be wise to determine why
or who opened it.
2. Fuse removed or blown. Again, was there a reason?
3. Overload protector tripped. Here, too, it is not a case of waiting until the
overload resets, but rather to determine why.
4. Control stuck in open position. Faulty contactors may be a cause, although
every effort is made to provide the best quality contactors. And heed this
warning: Don't use the insulated end of a screwdriver to hold the contactor in.
In doing so you run the risk of burning out a good compressor.
COMPLAINT "B" is Compressor will not start-hums and trips on overload.
1. & 2. have been discussed (see Complaint "A").

3. Starting capacitor defective. It says "determine reason." Possibly a start
capacitor was installed which had too Iowa voltage rating.
4. Relay failing to close. Is the correct one being used? There seems to be a
considerable tendency to substitute something other than the one specified-if it
works, leave it. We say, please don't do it.
5. Compressor has a winding open or shorted. The repair specified says simply
"replace compressor." This means if the cause indicated has been proved -
without doubt -conclusively -no question about it-only then replace the
compressor. Remember that replacing the compressor is generally the most
costly repair bill an owner can get. So be sure-first.
6. Internal mechanical trouble in compressor. If the serviceman has proved
without question that none of the other possible causes are the reason for the
condition, then and then only can it be mechanical trouble.
A "Troubleshooting Chart" of this kind is not the entire answer. There are probably a
number of other reasons for the cause of each "complaint" listed, so keep in mind that
application of knowledge gained through experience and common sense are as much a part
of troubleshooting as the use of any chart.
COMPLAINT "C" is Compressor starts but stays on run winding. How do you know
this condition is occurring? If the ampere stay higher than normal. Or if you don't hear
the changeover.
1. through 3. Covered previously (see Complaint "A" and "B").

4. Run capacitor defective. If the run capacitor is failed closed, there will be a
period of time when the current and running sounds will seem to indicate the
relay has not switched. In a relatively short period of time, the start winding will
burn, so time is of the essence in this case.
5. High head pressure. Be sure to check all the things listed in the "repair" column.

COMPLAINT "D" is Compressor starts and runs, but short cycles on overload
protector.
1. Mentioned before (see Complaint "A").

2. Low voltage to unit (or unbalanced if three-phase). In the matter of three-phase
unbalance-this is an instance in which it is probably wise to call in the power
company, or check with the building owner to determine what other equipment
is on the source of power to cause the unbalance.
3. Overload protector defective. Sometimes difficult to determine. One good clue is
how it looks-does it show to have been overheated?
6. Suction pressure too high. This will occur more often on refrigeration than air
conditioning, especially on low temperature equipment.
7. Compressor hot-insufficient gas cooling. Usually a result of a low charge.

Hermetic Compressor Service Chart
PROBLEMS AND CAUSES REMEDIES

Compressor will not start -no hum
1. Open line circuit. 1. Check wiring, fuses, and receptacle.
2. Protector opens. 2. Wait for reset -check current.
3. Control contacts open. 3. Check control, check pressures.
4. Open circuit in stator. 4. Replace stator or compressor.
Compressor will not start -hums intermittently (cycling on protector).
1. Improperly wired. 1. Check wiring against diagram.
2. Low line voltage. 2. Check main line voltage, determine
location of voltage drop.
3. Open starting capacitor. 3. Replace starting capacitor.
4. Relay contacts not closing. 4. Check by operating manually. Replace
relay if defective.
5. Open circuit in starting winding. 5. Check stator leads. If leads are all
right, replace compressor.
6. Stator winding grounded (normally will 6. Check stator leads. If leads are all
blow fuse). right, replace compressor.
7. High discharge pressure. 7. Eliminate cause of excessive
pressure. Make sure discharge shut-
off and receiver valves are open.
8. Tight compressor. 8. Check oil level -correct binding
condition, if possible. If not, replace
compressor.
9. Weak starting capacitor or one weak. 9. Replace.
capacitor of a set
Compressor starts, motor will not get off starting winding.
1. Low line voltage. 1. Bring up voltage.
2. Improperly wired. 2. Check wiring against diagram.
3. Defective relay 3. Check operation -replace relay if
defective.
4. Running capacitor shorted. 4. Check by disconnecting running
capacitor.
5. Starting and running windings shorted 5. Check resistances. Replace
compressor if defective.
6. Starting capacitor weak or one of a set 6. Check capacitance -replace if
open. defective.
7. High discharge pressure. 7. Check discharge shutoff valves.
Check pressure.
8. Tight compressor. 8. Check oil level. Check binding.
Replace compressor if necessary.
Compressor starts and runs but cycles on protector.
1. Low line voltage. 1. Bring up voltage.
2. Additional current passing through 2. Check for added fan motors and
protector. pumps connected to wrong side of
protector.
3. Suction pressure too high. 3. Check compressor for proper
application.
4. Discharge pressure too high. 4. Check ventilation, restrictions and
overcharge.
5. Protector weak. 5. Check current -replace protector if
defective.
6. Running capacitor defective. 6. Check capacitance -replace if
defective.
7. Stator partially shorted or grounded. 7. Check resistances; check for ground -
replace if defective.
8. Inadequate motor cooling. 8. Correct cooling system.
9. Compressor tight. 9. Check oil level. Check for binding
condition.
10. Unbalanced line (three phase). 10. Check voltage of each phase. If not
equal, correct condition of unbalance.
11. Discharge valve leaking or broken. 11. Replace valve plate.
Starting capacitors burnout.
1. Short cycling. 1. Reduce number of starts to 20 or less
per hour.
2. Prolonged operation on starting 2. Reduce starting load (install
winding. crankcase pressure limit valve),
increase voltage if low -replace relay if
defective.
3. Relay contacts sticking. 3. Clean contacts or replace relay.
4. Improper relay or incorrect relay 4. Replace relay.
setting.
5. Improper capacitor. 5. Check parts list for proper capacitor
rating -mfd. and voltage.
6. Capacitor voltage rating too low. 6. Install capacitors with recommended
voltage rating.
7. Capacitor terminals shorted by water. 7. Install capacitors so terminals will not
be wet
Running capacitors burnout
1. Excessive line voltage. 1. Reduce line voltage to not over 10
percent above rating of motor
2. High line voltage and light load. 2. Reduce voltage if over 10 percent
excessive.
3. Capacitor voltage rating too low. 3. Install capacitors with recommended
voltage rating.
4. Capacitor terminals shorted by water. 4. Install capacitors so terminals will not
be wet.
Relays burnout
1. Low line voltage. 1. Increase voltage to not less than 10
percent under compressor motor
rating.
2. Excessive line voltage. 2. Reduce voltage to maximum of 10
percent above motor rating.
3. Incorrect running capacitor. 3. Replace running capacitor with correct
mfd. capacitance.
4. Short cycling. 4. Reduce number of starts per hour.
5. Relay vibrating. 5. Mount relay rigidly.
6. Incorrect relay. 6. Use relay recommended for specific
motor compressor
Troubleshooting Guide
Basic System Requirements
 Electrical System
1. All electrical joints & connection must properly insulated & firm.
2. Equipment grounding connection must be firm & connected to earth.
3. Actual load current must not exceed to the nameplate current rating.
4. Actual voltage must play to the tolerance of  10% of the unit voltage
rating.
5. Wire size must be long enough to carry the load current.
6. All electrical components & parts must be in good condition before in
operation.
 Mechanical System
1. Sufficient liquid refrigerant in the evaporator.
2. Sufficient contact between the cool space & the evaporator.
3. Correct temperature & pressure in the condenser.
4. Properly size condenser.
5. Sufficient heat removal for the condenser.
6. Correct amount of refrigerant chart.
7. Free from leaks & moisture & properly evacuated.
Trouble Signals
A fault in any part of the refrigerating mechanism will usually show up as an

unsatisfactory temperature or operating condition of the refrigerator; such conditions may
include:
1. Refrigerator does not run.

2. Refrigerator runs all the time; temperatures are too cold.
3. Refrigerator runs all the time; temperatures are too warm.
4. Refrigerator runs all the time; temperatures are satisfactory.
5. Refrigerator cycles but food compartment is too warm; freezing
compartment is satisfactory.
6. Refrigerator cycles but freezing compartment is too cold.
7. Motor control cuts out.
8. Refrigerator cycles satisfactorily; refrigeration is poor. 9. Refrigerator
cycles; but does not freeze ice cubes.
9. Refrigerator cycles; too much ice accumulates on the evaporator.
10. Refrigerator mechanism is very noisy.

Hermetic Troubleshooting / Servicing Guide
 To service refrigerating units successfully, one must know how they should
perform when in good condition.
 Always check the system data before trying to locate the cause of the trouble.
System data is usually located on the identification plate mounted at the
motor compressor. Nameplate data must have in mind before beginning any
service operation, as follows;
70 oF Ambient 90 oF Ambient 100 oF

Temperature Temperature Ambient
Cabinet Temperature 38 o 40 o 47 o
% Operating Time 38 60 100
Cycles per Hour 3 2 none
kWhr./24 hour 3.8 6.0 9.9
Control Position 4 4 4
Evaporator Air Temperature 1.5 o -1o 0o
Suction Pressure (min-max) 2 in Hg – 13mpsig 0 – 13 psig 13 – 20 psig
Watts (complete system) 390  20 395  20 395  20
Chart shows operating characteristics of 18 cu. ft. combination refrigerator – freezer

which has 1/3 hp, two poles motor compressor.
Note that kW hr. (average over 24 hr.) changes as ambient temperature changes.
DATA
Refrigerant R – 134-a
Charge (in Ounces) 10 ½
Compressor hp 1/3
Compressor Speed 3450
rpm 5.6
Running Amperes 120
Voltage single
Phase
Refrigerant and electrical data which is typical of

information found on identification plate mounted on motor compres sor.

Normal Operation of a Refrigeration/Aircon
1. Evaporator coil completely covered with frost (ice).If evaporator temperature below
freezing point of water (32 degree F)
2. Condenser coil temperature is normal (120-130 degree F)
3. Evaporator coil is completely sweating (34 degree F- 45 degree F (aircon)
4. Low side pressure is normal (standard pressure). Low side pressure.
a) Refrigerator 3-12 psig (R-134-a) f3t4-
b) Aircon -60 -80 psig (R-22)
5. High side pressure is normal.
a) Refrigerator-130 - 180 psig
b) Aircon-260 280 psig
6. Full load ampere is normal base on nameplate.
7. Evaporator temperature is normal.
a) Refrigerator- 0 degree F-5 degree F
b) Aircon-34 degree F -45degree F
8. A few minutes of operation, a sharp temperature drop felt in suction line.
9. Filter drier temperature is normal (125 degree F).
10. During off cycle (off compressor motor) pressure in .low side and high side are
equalized.
Common Troubles of Compressor Motor Connections
Compressor motor fails to start…

A) no humming.
1. No power
2. Open overload protector
3. Open running winding
4. Loose connections
5. Open coil of current relay
B). With humming.
1. Low voltage  10% of power supply
2. Shunted winding
3. Open starting winding
4. Grounded winding
5. Tight/stuck-up compressor
6. Defective starting capacitor
7. Defective running capacitor
8. Defective starting relay (open contact)
9. Loose connection
C) Start and run by cycles on Overload Protector.
1. Low voltage :f: 10% of power supply
2. Relay does not get-off starting winding
3. Weak overload protector
4. Additional current flowing in overload protector
5. Shunted winding
6. Tight compressor
7. Grounded windings
8. Defective capacitor

Job Sheet 1
Troubleshooting Refrigeration/Air conditioning
Unit
Objectives:
At the end of this practice, the learner/trainee should be able to:
o Troubleshoot refrigeration/air conditioning unit
o Rectify troubles found in a unit.
o apply safety practices in troubleshooting refrigeration/air
conditioning unit
1. After the Information Sheet 5: Plan and Prepare for Troubleshooting, you are task to
troubleshoot an actual unit.
2. You can use this Information Sheet as a guide while performing your task.
3. The purpose of this activity is to enhance your knowledge and skill in troubleshooting
and repair.
4. Your tasks are;
o Ask your trainer for a defective refrigeration/air conditioning unit.
o Gather tools, materials and equipment that are necessary to perform this
activity.
o Troubleshoot the unit.
o If you found the possible trouble/s, ask your instructor to check your work.
o Rectify the troubles found.
o After completion, let your trainer check your work.
o Perform housekeeping.

Information Sheet 2
Hermetic Motor Compressor
Hermetic motor is a very common and considered as an important component in

refrigeration system. The design characteristic of motor depends on whether the unit starts
under load, no load, or a balance pressure condition. The torque is provided by a magnetic
force developed in the field winding. They induce strong current to the rotor and in return it
drives the compressor crankshaft and the connecting rod to allow the piston to move up and
down. A compressor is either piston or roller type with the electric motor fastened in it. It is
sealed and the whole unit is house in a dome.
The higher the starting torque (turning effort) needed for that unit that starts under
load requires the use of larger conductors in the starting circuit. Most manufacturers try to
provide starting power equal to twice the running power. That is a 1/8 hp motor is designed
to produce ½ hp during starting.
Hermetic motors are either single phase or polyphase. In this segment only single
phase induction hermetic motors are explained. The figure below illustrates the construction
of hermetic motor.

Compressor Winding
Hermetic compressor has its squirrel cage rotor directly coupled to the compressor
shaft and its stator inside the refrigeration system. The refrigerant vapor and oil surround the
whole unit. The construction and internal connection is similar to a split phase motor. It
consist of two identical windings the start and run winding. The former is fine while the latter
is a bigger wire wound in a core.
The split phase motors obtained the stator torque by adding a second winding to the
stator. This is a start winding. The conductor used in this winding is smaller than the
conductors used in run winding. It has higher resistance. Its purpose is to obtain a phase
displacement between windings so that it provides enough starting torque to spin the rotor.
Each winding has its specific resistance. The starting winding measures 30 ohms
while the run winding measures 4.5 ohms. These two windings are connected. The point of
connection is the common terminal. The end of starting is starting terminal while the other
end of running is running terminal. Since the windings are connected at common terminal.
The resistance is higher when measured between running and starting terminal which is 34.5
ohms. It is the combined resistance of two windings connected in series.
Hermetic Compressor Terminal
To obtain a correct compressor connection the motor terminal must be identified

correctly to prevent the motor from burning when supplied by electricity. Generally,
identification of compressor terminals is based on their arrangement. These are arranged in
triangular arrangements. The upper position is the “common” terminal; the left side is the
“starting” terminal and “running” on the other side. The figure below specifies the
arrangement of terminals.
COMMON
START RUN
Be careful not to interchange the connection to avoid burning out of windings. It will
immediately burn out after supplying power. The run winding should be wired directly to line
and should stay the circuit to maintain the rotor rotation while the start winding is wired to a
capacitor to correct the power factor of the compressor while it is operating.

If you are not certain, it is best to identify the terminal by testing the compressor
resistance. Just remember that the highest resistance is the combined resistance of starting
and running winding. The lowest resistance is the running winding while the joint wire of
running and starting winding is the common terminal, the other end of each winding should
be running and starting winding terminal.

Self-Check 1
Test what you have learned about hermetic compressor.
Fill in the Blanks

Direction: Complete the sentences below by filling the blanks with appropriate word/s.
1. Hermetic compressor is very common and considered as an important component

in _______________ system
2. A compressor is either __________ or __________ with electric motor fastened in
it.
3. It is sealed and the whole unit is housed in a __________.
4. Hermetic compressors are either _________ or _________.
5. The compressor winding is consist of two identical windings the _________ and
_________ winding.

1. refrigerating system
2. piston or roller type
3. dome
4. single phase or polyphase
5. starting and running

Assignment Sheet 1
Identifying Hermetic Compressor Terminal
Objectives: At the end of this practice the learner/trainee will be able to:
o Analyze the resistances of each terminal.

o Identify the terminals with the given resistances.
Procedures:
1. The table shown below is an obtained test result of a 1.5 hp compressor, it reveals
that the resistances are;
Terminals Resistance
1 2 3.5 ohms
1 3 1.5 ohms
2 3 5 ohms
2. Identify among the three which is the common, start and run winding terminals
based on the given data in the table.
3. Upon completion, check your work with the answer key provided at the back of this
module.

Self-Check 2
Identifying Hermetic Compressor Terminal
1. The table shown below is an obtained test result of a 1.5 hp compressor, it reveals
that the resistances are;
Terminals Resistance
1 2 3.5 ohms
1 3 1.5 ohms
2 3 5 ohms
2. From the table terminal 2 and 3 is the highest resistance either of this terminal is start
or run, therefore terminal 1 is COMMON.
3. Terminal 1 and 3 is the lowest resistance, this indicates that this is the run winding.
Since terminal 1 is already pin pointed as COMMON terminal, therefore terminal 3 is
RUN terminal.
4. The configuration of terminals therefore are as follows:
COMMON
2 3
START RUN

Operation Sheet 1
Determining Hermetic Compressor Motor Terminal

Using Multimeter
o Tag the three terminal using number or letter.

o Obtain resistance results from the three terminals of compressor
o Identify the terminals.
Equipment:
o Multi meter - 1 unit
o Compressor 1 unit
Materials:
o Rag - 1 pc
o sand paper 1 pc
o pencil/ball pen 1 pc
o masking tape
Tools:
o Phillips screw driver - 1 pc
o Flat screw driver 1 pc
o Long nose pliers 1 pc
o Diagonal cutting pliers 1 pc
Personal Protective Equipment:
o Gloves - 1 pair
o Goggles - 1 pc
Procedures:
1. Ask your instructor for 1 unit hermetic compressor.

2. Obtain the necessary tools materials and equipment.
3. Take the necessary data to identify the terminals of motor.
4. Upon completion, ask your instructor to check your work.
5. Perform housekeeping

Information Sheet3
Hermetic Compressor Motor Electrical Connection
There are four types of compressor motor connections used in air conditioning and
refrigeration units. The Permanent Split Capacitor (PSC) motor and Capacitor Start
Capacitor Run (CSIR) motor are use for air-conditioning units while Resistance Start-
Induction Run (RSIR) motor and Capacitor Start Induction Run (CSIR) motor are used for
refrigeration units.
The Permanent Split Capacitor (PSC) Motor

This compressor motor is ranging from ¾ hp to 2 hp. It employs running capacitor
connected in series with starting winding permanently. The capacitor remains in the circuit
while the motor is in operation. This enable to correct the power factor so that the line current
will be reduce and the motor operates in manner similar to two phase motor. This is a low
starting torque motor.

Capacitor Start Capacitor Run (CSCR) Motor
CSCR motor employs two capacitors, one is running capacitor and the other one is
starting capacitor. These capacitors are connected in series with the starting winding. A relay
switch disconnects the starting capacitor while the run capacitor stays in the circuit as long
as the motor operates. This kind of motor is very efficient especially in high torque
application.
The operation and function is similar to PSC motor however, starting capacitor is
added to increase the starting torque. This capacitor provided with a switch that will cut off
the circuit once the compressor operates at a normal speed. Because of the efficiency in the
operation it is capable of starting even in an extreme load condition. This motor connection is
very popular in air-conditioning with a compressor motor ranging from 2 hp to 7.5 hp.

Resistance Start-Induction Run (RSIR) Motor
A resistance start induction run motor has an electrical winding on the motor for
starting purposes. This is commonly used in refrigerators ranging from 1/10 hp to 1/6 hp. A
special winding in the armature gives it high starting torque. The motor starts as a repulsion
motor, using brushes against a commutator in the armature winding circuit. This increases
the induced electrical flow in the armature and produces more magnetic power. As soon as it
reaches a certain speed, the armature winding are shorted. Then the brushes are usually
lifted from the commutator and the motor operates as induction motor.

Capacitor Start Induction Run (CSIR) Motor
The operation of CSIR is quite simple, when the motor starts, the relay (closed when
the motor is running) causes the current to pass through both the starting and the running
winding. The starting winding is connected in series with the capacitor. This capacitor puts
the electrical surge in the starting winding out of step of phase with those of running winding.
At about 75% of motor’s rated speed, the relay opens and disconnects the starting winding.
The unit, however, continues to run as induction motor.

Compressor Lock Rotor and Running Load Amperage (LRA and RLA)
All compressors has specific running load and lock rotor amperage. You should be
familiar with this current amperage rating because this is very critical especially in the field.
For your guide, the table below is very useful:
Motor Compressor Amperage Rating
Horse Power Running Load Lock Rotor

Rating Amperage Amperage
¾ 3.81 22.9
1.0 5.08 30.5
1.25 6.35 38.1
1.5 7.62 45.7
2.0 10.17 61.0
2.25 11.44 68.6

Self-Check 3
Compressor Motor Electrical Connection
Test what you have learned about compressor motor electrical connection.
Fill in the Blanks

Direction: Complete the sentences below by filling the blanks with appropriate word/s.
1. The two types of compressor electrical connections in air conditioning units are
__________ and __________.
2. This kind of motor connection is usually used in air conditioning unit using a
compressor ranging from _________ and _________ horsepower.
3. Permanent split capacitor motor employs _________ capacitor connected in series
with the starting winding permanently.
4. Capacitor start capacitor run motor employs two capacitors, these are _________
and _________.
5. A _________ switch disconnects the starting capacitor connected while the run
capacitor stays in a circuit as long as the motor operates.

Compressor Motor Electrical Connection
1. Permanent split capacitor motor and capacitor start capacitor run motor
2. ¾ to 2 hp
3. running
4. running capacitor and starting capacitor
5. relay

Operation Sheet 2
Connecting Hermetic Compressor (Permanent Split

Capacitor Motor)
o Connect PSC compressor motor

o Follow safety practices in connecting compressor motor.
Equipment:
o Clamp Ammeter - 1 unit
o compressor - 1 unit
Materials:
o rag - 1 pc
o masking tape - 1 roll
o overload protector - 1 pc
o run capacitor - 1 pc
o terminal ends - 10 pcs
o extension cord - 1 pc
o stranded wire, 12 AWG - 5m
o schematic diagram or working drawing - 1 pc
Tools:
o Flat screw driver - 1 pc
o Long nose pliers - 1 pc
o Lineman’s Pliers
o Diagonal cutting pliers - 1 pc
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Prepare the necessary tools,

equipment and materials.
Note: Always wear PPE as necessary!
2. Connect a compressor circuit using

Permanent Split Capacitor motor.
Refer to the diagram on the right.
3. Have your instructor check your work

before energizing.
4. Perform housekeeping.

Operation Sheet 3
Connecting Hermetic Compressor (Capacitor Start

Capacitor Run Motor)
o Connect CSIR compressor motor.

Equipment:
Materials:
o rag - 1 pc
o run capacitor - 1 pc
o starting capacitor
o potential relay - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:


CSCR. Refer to the schematic diagram
on the right.
3. Ask your instructor to check your work

before energizing.

before energizing.

Operation Sheet 4
Connecting Hermetic Compressor (Capacitor Start

Induction Run Motor)
o Connect CSIR compressor motor.

Equipment:
o Compressor - 1 unit
Materials:
o Rag - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:


CSIR. Refer to the schematic diagram
on the right.

before energizing.

before energizing.

Operation Sheet 5
Connecting Hermetic Compressor (Resistance Start

Induction Run Motor)
o Connect RSIR compressor motor.

Equipment:
Materials:
o rag - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:


CSIR. Refer to the schematic diagram
on the right.

before energizing.

before energizing.

Operation Sheet 6
Testing Compressor Motor Winding
o Identify shorted compressor winding

o Identify open compressor winding
o Determine grounded compressor winding.
o Observe safety precautions in testing compressor winding.
Equipment:
o compressor 1 unit
Materials:
o rag - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit
2. Disconnect the wiring connection of

compressor motor.
3. Set the multimeter to Rx1. Calibrate

the multimeter by adjusting the 0-ohm
adjust knob while the leads are
shorted.

4. Record the resistance reading
obtained from the different terminals.
Using the formula:
SR = CR + CS
13Ω = 5Ω + 8Ω
13Ω = 13Ω, therefore compressor
motor winding is good.
Note: If the resistance reading did not
conform to the formula, compressor
motor winding is defective.
5. Set the ohmmeter to Rx10, 000.

Calibrate the meter to zero and place
the test prod to common terminal and
compressor body.
Note: If the pointer deflects, the
compressor is grounded. If the pointer
did not deflect, the compressor
winding is not grounded (good).
6. Observe the following data of winding

resistance to indicate possible
compressor troubles.
Troubles Test Point Meter Indicator

Open Winding
Terminals 1 & 2 and 1 &3 infinity
(R x 1)
Shorted Winding
Terminals 1 & 2 and 1 &3 0 ohm reading
(R x 1)
Grounded Winding
Terminals to casing With deflection or continuity
(R x 10k)
7. Have your instructor check your work.

Job Sheet 2
Replace Compressor Motor
Objectives : When you have completed this job sheet, you will be able to:
 Replace defective compressor motor
 Follow safety practices in replacing defective compressor motor.
Equipment:
o Refrigerator Unit/Air-conditioning unit - 1 unit
o Set of system analyzer - 1 unit
o Recovery/recycling machine -
o Torch set -
Materials:
o Rag - 1 pc
o Silver alloy brazing rod - 2 pcs
o Filter drier with sweat fittings - 1 set
o Sand cloth -
o Silver brazing flux -
Tools:
o Tubing cutter - 1 pc
o Striker - 1 pc
o Refrigeration ratchet wrench - 1 pc
o Combination open end, box end wrench - 1 set
o Shop towels - 1 pc
o Gloves - 1 pair
o Goggles - 1 pc
o Safety glasses -

1. Wear appropriate PPE
2. Check that the refrigerator is

disconnected from electrical power.
Caution: Make sure that the
unit has no pressure either
refrigerant or nitrogen.
3. Use sand cloth and polish the liquid
line prior to cutting
4. Disconnect electrical components

from the compressor.
5. Remove the compressor motor.
6. Install the new compressor.

Note: Make sure to clean the
system thoroughly before
connecting the new
compressor.

7. Replace hold down bolts and tighten
to secure the new installed
compressor.
8. Reconnect the electrical connections
of the new compressor motor.
9. Ask your instructor to check your
work.

Information Sheet 4
Fan Motors
ELECTRIC FAN MOTOR
An electric fan motor is a mechanical device that converts electric energy into mechanical
motion. In an electric motor, electricity is used to produce magnetism. The magnetism is
used to turn a shaft, and the turning shaft is used to do work.
Electric motors are the most popular

and common type used for providing
mechanical power for air conditioning and
refrigeration system. They are popular
because they are readily available with the use
of electricity and their motors are simple.
MAJOR PARTS OF ELECTRIC (FAN)

MOTOR
1. Frame – the part that holds everything

together. It includes the end bell, outside
enclosure and the bearing or bushing.
2. Stator – the stationary part of the motor. It
includes the field coils (winding).
3. Rotor (armature) – the revolving part of the
motor. It includes the shafting.
In air conditioning unit fan motor is commonly used to drive the evaporator blower and
fan blade. The main purpose is to move the air across air-conditioning unit to create a free air
cycle. This will enable the fresh air to cool the condenser and at the same time circulate the
conditioned air around the conditioned room.

Fan motor used in air-conditioning units are capacitor motor with either a single or
multiple speed. The most commonly used is a two speed fan motor. The term speed here
refers to the rotation or revolution per minute of the fan motor.
1. Fan motor windings

A fan motor like the compressor, consist of magnet wire coiled in the slots at
the stator. This magnet wire converts the electricity into magnetic force which will
enable the rotor repulse into a rotating motion. The higher the magnetic force the
slower the rotor rotates.
The magnetic force of the fan motor winding depends on the amount of coil
resistance. The more coiled wires, the higher resistance it has and the greater
magnetic force it creates
You should understand that fan motor consist of two windings. These windings
are the main (running) winding and auxiliary (Starting winding. These two winding is
quite similar to compressor. As the name implies main winding sustain the operation
of the motor while auxiliary winding help the motor start.
There is only one feature which a fan motor plays advantage with compressor. A fan
motor is capable of increasing or decreasing the rotation speed. This is done by varying the
amount of magnetic force in a magnetic coil. Most fan motor employs two or three main
winding. This winding are called speed winding. The main winding is divided into segment,
namely, the first coil is the high speed winding, the high speed coil plus additional coil is
called the medium speed winding and the medium speed coil plus another coil is called the
low speed winding.
2. Fan motor Speed and Terminal Leads

Number of fan motor speed is easily identified by simply counting the numbers
of terminals. Most common as mentioned earlier is two speed fan motor. This kind of
motor usually has four (4) terminal leads, these are called as common, starting, fan
high and fan low. Likewise a three speed fan motor is composed of five (5) terminal
leads namely, common, starting fan high, fan medium and fan low.
The different types of fan motors are as follows

a. Three (3) leads single speed
This fan motor has three leads namely, common (represented by white
wire and connected to one line of the source), starting (represented by brown
wire and connected to the capacitor) and running (represented by black lead
connected to the switch).

Schematic symbol of a three leads single speed fan motor
b. Four (4) leads single speed (reversible)

This type of fan motor has the line lead (white wire), capacitor leads (two brown
wires) and running lead (black wire). There are two externally connected leads,
yellow and purple wires for changing the rotation of the fan motor.
c. Four (4) leads two (2) speed

Four leads fan motor has common lead (represented by white wire
connected to one line of the source), start lead (represented by red wire
connected to the capacitor) high speed lead (represented by black wire
connected to the switch) and low speed. Another wire codes used for this motor
is listed below:
Yellow wire = common lead
Blue wire = start lead
Red wire = low speed lead
Black wire = high speed lead

d. Five (5) leads three (3) speeds
Brown wire = Start lead
White wire = Common lead
Black wire = High speed lead
Blue wire = Medium speed lead
Red wire = Low speed lead
e. Six (6) leads three (3) speeds
Orange wire = Common or line lead

Yellow wire = Common or fan capacitor
Fan motor leads can also be identified using an ohm meter. Based on the
figure below you can see that the motor is composed of coils in series and parallel.
Auxiliary windings

The main winding and starting winding connected in series has the highest
resistance to the entire coil. The starting winding, auxiliary 1 and auxiliary 2 connected
in series has the second highest resistance. Auxiliary 1 and auxiliary 2 has the same
resistance. You can use this information to locate the different terminals of a five leads
2 speed motor (refer to operation sheet about identifying terminals of fan motor).

Operation Sheet 7
Identify Fan Motor Terminals
Objectives: At the end of this practice, the learner/trainee should be able to:
o Identify fan motor terminals by color coding
o Identify fan motor terminals by using ohm meter
o Check the condition of fan motors
Materials, Tools and Equipment:
Materials:
o Fan motor - 1 pc
o Masking tape or other material which can
be used to tag the leads of fan motor
Equipment
o Ohm meter - 1 unit
* - Item is optional

Introduction:
Terminal leads of fan motors are identified by color-coding and by the resistances of the
windings. The colors of the terminal leads may fade, making them hard to identify. The
terminal leads may have to be identified by the resistances of the windings.
Steps in identifying the terminal leads of a 3-speed fan motor

using an ohm meter
1. Label the terminal leads from 1 to 5 as shown in Figure 1. Use a masking tape.
Figure 1.
TERMINAL RESISTANCE RANK

S (OHMS)
1 1&2
2. Make a table like the one 2 1&3
shown on the right to record 3 1&4
the resistances of the 4 1&5
different terminal lead 5 2&3
combinations. 6 2&4
7 2&5
8 3&4
9 3&5
10 4&5

3. Set the multimeter at R x 1. Measure and
record the resistances of the different
terminal lead. Use the table prepared in
Step 2.
NOTE:
Adjust first the VOM to zero reading before
taking any resistance reading.
Countercheck the values or resistances
(Figure 2).
Figure 2
4. Rank the readings from highest to lowest,

making the highest reading as rank 1 and
the lowest as rank. 10.
Figure 3 illustrates diagrammatically the windings of

a 3 -speed fan motor.
Figure 3: Windings of a 3-speed fan motor

Characteristics of the Windings
Terminal:
A and C - highest resistance
A and L - second to the highest
H and M - is equal to M and L
C and H - higher than H and M or M and L
5. The terminal lead found both on the highest (Rank 1) and second highest resistance
(Rank 2) is the auxiliary terminal lead.
NOTE:
If there is no terminal lead found on both the highest and second highest resistance,
check the values by measuring the resistance of the terminal leads again.
a. With the auxiliary terminal lead now identified, the other terminal lead on the highest
reading (Rank I) is the COMMON terminal lead.
b. The other terminal lead on the second to the highest reading (Rank 2) is the LOW
terminal lead.
6. Using the LOW terminal lead now as the reference terminal, measure the resistance of
the two remaining terminal leads.
a. The one with the higher resistance is the HIGH terminal lead.
b. The other unidentified terminal is the MEDIUM terminal lead.
7. Using now the LOW terminal lead as the reference point, measure the resistance of the
other terminal leads.
NOTE:
If the terminal leads are identified correctly, they must follow the table below.
Terminals
L and A - highest resistance
L and C - second highest resistance
L and H - second lowest resistance

L and M - lowest resistance
NOTE:
If the readings of the resistances do not follow the pattern above, repeat identifying the
terminal leads.
Procedure:
Identifying terminals
1. The color coding of five leads 3 speed is written below.
White wire = Common lead
2. Given a five lead out fan motor, identify the terminals using the color coding system.
3. Using a masking tape tagged the leads with their corresponding terminals.
4. Upon completion, have it check by trainer.

Information Sheet 5
Identifying Capacitors
Capacitors
Capacitor is an electrical storage device used in starting and/or running circuitry in

many applications of electric motor. It is used for adding additional current to create a strong
starting torque and at the same time use to reduce line current and improve the power factor
of the motor.
There are two types of capacitor, namely start capacitor and run capacitor. The
function of start capacitor is to provide out of phase starting current to the starting winding,
forcing the motor to operate as two phase motor during starting period. It is designed to give
extra starting torque to provide the motor high starting capability.
Starting Capacitor
A starting capacitor is manufactured using a high purity aluminum foils, separated by

chemically treated pure paper saturated with electrolyte for low power factor. It is provided
with an internal protection against vibration and covered with seal made up of rubber
phenolic laminated and has a positive pressure safety vent. It is finish with high impact
phenolic case. Starting capacitor storage is normally in cylindrical form and with black color
casing.
Starting Capacitor Running Capacitor

Run Capacitor
The primary function of running capacitor is used to reduce the line current while
greatly improving the torque characteristics of a motor. It reduces the line current of the
motor by improving the power factor of the load. It provides 90 electrical degrees phase
relationship between the capacitor current and voltage in conjunction with the motor windings
so that the motor will give two phase operation when connected to a single phase circuit.
The running capacitor is made up of finest dielectric paper and impregnated oil. It is
carefully process by vacuum heat treatment and then hermetically sealed in a sturdy metal
container, usually in oval form. This could be available either single or dual type.
Capacitor Replacement
The capacitor is rated in terms of ability to hold electric charge in micro farad (MFD or
µf). it is also specified in terms of maximum operating voltage. So when ordering capacitor
the MFD and the operating voltage should be carefully listed. For example 35 MFD/370 VAC
(Voltage Alternating Current). Several examples of capacitor applications are given in Table
1. These data are based on compressor manufacturer and are useful whenever you replace
capacitor.
Staring Capacitor Run Capacitor

HP Rating
MFD (µf)/VAC MFD (µf)/VAC
¼ 40/220
1/3 40-60/220
½ 40-60/220
3/8 40-60/220 8/440
¾ 40-60/220 10-15/440
1.0 60/220 15-20/440
1.25 80-120/220 20-25/440
1.5 80-120/220 25-30/440
2.0 80-120/220 30/440
2.25 80-120/220 35/440
NOTE: These data is based on Tecumseh compressor with
model series AE (1/4-3/4 hp), AJ (1.0-1.5 hp) and AH (2.0-2.25
hp).

Replacement of defective capacitor should of course be made by using the identical
data. Not necessarily the same brand, but replacement which has the same capacitance
rating with the voltage equal to or higher than the failed unit.
Any deviation from the original capacitance value should be avoided as this will alter
the operating characteristics of the motor and may results in early failure.
When required capacitance value is not available it is possible in an emergency to

connect several capacitors in series or in parallel to obtain the desired capacitance. This
implies to both start and run capacitors to provide the desired characteristics if the voltage
and microfarads are properly selected.
Capacitor Connections and its Characteristics
When capacitors are wired in parallel connection, the capacitance rating increases.
This will add the capacitance value by summing up each rating. Example; a 15 MFD is
connected in parallel with 30 MFD, the total capacitance will be 45 MFD. It is express in
mathematical formula as
Total capacitance in parallel = µf1 + µf2

60µf = 15µf + 45µf
For total capacitance in series, the formula would be:
µf1 x µf2
µft=
µf1 + µf2
For example, using the value of capacitor above if connected in series, the total
capacitance rating would be:
15µf x 45µf
µft=
15µf + 45µf

Self-Check 4
Test what you have learned about capacitors.
ESSAY:
Direction: Answer the following briefly
1. What is capacitor?
2. Differentiate running capacitor and starting capacitor.
3. What are the types of compressor motor connection using starting capacitor?
4. What are the types of compressor motor connection using running capacitor?
5. What are the two type of capacitor connection?

1. Capacitor is an electrical storage device used in starting and/or running circuit in

electric motors.
2. Starting capacitor is use in CSIR a CSCR compressor motor to give extra starting
torque for motor high starting capability while running capacitor is used in PSC and
CSCR for efficient compressor motor running operation. It also improves the torque
characteristics of a motor.
3. Running capacitor and starting capacitor
4. Types of compressor motor connection using starting capacitors are CSIR motor and
CSCR motor.
5. Types of compressor motor connection using running capacitors are PSC motor and
CSCR motor.
6. Type of capacitor connections are series connection and parallel connection.

Operation Sheet 8
Testing capacitor using ohmmeter (Running and

Starting Capacitor)
o Identify grounded, shorted, open and leaky capacitor.

o Discharge capacitor safely.
o Observe safety precautions in testing capacitor.
Equipment:
Materials:
o Running capacitor - 1 pc
o Starting capacitor 1 pc
Tools:
o Lineman’s pliers 1 pc
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Disconnect capacitor from the unit.
2. Discharge the capacitor by shorting the

terminals using a piece of wire.
Note: Capacitors must be
discharged before testing to
prevent damage to the meter.
3. Set the multimeter to Rx100 and

calibrate by adjusting the zero ohm
adjust knob
4. Connect the meter leads to the

capacitor terminals
Note: If the capacitor has
permanent bleed resistor
connected to the terminals,
disconnect at least one side of it.

5. Observe the deflection of the meter
pointer.
Good – the pointer deflects to a

certain resistance and then slowly
return to infinity.
Shorted – the pointer deflects to

zero and stays there.
Open – no deflection at all.

Leaky – the pointer deflects to zero,
return to a definite resistance and
stays there.
6. If the capacitor is defective, mark it

using permanent marker or a piece of
masking tape.

Job Sheet 3
Replace Capacitors
 Replace defective capacitor
 Follow safety practices in replacing defective capacitor
Equipment:
o Domestic Refrigeration/Air conditioning - 1 unit
Unit
Materials:
o Rag - 1 pc
o Wires - 1 pc
o terminal lugs - 1 pc
Tools:
o Lineman’s pliers - 1 pc
o Gloves - 1 pair
o Goggles - 1 pc
o Safety shoes - 1 pair

Procedures:
2. Disconnect power cord to electrical

power
3. Pull-out air-conditioning
unit/refrigerator
4. Disconnect capacitor’s electrical

connections and remove the defective
capacitor.
5. Install the new capacitor
6. Reconnect capacitor’s electrical

connections
Note: To tighten the terminal
lugs, press it with pliers at its side.
8. Connect the unit to electrical power
9. Place the ammeter probe to one line
of the power cord and check the
running amperage
10. Have the instructor check your work

11. Disconnect the unit from electrical
power
12. Reinstall the unit.

Information Sheet 6
Selector Switch
Selector switch is an electrical device fitted to the air-conditioning unit for switching
operation. It is capable of changing the air-conditioning operating function from a low cool to
fast cool.
A selector switch is either a push button switch, rotary shifting switch or electronic
selector switch. It is a combination of mechanical or electrical contacts that allows
compressor and fan motor to operate by connecting it to the source line.
The selector switch generally has three switching position namely, fan, low cool,
medium cool and high cool. It is capable of switching compressor and fan motor
simultaneously. It changes the fan motor operation without affecting the compressor. Below
is a chart which describes the operation of a selector switch:
Compressor Fan Motor

Switch Position
Motor High Terminal Med Terminal Low Terminal
Off 0 0 0 0
Fan 0 0 1 0
Low cool 1 0 0 1
Medium cool 1 0 1 0
High cool 1 1 0 0
Legend:
0 – OFF
1 - ON
As you can see, the compressor only turns ON at low cool, medium cool and high cool
settings while the fan motor turns ON at all setting except OFF. It only varies its speed in
accordance with the selector setting.

Operation Sheet 9
Checking Selector Switch
o Locate the terminal for common, compressor and fan speeds
terminals in the selector switch
o Check the condition of the selector switch
Materials Tools and Equipment:
Materials
o Selector switch (push button)
Equipment
o Multitester - 1 unit
Introduction:
Selector switch is a mechanical control intended to turn on the fan and compressor of
the air-conditioning unit. It is also the control for the different fan speed like low, medium and
high cool.
Defective switch may be mistaken as defective fan motor or defective compressor if

not checked properly. Below is the procedure in testing selector switch.
Procedure:
Table 1
Fan Motor
Switch Compressor
High Med Low
1. Analyze table 1. You will use this as Position Motor
Terminal Terminal Terminal
reference in checking the selector Off 0 0 0 0
switch. Fan 0 0 1 0
Low
1 0 0 1
cool
Medium
1 0 1 0
cool
High
1 1 0 0
cool
Common terminal is used as reference for this table.
Legend:
0 – Open contact
1 – Closed contact

2. Locate the common terminal of the
selector switch. Usually the common
terminal of the selector switch has the
label L1. If the label has been erased,
you can locate it by using an ohm
meter or continuity tester.
L1 label
The common terminal will be the
source line of compressor motor and
fan motor therefore it has a contact on
the compressor terminal, low cool
terminal when the selector is switched
to low cool mode; it has a contact on
the compressor and medium terminal
when the selector is switched to
medium cool mode; or it has a contact
on or high cool terminal every time the
switches are activated (see table 1 for
more information).
3. Switch the selector to OFF mode. Then

measure the continuity of the terminals
L1 - PL, L1 - 1, L1 - 4, L1 - 3 and L1 - 2.
Based from the chart on step 1, there is
no closed contact on any of the
terminals in reference with common
terminal when the selector is switched
to OFF mode.
Table 2
4. Turn the selector switch to fan mode. Is there a
Measure the continuity of all terminals Terminals connection?
in reference with the common terminal. Yes No
Answer the table. L1-PL
L1-1
L1-4
L1-3
L1-2

Table 3
Is there a
5. Turn the selector switch to low cool Terminals connection?
mode. Measure the continuity of all Yes No
terminals in reference with the common L1-PL
terminal. Answer the table. L1-1
L1-4
L1-3
L1-2
Table 4
Is there a
6. Turn the selector switch to medium cool Terminals connection?
L1-4
L1-3
L1-2
Table 5
Is there a
7. Turn the selector switch to high cool Terminals connection?
L1-4
L1-3
L1-2
Based on table 1. Analyze the result of
your measurement (see table 2-6)
The common terminal is the terminal
which have continues connection when the
selector is switched to low cool, medium
cool and high cool.
Low cool terminal is the terminal with
connection every time the selector is
switched to low cool.
Medium cool is the terminal with
switched to medium cool.
High cool is the terminal with
switched to high cool.

Information Sheet 7
Electrical Controls: Current and Potential Relays
1. As the motor runs, the control bulb is

cooled and the pressure in the bellows
is reduced. The reduction of pressure
allows the spring to push the bimetal in
opposite directions, snapping the switch
and stopping the motor. The control
bulb slowly warms up until the motor
starts again and the cycle is repeated.
Current relays and magnetic switches

are generally used on low torque
smaller (H.P.) motors. Shown below is
the diagram of a current relay switch. Relay – current type
Shown below is a diagram of current relay and magnetic switch connection.
Current Relay Connection

1. Current relay and magnetic switch are
normally open, as shown.
2. This normally open contact closes

immediately when the motor is energized
by the surge of current which occurs at the
time of starting (see illustration at right).
3. When the motor speeds up, the current drops and the magnetic coil which is in the main
winding circuit releases the movable contact, disconnecting the starting winding, as
shown.

4. POTENTIAL RELAYS are generally used on high torque capacitor motors. Shown below
is diagram of the parts of a potential relay.
Parts of Potential Relay
POTENTIAL RELAY CONNECTIONS
High starting torque motors 2 terminal overload potential relay

1. The contacts are normally closed, as
shown.
2. The coil is continuously connected to the

starting winding, as shown.
3. The coil opens the starting contact when a

predetermined voltage appears across it,
as shown.
4. The contacts remain open during normal

operation, due to the induced start winding
voltage, as shown.

5. Contact closes when the voltage across it
is cut or stopped.

Self-Check 5
Direction: Read the items carefully and answer each question correctly. Write only the letters
on the space provided.
_____ 1. The function of which is to disconnect the motor from the source when the motor
becomes overloaded
a. pressure control
b. thermostat
c. temperature control
d. overload protector
_____ 2. Which one is NOT an electric control?

a. float switches
b. relays
c. capacitor
d. thermostat
_____ 3. An automatic switching device that disconnects the starting winding after reaching
its three-fourth rated speed is called
a. relay
b. overload
c. thermostat
d. running capacitor
_____ 4. A relay generally used on low torque smaller H.P. motor.

a. potential
b. current
c. pilot
d. capacitor
_____ 5. A winding of the motor that is disconnected when the motor has reached its
equivalent value
a. running
b. common
c. starting
d. secondary

_____ 6. Current and potential relays have similarities except in
a. overload
b. compressor terminals
c. control
d. motor capacity
_____ 7. When the motor resumes its normal operation, this winding is the only one
connected to the circuit.
a. starting
b. running
c. secondary
d. common
_____ 8. A type of relay generally used on a high torque capacitor motor.
a. potential
b. current
c. pilot
d. hot wire

1. d
2. c
3. a
4. b
5. c
6. d
7. b
8. a

Operation Sheet 10
Checking Current Relay (Coil type)
o Identify defective relay contacts.

o Follow steps in checking current relays.
Equipment:
o Refrigeration Unit - 1 unit
Materials:
o Current relay, coil type - 1 pc
Tools:
o Multimeter - 1 unit
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.
2. Disconnect wiring connection of

current relay and remove it to from the
compressor.
3. Set the multimeter to Rx100 and

calibrate the meter through zero ohm
adjust knob.
4. Place the test prods of the meter to L

and M terminals of the current relay.
5. Hold the current relay in upside down

position.

pointer.
Note: If the ohmmeter reads

approximately 1 ohm, the relay is
good, if the pointer did not deflect,
the current relay is open.
7. Now place the test prods of the meter

to L and S terminals of the current
relay while the relay is in upside down
position
Note: If the pointer did not deflect,

the relay contact is open as it
should be, but if it has low
resistance reading, the contacts are
stuck-up and therefore defective.
8. Transfer the test prods on M and S

terminal. Still in upside down position.
Note: If the ohmmeter reads a low
resistance, the contacts are close
(good), but if the pointer did not
deflect, contacts are not closing
properly.

Operation Sheet 11
Checking Potential Relay (Voltage Relay)
o Identify defective potential relay using multimeter

o Follow steps in checking potential relay.
Equipment:
Materials:
o Potential Relay - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.
2. Disconnect wiring connection from potential

relay and remove it from the compressor.
3. Set the multimeter to Rx100 and calibrate

the meter through zero ohm adjust knob.
4. Place the test prods of the meter to #5 and

#2 terminals of the potential relay.
5. Observe the deflection of the meter pointer.

Note: If the ohmmeter reads a resistance,
the relay coil is good. If the pointer did
not deflect, the coil is open.
6. Now place the test prods of the meter to #1

and #2 terminals of the potential relay.
Note: If the ohmmeter reads a low
resistance, the contacts are close (good),
but if the pointer did not deflect, contacts
are open and it is defective.

Information Sheet 8
Overload Protector
INTRODUCTION
Overload protector is in series with the running and starting winding. Overload protector
allows an excessive current for a very short time (about 3 to 4 seconds - approximate time
for the motor to start. It will break the circuit of the high current flows lasts for any length of
time (5 seconds or more) As shown in figure below.
Wiring Diagram
A. External Overload Protector
An overload protector during normal and

overcurrent/over heating conditions.
Normal condition (contact close)

When there is a high rise in temperature,
copper expands more than steel, causing
warping (or bending) of the bimetal disc
which opens the overload contacts thus,
removing the motor from the circuit. When
the temperature goes down to normal
level, the bimetal disc returns to its normal
Over control/overheating
position and the contact points close.
(contacts open)
Overload protector on normal and
overheating or overheating position.

Basic Parts of an Overload Protector
1. Heater - safeguards the

compressor against the overcurrent.
It is in series with the contacts and
the motor windings. When the motor
is subjected to a sustained
overcurrent, the current through the
heater is high, and the temperature
of the heater increases. This heats
the bimetal disc.
Parts of an overload protector.
2. Bimetal disc and contacts
Safeguards the compressor motor

against overheating. The bimetal is
positioned beside the heater and this
senses the temperature change in the
heater and compressor dome (or
housing). It opens or closes the
contacts depending on the
temperature condition of the motor.
Overload Protection
3. Terminals and pin connector
- enable the overload protector to
be electrically connected to the circuit.
4. Case - holds the other parts in place.

Also makes the installation of the
overload protector possible.
B. Internal Overload Protector
Internal overload protector is mainly used

in hermetic motors. It is installed inside the
motor winding and protects the motor from
overheating. When the winding
temperature rises above safe limits, the
internal overload protector opens and
disconnects the motor windings from the
power source, preventing damage to the
motor.
Locations of internal overload protector

Internal overload protector
The contact points are made of fine silver for excellent conduction of current. The bimetal
strip (disc) responds to temperature in the motor windings and closes the circuit when the
temperature goes down to a safe value.

Self-Check 6
Overload Protectors
A. Without looking back on the previous pages, answer the following questions on a piece of
paper:
1. What are the functions of an overload protector?
2. How does a bimetal disc open or close the circuit?
3. What is the purpose of the heater?
4. Differentiate an external overload protector from an internal overload protector
B. Below are the parts and an illustration of an overload protector. Identify the parts by writing
the corresponding number of each part in the circle provided in the illustration. When you
have completed the activity. CALL YOUR INSTRUCTOR.
Parts of an Overload Protector
_______________ Case _______________ Bimetal disc

_______________ Terminals _______________ Contact
_______________ Pin Connector _______________ Heater

Operation Sheet 12
Checking Overload Protector
o Identify defective overload protector.
Equipment:
Materials:
o Overload protector - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.
2. Disconnect wiring connection from

overload protector and remove it from
the compressor.

the meter through zero ohm adjust
knob.
4. Place the test prods of the meter to 1

and 3 terminals of the OLP

pointer.
Note: Good – if it indicates low
resistance reading; Defective – no
deflection.

Information Sheet 9
Temperature Control Switch (Thermostat)
INTRODUCTION
Most refrigerator manufacturers design their units to operate only for 8 to 14 hours a
day. This is done by means of a thermostat temperature actuated control.
FOUR TYPES OF SENSING ELEMENTS OR BULBS USED IN A THERMOSTAT
1. Sensing element with gas charged

temperature bellows.
2. Vapor pressure temperature bellows.
3. Liquid charged temperature response

diaphragm.
4. Capillary tube coil used as bulb.
5. The capillary tube is the one that contacts the sensing element and the operating
mechanism.

6. Copper has a greater coefficient of expansion than iron. This bimetal strip will bend as
the temperature changes. The bending action of the bimetal will open and close the
contact point in an electrical circuit. You will observe that when the bimetal is heated, it
bends upward and when cooled, it bends downward.

FUNCTIONS OF A THERMOSTAT
1. It starts the compressor driving motor.
2. It stops the compressor driving motor.
PRINCIPLES OF OPERATION
1. Any change in temperature will be sensed

by the sensing bulb.

2. The bellows will expand or contract
3. The bellows will push the bimetal.
4. The contact will be closed.
5. When contact is made, the motor

compressor will run until such time that the
predetermined cooling temperature is
attained.

6. When the predetermined temperature is
attained, the sensing bulb senses the
temperature, the bellows contract, contact
is cut off and the compressor motor stops.
RANGE ADJUSTMENT
It is the difference between the cut-in and

cut-out temperatures.
Example: cut-in temp. = 30F

cut-out temp. 20F
The range is between 30F and 20F

limits.
DIFFERENTIAL ADJUSTMENT
It is the difference in cut-in and cut-out

temperatures.
Example: cut-in temp. = 30F

cut-out temp. = 20F
differential = 10F
METHODS OF ADJUSTING THE RANGE SETTING
1. Turning the range adjusting screw

clockwise increases the spring tension and
raises the cut-in and cut-out temperatures.

2. Turning the range adjusting screw
counterclockwise decreases the spring
tension and lowers the cut-in and cut-out
temperatures.
METHODS OF ADJUSTING THE DIFFERENTIAL ADJUSTMENT
1. Turning the differential adjusting screw

clockwise causes the limit bar to move
towards the screw head, thereby
increasing the travel of pin B in the slot.
This increases the differential by lowering
the cut-out temperature.
2. Turning the differential adjusting screw

counter clockwise raises the cut-out
temperature and reduces the differential.

Self-Check 7
MATCHING TYPE:
Direction: Matching type. Match column A with column B by writing the answer on the space
provided.
Column A Column B
______ 1. Sensing bulb a. part of a thermostat that gets in contact
with metal during an increase in
temperature
______ 2. Bellows b. part of thermostat that relays the

temperature to the bellows
______ 3. Bimetal c. it connects the sensing bulb and the

bellows.
______ 4. Copper d. a metal which has a greater coefficient

of expansion than iron
______ 5. Contact point e. the point where the flow is opened or

closed
______ 6. Evaporator f. part of the system where the sensing

bulb is mounted firmly
______ 7. Range adjustment g. the difference between cut-out and cut-

in temperature
______ 8. Differential adjustment h. change within limit
i. snap action

1. b
2. a
3. c
4. d
5. e
6. f
7. i
8. g

Operation Sheet 13
Checking Thermostat
o Identify defective thermostat

o Follow safety practices in checking thermostat.
Equipment:
o Refrigeration/Air conditioning Unit - 1 unit
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.
2. Disconnect wiring connection of the

thermostat and remove the thermostat
from the unit.

knob.
4. Place test probes across terminals of

thermostat
Note: The cord is good if there is
continuity. It is defective if the
pointer did not deflect.
5. Observe the meter reading;
Good: At OFF position there must

be no continuity between terminals.
At ON position, there must be
continuity between terminals.

Defective: At ON position, no
continuity. At OFF position, there is
continuity between terminals.
6. Check the refrigerant charge at the

capillary tube. To do this, prepare
water with ice in a small container.
Note: The container must be big
enough for the thermocouple to
submerge.
7. Turn the thermostat ON. Place the test

probes across the terminals of the
thermostat.
Note: There must be continuity
between terminals.
8. Submerge the thermocouple in the

container with water and ice. Wait for a
few moments.
Note: The thermostat must turn
OFF after few moments. If the
thermostat did not turn OFF, it is
defective.

Information Sheet 10
Defrost Timers
TECHNICAL INFORMATION:
The most common method of defrosting a refrigerating system is to turn the

system “OFF” until all the frost in the evaporator/freezer melts, after which it is turned
“ON” again manually.
In systems where automatic defrosting is required, a defrost timer is used to shut

the system down, and to start it again when the unit is defrosted. These timers defrost
the refrigerating system for a fixed period of time at regular intervals of 12 or 24 hours,
depending on the specific requirements of the unit.
Figure 1 shows a typical diagram of the electrical circuit used in an automatic defrost
refrigerator. During the defrosting process, the compressor is turned off and current flows
into the defrost heater which melts the frost.
Figures 2-A and 2-B show the commonly used defrost timers in refrigerators. Figure 2-C
illustrates the switching mechanism of a typical defrost timer. Defrost timers consists simply
of a synchronous motor driving a single-pole-double-throw switch (SPDT). The motor makes
one defrost cycle every 12 hours.

Figure 2-A. Parts of a defrost timer.
Figure 2-C. Symbol of the defrost timer shown in

Figures 2-A & 2-B.
Figure 2-B. Another form of defrost timer.
HOW THE DEFROST TIMER OPERATES
During the refrigeration cycle, the defrost timer switches the compressor ON and the
defrost heater is turned off (Figure 3). After a specific length of time, the defrost heater is
switched ON automatically, (see Figure 4). The defrost heater, which is attached to the
evaporators then melts all the frost. The timer stays in the defrost position from 12 to 30
minutes depending on the manufacturer’s specifications. After all the frost is melted, the
defrost heater is turned OFF and the compressor is again switched on.

Figure 3. Defrost timer in refrigeration position. Figure 4. Defrost timer in defrost position.
Another type of defrost timer is shown in Figure 5. The additional switch makes it possible
for the connection of other electrical components to be controlled by the defrost timer.
Figure 5. Defrost timer with switches.
EVAPORATOR FAN CONTROLLED BY THE DEFROST TIMER
Figure 6 illustrates the wiring diagram of a refrigerator using an evaporator fan. As shown,
the fan is controlled by the defrost timer. When the timer is in defrost mode, the compressor
and the evaporator fan are removed from the circuit. The defrost heater melts all the frost,
after which the compressor is in operation for 5 minutes. The fan is not activated immediately
so that it will not circulate the hot air generated by the defrost heater (see Figure 7-9 for
details).

Figure 6. Electrical circuit for delayed fan shut off during defrost.
Figure 7. Defrost timer in refrigeration position. Figure 8. Defrost timer at start of defrost cycle.
Figure 9. Defrost timer near end of defrost cycle.

Figure 10. Defrost timer which only shuts off the
refrigerating unit. No defrost heater used. (Timer
on defrost position)

The same defrost timer can be used for several types of defrost control arrangements.
Figures 10 - 13 illustrate these variations as used by different manufacturers of automatic
defrost refrigerators.
Figure 11. Defrost timer which turns on defrost Figure 12. Defrost timer which shuts off
heater as it shuts off the refrigerating unit. (Timer compressor and fan motor and turns on the defrost
on defrost position) heater. (Timer on defrost position)
In some refrigerators, the defrost timer

turns on a solenoid valve instead of a defrost
heater.
Figure 13. Defrost timer which shuts off the

compressor and fan motor and turns on two
defrost heaters. (Timer on defrost position)

Self-Check 8
Defrost Timers
Without looking back at the previous pages, answer the following questions briefly.
1. What is the use of the defrost timer?
2. Sketch the electrical diagram of a defrost timer controlling the compressor and a
defrost heater.

Operation of a Semi-Automatic Defrost Timer
Too much time and effort are usually spent manually in defrosting a refrigerator. To
defrost the refrigerator it is turned off and is turned on again when all the frost have melted
and removed from the evaporator.
However, semi-automatic defrost refrigerators are defrosted by manually starting the

defrost unit but will automatically run normally when all the frost have melted.
Figure 1 shows the wiring

diagram of a semi-automatic
defrost refrigerator. It has two
controls: the thermostat and the
defrost control.
- The thermostat controls

the operation of the
compressor motor.
- The defrost control

operates the solenoid
valve.
Figure 1. Wiring diagram of a semi-automatic defrost refrigerator.

During normal operation, no current flows to the
solenoid valve so the valve is closed. Figure 2 shows a
refrigeration cycle. The refrigerant flows to the
condenser, to the capillary tube, and then, to the
evaporator where it does some cooling.
During the defrosting period, the compressor

runs continuously.
Figure 2. Refrigerating in refrigeration

cycle (Solenoid valve is close)
To defrost the system, the defrost control

button is pressed. Current flows to the
solenoid valve so that the valve opens. Figure
3 shows the system in defrost position. The
refrigerant from the compressor now flows
directly to the evaporator. The hot refrigerant
from the compressor melts the frost on the
evaporator.
When all the frost are melted, the defrost

control automatically turns off the solenoid
valve. The refrigerant flows to the condenser.
The system is now in normal operation.
Figure 3. Refrigeration system in defrost

position (Refrigerant flows through the
tube with less resistance))
Figure 4 shows a thermostat and a defrost
control combined. The thermostat has its own
sensing bulb to control the compressor motor.
The defrost control also has its own sensing
bulb to control the solenoid valve. The sensing
bulb of the defrost control detects the
presence or absence of frost in the evaporator.
When the sensing bulb has detected that all

the frost are melted during the defrosting
period, it cuts the flow of current to the
solenoid valve.
Figure 4. When frost accumulates in the

evaporator again, press the push button to
defrost it. When all the frost are melted, the
refrigerator automatically operates
normally all over again.

Self-Check 9
Operation of a Semi-Automatic Defrost Timer
Without looking back at the previous pages, answer the following questions. Write the
letter only of the correct answer in a separate answer sheet.
1. To defrost a semi-automatic defrost refrigerator, one must:
a. turn off the thermostat
b. press the defrost button
c. remove/unplug the unit
d. leave the door open
2. The defrost control operates the:
a. cabinet light
b. compressor motor
c. solenoid valve
d. starting relay
3. During the defrosting period, the solenoid valves are
a. opened
b. closed
c. turned on
d. turned off
4. Circuit Diagram

Operation Sheet 14
Testing Defrost Timer
o Identify defective defrost timer.

o Follow steps in testing defrost timer.
Equipment:
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.
2. Disconnect all wiring connection from

the selector switch.

knob.
4. Place the test probes to terminal pin 1

and 3. This is the motor coil.
5. Observe the meter reading;

Good: If 1 and 3 terminals indicate
resistance reading, the motor coil is
intact.
Defective: Infinite reading

6. Test the contacts. Place the test
probes to terminal pin 1 and 4. There
must be continuity.
7. Turn the defrost timer knob counter

clockwise until clicking sound is heard.
8. The contacts 1 and 4 must be open at

this moment, contact between 1 and 2
will close. If this scenario did not
happen, the defrost timer is defective.

Job Sheet 4
Replace Defrost Timer
 Replace a defective defrost timer
 Follow safety practices in replacing defective components.
Equipment:
o Refrigerator unit - 1 unit
Materials:
o Rag - 1 pc
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Wear PPE
2. Disconnect electrical power to the

refrigerator.
3. Locate defrost timer at the back of

the unit.
4. Remove mounting screws to loosen

the timer.
5. Pull timer out enough to disconnect

the wires.

6. Disconnect wires from the timer.
Note: If necessary mark all
terminals by taping it with masking
tape before removing the wires.
7. Reconnect electrical wires and install

the new defrost timer.
8. Have your instructor check your

work.
9. Plug in refrigerator to electrical power

and check the amperage.
10. Have your instructor check your

work.

Operation Sheet 15
Test Air Swing Motor
o Identify defective air swing motor

o Follow steps in testing air swing motor.
Equipment:
o Air conditioning unit - 1 unit
Materials:
o Rag -
o Sand paper - 1 pc
o Pencil/ballpen - 1 pc
o Air swing motor - 1 pc
Tools:
o Philips screw driver - 1 pc
o Line man’s pliers - 1 pc
PPE:
o Goggles - 1 pc
o Gloves - 1 pair

Procedures:
1. Wear PPE
2. Unplug the unit
3. Disconnect wire terminals of air swing

motor from the unit.

the zero ohm adjust knob to ensure
accurate reading.
5. Test the resistance of the coil of air

swing motor.
Note: Good – has a resistance

reading; open – infinite; shorted –
zero ohm reading. Grounded if the
pointer deflects from one terminal
against the metal casing of the air
swing motor.

Job Sheet 5
Replace Air Swing Motor
 Replace defective air swing motor
 Follow steps in replacing defective air swing motor.
Equipment:
o Window Air Conditioning Unit - 1 unit
Materials:
o Rag - 1 pc
o sand paper - 1 pc
o pencil/ball pen - 1 pc
o Air swing motor 1 unit
Tools:
o Lineman’s pliers
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
2. Disconnect power cord to electrical

power
3. Remove the defective air swing motor
4. Install the new air swing motor to its

location

5. Reconnect the wire of the air swing
motor to the terminal marked for the
terminal
7. Connect the unit to electrical power
8. Place the ammeter probe to one line of

the power cord and check the running
amperage
9. Turn on the unit

Note: Unit should run normally
11. Disconnect the unit from electrical

power
12. Install the unit.

Operation Sheet 16
Checking Door Switch
o Identify defective door switch using multimeter.
Equipment:
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.
2. Disconnect wiring connection of air

swing switch.

knob.
4. Place the test prods across terminals

of the air swing switch.

pointer.
Note: Good – at ON position full
deflection, OFF position no
deflection; Defective –at ON
position, no deflection.

Operation Sheet 17
Checking Service Cord/Plug
o Identify defective service cord/plug using multimeter.

o Follow steps in checking service cord/plug.
Equipment:
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Unplug the unit.

knob.
3. Place one test prod to one terminal of

the plug and the other test prod to the
end point of the cord.
Note: The cord is good if there is

continuity. It is defective if the
pointer did not deflect.
4. Repeat step number 3 for the other

part of the cord

Operation Sheet 18
Continuity Test Air conditioning Unit (Power Cord)
o Troubleshoot the unit though continuity testing.

o Observe safety practices in troubleshooting the unit.
Equipment:
o Air conditioning unit - 1 unit
Procedures:
1. Unplug the unit

the zero ohm adjust knob to ensure
accurate reading.

3. Put the test prod to the power cord.
Note: be sure that the selector

switch of the unit is in off position
4. Switch the unit to the following

position;
Fan position
There must be a definite resistance
reading
Low cool
The resistance reading in this stage
must be lower than the resistance in
FAN POSITION
High cool
The resistance reading in this stage
must be lower than the reading in LOW
COOL

Off Position
The reading must be infinite
Note: For shorted wiring connection, the
pointer will deflect to zero. For
grounded, set the multimeter to
Rx10,000 and the pointer will indicate a
reading.

Oxyacetylene
One of the best methods of making leak proof connections while providing maximum
strength is to braze the joints. These joints are very strong and will stand up under the most
extreme temperature conditions.
Oxyacetylene brazing equipment is used to achieve maximum strength and a leak

proof joint. Oxyacetylene is the introduction of pure oxygen to acetylene. This combined
mixture produce very hot flame.
Correct use of oxyacetylene depends upon the technician constantly metering the flow
of oxygen and acetylene. The oxygen tank and the acetylene tank have pressure regulators
and a set of gauges. One gauge registers tank pressure, the other displays pressure of the
torch.
Acetylene is high flammable gas, especially when mixed with oxygen. Therefore,
safety glasses should always be worn when brazing. Never point the torch (lit and inlet)
towards an open flame or source of sparks. Light the torch only with a sparker- do not use
matches. The acetylene valve adjusts the needed flame size. Slowly turning the oxygen
valve will give required flame. A neutral flame has a blue cone with a bit of reddish purple at
the tip and is most efficient in brazing.

Parts of oxyacetylene equipment
 Cylinder or tanks- Contains pressurized gases required for any gas welding process.
They are strong metal containers specially designed to safety hold the particular gas
they contain.
o Fuel gas cylinder- this cylinder provides the fuel for the flame. The gas maybe
acetylene (Maroon cylinder) or liquefied petroleum gas (L.P.G.)
o The oxygen cylinder- to achieve a very high flame temperature, it is

necessary to mix pure oxygen with the fuel gas before it is burnt. The color for
the oxygen cylinder is black.

 Regulators- The function of the
regulator is to break down the high
pressure gas as it leaves the
cylinder so that it can be delivered
through the hoses to hand torch at
a safe manageable pressure
 The welding torch- A welding blow pipe consists of four parts each with their own
individual functions
Control valves: This control the
volume of each gas which is
delivered from the regulators to Welding tip
the welding tip
Hand piece: This is the actual

handle section of the blowpipe. Mixer
Mixer: This mixes the two gases

ready for burning at the welding
tip
Welding tip: This is the actual

burner of the blow pipe. It takes
the mixed fuel gas and oxygen Hand piece
from the mixer and passes it
through the correct sized hole for
the required flame size. There are
number of different tip sizes
available to given a selection of
flame sizes for welding brazing.
Control valve

Operation Sheet 19
Setting-up Oxyacetylene Equipment
o Set-up oxyacetylene equipment
o Practice safety precaution in setting-up oxyacetylene
Equipment
o Oxyacetylene equipment - 1 set
Introduction:
Oxyacetylene equipment is the primary equipment used in performing silver brazing. A

refrigeration and air conditioning technician should be able to handle this equipment properly
to ensure safe working environment and quality work. Setting-up is the first step that needs
to be done for this type of equipment. Below is a setting-up and shutting down procedure for
oxyacetylene equipment.
Procedure:
Before proceeding to activity proper, make sure that you wore the required personal
protective equipment for this task.
1. Crack the cylinder valves to blow any

foreign matter which may damage the
seats or block orifices

2. Connect regulator to the cylinder and
tighten the nut securely with a wrench
3. Connect the hose assembly to the

regulator and handle
4. Connect the correct size tip to the

handle. Tighten the lock nut finger
tight only
5. Open the tank valve ¼ turn. Use tank

key and leave it on the tank.

6. Setup the pressure adjusting screw
for the approximate pressure desired
7. Light the flame using flint lighter.

Make sure that the handle tip is not
pointing at flammable object or
person before lighting.
8. Adjust pressure valves to get the

desired flame.
Characteristics of flame
 Neutral flame- burns equal
amount of oxygen and gas is
used in welding steel, stainless
steel, cast iron, copper and
aluminum.
 Oxidizing flame is achieved by

burning an excess amount of
oxygen. The center blue cone
has a distinct point and
achieved by setting a neutral
flame, then reducing the
amount of acetylene. This
flame is used when welding
brass.

 Carburizing or reducing flame
is obtained by opening the
acetylene further than required
for neutral setting
9. To shut off the torch, close oxygen

valve in the blowpipe then close the
acetylene valve in the blowpipe.
10. Close the tank valve and open the

blowpipe valves to allow the gas to
drain out from the hose

Operation Sheet 20
Perform Brazing and Soldering
o perform brazing and soldering
o apply safety practices in brazing and soldering
Materials:
o Silver rods - 5 pcs
o Flux 1 qrt
o Wet cloth 1 pc
o Sand paper 1 sheet
o T Copper tubes 3/8 1 pc
o Copper tube 3/8 2 mtrs
Tools
o Pliers - 1 pc
o Steel brush - 1 pc
o Mallet - 1 pc
Equipment
o Oxyacetylene equipment - 1 set
o PPE - 1 set
Introduction:
Brazing is the method of joining metals with nonferrous (non-iron) filler using heat
between 800 °F (427 °C) and melting point of base metal.
Soldering is a method of joining two or more metals by adhesion of a metal with a

melting temperature of less than 800 °F (427 °C).
In modern times, most tube and fitting connections are made by either soldering or
brazing. Soldered joints are used for water pipes and drains. Brazed joints are used for
refrigerant pipes and tubing. The difference between soldering and brazing is the
temperature at which solder flows.

Solder joints used capillary action to draw molten solder into the area between fittings
and the tube. The selection of solder is based upon two factors: operating pressure and
temperature of the line. A 50/50 tin-lead solder is appropriate for moderate pressure and
temperature. It is a mixture of one-half tin and one half lead. It melts at 360°F (182 °C) and is
fluid at 415 °F (213 °C). For higher pressure or greater joint strength, 95/5 tin-antimony
solder is used. This mixture contains 95% tin and 5% antimony and is harder than 50/50
solder. A 95/5 solder melts at 450 °F and is fully liquid at 465 °F (241 °C).
In brazing, brazing filler metals are used to produce a stronger bond. They also have
the advantage of joining similar and dissimilar metals at low hazing temperature. Brazing
filler metals melt at temperature in range of 1000 °F (583 °C) and 1500 °F (816 °C). Brazing
filler metals used for joining copper tubing are of two categories; alloys containing 30-60%
silver, and copper alloys which contain phosphorus. These two classes vary in melting,
flowing and fluxing characteristics. Strength of brazed copper joint is not as dependent upon
choice of filler metals but depends upon proper clearance between the tube and the socket
of the fitting.
Recommended step by step procedure to follow soldering tubing

Procedure:
1. Cut the tube to length and remove

burr with file or scrape
2. Clean outside of tube with clean

sandpaper or sand cloth
3. Clean inside of fitting with a clean

wire brush, sand paper or sand cloth.
Do not use emery cloth

4. Apply flux thoroughly to outside of
tube then assemble tube and fitting
5. Apply heat with torch. When solder

melts upon contact with heated
fitting, the proper temperature for
soldering has been reached.
Remove flame and feed solder to the
joint at one or two points until a ring
of solder appears at the end of the
fitting.
6. Tap larger sized fitting with mallet

while soldering, to break surface
tension and to distribute solder
evenly in joint

Assignment Sheet 2
Soldering and Brazing Tube Fittings
Objectives:
At the end of this practice, the learner/trainee should be able to:
o perform brazing and soldering
o apply safety practices in brazing and soldering
2. After learning how to solder or braze tube fittings, you will perform soldering and
brazing on your own.
3. The purpose of this activity is to enhance your knowledge and skill in soldering and
brazing of tube fittings.
4. Your tasks are;
o Ask your trainer about common fittings which maybe soldered or brazed to
tubing.
o Based on the step by step procedures in soldering and brazing, solder/brazed
tube fittings
o After completion, let your trainer check your work.

Evaporator
The Evaporator is the part of the low-pressure side of the refrigeration and air
conditioning system in which the low-pressure liquid refrigerant boils and evaporates. Here
the liquid refrigerant picks-up (absorbs) heat from a cooling medium and changes it into gas
(evaporation). The evaporator is commonly called freezer coil, cooling coil, or chiller.
Two Main Types of Evaporator
1. Dry or direct expansion type

2. Flooded type
1. Dry or direct expansion evaporator

is not actually “dry” but has a
refrigerant control device that admits
only enough liquid refrigerants to be
completely evaporated by the time it
reaches the outlet of the coil. All the
refrigerants leave the coil in a dry state
or dry vapor. The feed for such
evaporator may be either at the top or
the bottom.
Direct or dry expansion evaporator
2. Flooded evaporator recirculates the

refrigerant by using surge chamber or
accumulator. The surge chamber is a
drum in which liquid enters from
metering device. The whole surface of
the evaporator coil is in contact with
the liquid refrigerant under all load
condition.
Flooded type

STATIC
Cold Plate
Fin Shell

EVAPORATOR LOCATION

Condenser
Refrigeration in real sense is simply moving heat from a place where it is not wanted
to a place where it is not objectionable. The condenser is a device used for removing heat
from the refrigeration system. It is a component which transfers the heat from the
refrigeration system to a medium which has lower temperature than refrigerant present in
condensers; it can absorb and move heat to an ultimate disposal point. The condenser is the
door opening provided to transfer unwanted heat out of the refrigeration system. Air and
water are the two basic media in which condensers could reject their heats. These two are
selected because they are usually available in sufficient quantities and are cheap. They are
also easy to handle and are not dangerous. Their normal temperature range is also
satisfactory for liquification of refrigerant.
TYPES OF CONDENSER
There are three types of condensers. The name of each type is determined by the
condensing medium. An air-cooled condenser uses air as the condensing medium; a water-
cooled condenser, water and the evaporative condenser both air and water.

CLASSIFICATION OF CONDENSER
STATIC

FORCED AIR

Identifying Cleaning and Rinsing Solvents
INTRODUCTION
A good cleaning material for refrigeration systems should be able to remove oil, grease and
sludge. The cleaning method to be followed must remove moisture and not injure the parts of
the unit or harm the user.
1. Cleaning and rinsing solvents come in

various kinds depending on the parts
to be cleaned or rinsed. The most
common ones are soap and water,
kerosene, gasoline and carbon
tetrachloride.
2. The refrigerator body and the

compressor housing may be cleaned
by scrubbing the surface using brush
and washing it with water.

3. Plastic parts should be cleaned gently
with soft bristles or cloth. Use water
mixed with a few milliliters of vinegar.
NOTE: Do not use gasoline or thinner in

cleaning plastics.
4. Soiled parts can easily be cleaned

using kerosene and rubbing the dirt off
with a brush. Corroded metal parts
may be cleaned using a rust converter
and a steel brush.
5. The inside of a compressor can easily

be cleaned using gasoline or
kerosene.
NOTE: When using gasoline, keep away

from open flame or sparks to avoid
explosion. Gasoline is highly flammable.

6. Evaporators and capillary tubes are
cleaned by using liquid carbon
tetrachloride. This may be bought from
local drugstores.
WARNING:
The American Standards Association

cautions that constant contact of this
substance with the skin may be toxic to
the user. (The threshold limit for carbon
tetrachloride is placed at 10 parts per
million at an eight-hour exposure time).
NOTE:
Carbon tetrachloride however, should

never be used in cleaning the refrigerator
or air-conditioning mechanism because it
is toxic and harmful to the skin and
respiratory system.
7. Most servicing centers recommend the

use of R-123 for flushing the system
contaminated by motor burn-outs
because it is non-toxic and non-
flammable. It does not also leave non-
condensable residues and has no
reaction to electrical insulation.
Container with R 123 Dichlorotrifluoroethane

8. Most of the oil from coated pieces is
removed by using solvents. They are
immersed into the solvent usually
mineral spirits placed in hooded and
vented containers.
9. To remove grease or lubricants made

from animal or vegetable oils, soak the
piece in alkaline solution so that the oil
will react with the alkali to form water
soluble soap compounds. This
process is called saponification.
10. If minerals cannot be removed by

saponification process, you may try
the emulsification process - the
process by which solid are melted by
mixing them with liquids.

11. The steam cleaning method may also
be tried. This is done by exposing the
piece to hot water or steam so that the
grease will turn into fluid and float to
the surface. Extra care should,
however, be taken so that the service
technician will not suffer from burns.
12. Caustic solution cleaning is done by

dissolving caustic solution in hot water
and rubbing the piece with the hot
solution to remove grease and oil.
13. Nowadays, there are several cleaning

fluids available in the market. When
using them read and follow the
manufacturer’s recommendations
carefully.

Self-Check 10
Identifying Cleaning and Rinsing Solvents
MATCHING TYPE:
Direction: Match column A with column B. Write the letter before each number.
Column A Column B
______ 1. Caustic solution cleaning a. carbon tetrachloride
______ 2. Steam cleaning b. for cleaning soiled pieces
______ 3. Solvent cleaning c. dissolving solids by mixing with

liquids
______ 4. Saponification d. soaking into alkaline solution
______ 5. Emulsification e. for flushing contaminated systems
______ 6. For cleaning evaporators and capillary f. for cleaning plastics

tubes
______ 7. Refrigerant 11 g. for cleaning body of refrigerator
______ 8. Water with vinegar h. for cleaning inside of compressor
______ 9. Kerosene i. for removing oil from coated pieces

by immersion
______ 10. Water j. removing grease and oil by
immersion in hot solution
k. exposing part to hot water or
steam to remove dirt
l. for cleaning body of refrigerator or
compressor

Job Sheet 6
Cleaning, Removing and/or Replacing the Evaporator
o Clean evaporator and heat exchanger surfaces

o Remove and repair evaporator
o Pressure wash a finned evaporator
o Straighten bent fins.
o Observe safety precautions in testing capacitor.
Equipment:
o Oxy-acetylene - 1 unit
o Leak tester - 1 unit
o Steam cleaner - 1 unit
Materials:
o Soap and water solution - 1 pc
o Brazing rod - 1 pc
o Sand paper (water proof) - 1 pc
o Clean rag - 1 pc
Tools:
o Paint brush - 1 pc
o Tube cutter - 1 pc
o Hacksaw - 1 pc
o Gloves - 1 pair
o Goggles - 1 pc

INTRODUCTION
The inside and outside surfaces of the evaporator must be kept clean for good heat
transfer. Air or water being cooled must flow in and out of the evaporator efficiently. See
illustration below.

CLEANING THE EVAPORATOR SURFACES
Procedures:
6. Brush off dust or foreign materials

with a paint brush, as shown.
7. Blow compressed air to the

evaporators to remove dust and
foreign materials.
8. Isolate the parts to be opened from

the rest of the system.

9. Using soap and water clean and dry
the joints to be opened.
10. As soon as the ends of the evaporator

tubing are opened, plug the openings
using wood or cork.
11. Polish the weld or clean the brazed

joint with sand paper.

12. Test for Leaks. If leak is detected,
repeat brazing again.
13. For aluminum evaporators, repair with

an aluminum solder, aluminum braze,
aluminum weld or a special epoxy.
- Locate the leak.

- If necessary, refer to the L.E. on
“Leak Testing”.
14. Recover the refrigerant. If necessary,

refer to the L.E. on “Evacuating or
Flushing the System”.

15. Clean the metal around the leak with
a cloth or brush.
16. Using a file/sandpaper, remove the

hard surface oxide.
17. Braze or weld the leak
NOTE: If necessary, refer to the

Learning Element on “Soldering and
Brazing”

joints using sandpaper.
19. Test for leaks. If a leak is detected,

repeat brazing again.

joints using sandpaper.

Job Sheet 7
Pressure Washing Finned Evaporator
 Clean finned evaporator using pressure washer
 Straighten bent fins
 Observe safety practices in cleaning finned evaporator using
pressure washer.
Equipment:
o Pressure Washer - 1 unit
Materials:
o Cleaning agents -
Tools:
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Dirt insulates the condenser, thus hampers

the heat transfer. The fins and coil of the
condenser must be clean so that the
airflow through the coils will not be
insulated from the fin or plate area and
there will be efficient transfer of heat.
- The finned condenser can be cleaned by

compressed air, nitrogen or carbon
dioxide. See figure below for equipment
to be used.
2. Set the pressure regulator of the

compressed air, nitrogen or carbon dioxide
at 6.90 kg/cm by turning the pressure
regulator valve handle clockwise, as shown
by the arrow in the picture.
3. Slowly work the spray up and down the

fins.
4. Direct the spray nozzle so that it is parallel

to the fins. Do not spray at an angle to the
fins because they could be bent and may
cause damage to the coil.

5. Bring the spray nozzle up in a vertical
angle with the fins and then cross about
2.54 cm. Bring the nozzle down and repeat
the up and down movement of the spray.
6. Keep repeating the spraying pattern until

the entire coil is covered.
7. If the compressed air, soap and water

spray fail to thoroughly clean the
evaporator, a portable steam cleaner may
be used. (See figure below.) The steam jet
should be sprayed with the same technique
as the compressed gas and soap and
water cleaning. The fins may be bent
slightly but they can be easily straightened
with wide-nosed pliers.
STEPS IN USING PORTABLE STEAM

CLEANER
1. Open gate valve of water source by turning

counter-clockwise, as shown.

2. Plug-in steam cleaner to run motor and
pump, as shown.
3. Position evaporator to be cleaned by

putting on top of 2 wooden blocks, as
shown.
4. Point the nozzle of the steam to the

evaporator and press the switch to bring
out the steam, as shown.

5. Slowly move the nozzle upward and
downward moving sideways to other fins
until all the evaporator area is cleaned.

Job Sheet 8
Straightening Bent Fins
 Observe safety practices in straightening bent fins.
Equipment:
o Evaporator 1 pc
Tools:
o Fin comb - 1 pc
o Gloves - 1 pair
o Goggles - 1 pc

Procedure:
1. Insert the wide nose pliers to the bend fins.
2. Press the wide nose pliers slightly until you

see that bends are already straight.
3. Repeat steps one and two until bent fins are

straightened.


Job Sheet 9
Cleaning Condenser
 Observe safety practices in straightening bent fins.
Equipment:
o Condenser - 1 pc
o Pressure washer - 1 unit
Materials:
o Cleaning agents
o Degreasing Solvent
Tools:
o Pail - 1 pc
o Fin comb - 1 pc
o
o Gloves - 1 pair
o Goggles - 1 pc

Procedures:
1. Remove air conditioner from the cabinet
Caution: Always ask for assistance when

lifting heavy objects
2. Set air conditioner close to the floor drain or

outside the room
3. Wrap the fan motor with plastic bag to avoid
water from getting inside the motor.
4. Remove the screws that hold the condenser
fan shroud.
5. Carefully swing the condenser out. Figure 1
6. Spray degreasing solvent onto condenser.
7. Allow solvent time to work.
(CAUTION: Do not swing the condenser out
far enough to avoid kinking or breaking the
refrigerator lines.)
8. Attach water hose to hydrant.
(NOTE: If using hot water, be sure the hose is

designed for use with hot water.)
9. Attach spray nozzle to water hose.
10. Spray condenser with water (Figure 2).
Figure 2
11. Tilt air conditioner sideways so that water will
run out.
12. Remove plastic bag from fan motor.
13. Dry all electrical components with a shop
towel.
14. Carefully move condenser back into proper
position.
15. Replace screws which hold the condenser to
the shroud.
16. Have instructor check your work
17. Replace air conditioner in cabinet.

Job Sheet 10
Determining Defective Compressor (Stuck-up and

Loss Compression)
 Determine the condition of the motor
 Identify defective compressor through pressure data.
 Follow steps in determining stuck-up compressor motor
 Observe safety practices in determining defective compressor.
Equipment:
o Refrigeration/Window type ACU - I unit
o Recovery/Recycling machine - I unit
o System analyzer - I unit
o Oxy-acetylene - I unit
Materials:
o Rags - 1 pc
o Sand paper - 1 pc
o Masking tape - 1 pc
Tools:
o Extension Cord - 1 pc
o Adjustable wrench - 1 pc
o Ammeter
o Gloves - 1 pair
o Goggles - 1 pc
o Safety shoes - 1 pc
Procedures:
1. Prepare all the necessary tools,

materials and equipment
2. Wear PPE
3. Recover/recycle refrigerant if
necessary.
4. Disconnect compressor motor from the
unit
5. Install process tube on both suction
and discharge lines.
6. Test and run the compressor for at

least 5 seconds.
7. Record data on discharge pressure

and amperage reading. The ampere
reading is below full ampere if the
motor is loss compression.
8. If the discharge pressure is less than

100 psig, the motor compressor is
defective (loss compression).
9. If the motor produces humming sounds

with high amperage reading and
probably the overload protector trips.
The compressor may be stuck-up.
10. Replace compressor.

Job Sheet 11
Determining Leaky Refrigeration/Air conditioning

System
 Find leaky part of the system
 Repair leak.
 Observe safety practices in determining defective compressor.
Equipment:
o Leak detector - I unit
Materials:
o Rags - 1 pc
o Sand paper - 1 pc
Tools:
o Ammeter
o Gloves - 1 pair
o Goggles - 1 pc
Procedures:

2. Wear PPE
3. Install system analyzer
4. Inject 150 psig nitrogen into the
system

5. Observe system analyzer, evaporator
coil, condenser coil and other piping.
6. If the low side pressure continues to

decrease, apply soap suds or use leak
detector to parts with suspected leaks.
7. Leaky system has less full ampere.
8. If leak found, rectify.

9. If the leak found cannot be repaired,
replace it with new one. (Example;
evaporator, piping lines, condenser
coil, metering device)
10. Service the system, then observe its
performance.

Job Sheet 12
Determining Clogged Refrigeration/Air conditioning

System
 Troubleshoot clogged accessories.
 Repair/Replace clogged accessories
 Observe safety practices in repairing clogged accessories.
Equipment:
o Leak detector - I unit
Materials:
o Rags - 1 pc
o Sand paper - 1 pc
Tools:
o Ammeter
o Gloves - 1 pair
o Goggles - 1 pc
Procedures:

2. Wear PPE
3. Tests run the unit.
4. Check for kinks in metering device.
5. Check for any frosting portion on the
inlet of the evaporator.
6. Check for sweating, frosting or cold
filter drier., filter drier should be warm
during normal operation
7. If leak found, rectify.
8. If clog found, recover/recycle the
refrigerant from the system and
replace the clogged accessories.
9. Pressurize the system with 150 psig
nitrogen and check for leak.
10. If no leaks, evacuate and charge the
system.
11. Observe the operation (record
operating pressures, temperatures and
ampere reading. Low side pressure is
vacuumed at 25 in Hg. and the high
side pressure is increasing.


PERFORM REFRIGERANT RECOVERY / RECYCLING AND RETROFITTING
/ CONVERSION ON DOMESTIC REFRIGERATION AND AIR CONDITIONING
Introduction
Recognizing the problems caused by ozone depletion makes everyone aware on the
importance of preventing ozone-depleting substances (ODS) emission to atmosphere. One-
way of doing this is through the use of recycling and recovery machine in the refrigeration and
air-conditioning (RAC) and mobile air-conditioning (MAC) industry.
Recovery and recycling is the heart of the refrigerant issue. We can reduce the need
to handle refrigerant by understanding the refrigeration theory, systems, applications and
good service practices, but we will have failed in our mission of reducing unnecessary
refrigerant releases if we don’t train every technician in the art of refrigerant handling.
This module covers the knowledge, skills, and attitudes in recovery and recycling of
refrigerants in refrigeration and air-conditioning system, and mobile refrigeration and air-
conditioning system. This also includes awareness in environmental protection and good
servicing practices.
Summary of Learning Outcomes
1. Recognize the importance of recovery/recycling of refrigerants
2. Set-up the recovery/recycling equipment
3. Perform recovery/recycling of refrigerants
Performance Criteria
After completion of the lessons in this module, the student must be able to:
• Explain the prevention of ozone layer depletion
• Explain the Montreal Protocol
• Discuss the effects of ODS emission
• Identify refrigerants using refrigerant identifier
• Identify accessories, parts and functions of recovery/recycling equipment
• Familiarize with the operations of recovery/recycling equipment in
accordance with manufacturer’s specifications
• Prepare tools, materials and instruments for recovery/recycling equipment
• Set-up recovery/recycling equipment in accordance with manufacturer’s
manual
• Perform recovery/recycling in accordance with manufacturer’s manual
• Recover 100% of the refrigerants from the system
• Recover refrigerant from the tank and must be labeled prior to recycling of
refrigerants
• Practice safety measures in recovery/recycling of refrigerant.
Conditions
The trainee must be provided with the following:
1. Learning Materials
• Module1: Recovery/Recycling
Refrigerants
• Service Manual
• PT Chart
• Video tapes:
• Payong ng Kalikasan
2. Training Facilities
• Computer
• TV Monitor
• VHS/VCD player
• Flip Chart
• Blackboard/Whiteboard
3. Equipment
• Recovery/recycling machine
• Weighing scale
• Actual equipment
• Vacuum pump
4. Instruments
• System analyzer
• Leak detector
• Refrigerant identifier
• Thermometer
5. Tools
• Spanner
• Ratchet/wrench
• Piercing valve
• Screw drivers
• Set of pliers

6. Personal protective equipment
• Apron
• Safety shoes
• Goggles
• Gloves
• Gas mask
7. Supplies and materials
• Refrigerants
• Teflon
• Madden rubber
• Soap solution
• Rags
• Bucket
• Pen/marker
Prerequisite
Before starting this module, you should have already completed the manual on:
• Code of Practice in Refrigeration and Air Conditioning
Reference
A. Books
• Good Practices in Refrigeration Training Manual. UNEP, December 1994
• Recovery and Recycling System: Guidelines, UNEP, 1999
•National Regulations and Import Licensing System for Phase-out of
Ozone Depleting Substances in the Philippine, Country Handbook, DENR
• Modern Refrigeration and Air-conditioning. Althouse/Turnquist/
Brancciano. Copyright 2002
B. Curriculum guides
• HVAC Competency Standard
• HVAC Competency-Based Curriculum
C. Manuals
• Service Manual
• Code of Practice in Refrigeration and Air Conditioining

The Importance of Recovery/Recycling of Refrigerants

I. How Refrigerants Affect Ozone Layer and Global Warming
Some refrigerants, especially

chlorofluorocarbons (CFCs), contribute to
the reduction of the earth’s ozone layer.
The ozone layer is a vital part of the earth’s
atmosphere and protect life from the
harmful effects of excessive ultraviolet
(UV) radiation, which come from the sun.
1. UV-B radiation -- On land, ultraviolet

radiation endangers all living forms. The
danger of Ultraviolet Radiation are:
• Harmful to human health
• Causes skin cancer
• Causes eye cataracts
• Suppresses man’s immune system
• Arrest the growth of crops and trees
• Practically destroy all life on earth

2. What is Ozone Layer?
Ozone layer is a thin, fragile shield of kind

oxygen in the stratosphere. It envelops the
entire earth and blocks off most of the
harmful UV rays from the sun from
reaching the earth’s surface.
3. What is “0zone hole”
Ozone hole refers to the loss of the

blocking effect of ozone against ultraviolet
rays. This is the consequence when the
ozone layer is severely depleted, in effect
allowing the entry of greater
concentrations of UV-B imperiling all living
things on earth.
Note:
Joe Farman, a British Antarctic survey

scientist, discovered the “ozone hole” over
the Antarctic area.
A similar “hole”, but not as damaging as

the one over the Antarctic, has been found
over the Arctic region.
The discovery of the ozone hole in

Antarctic shocked the world. It has come
to be regarded as one of this century’s
major environmental disaster.

4. What is ozone depletion?
Ozone depletion is the loss of the blocking

effect of the ozone layer against UV rays
from the sun. The continuous use of ozone
depleting substances(ODS) like CFC and
halons destroy the ozone layer.
These ozone depleting substances are

used in the wide range of household
and industrial uses as follows:
• As refrigerants for refrigerators and
airconditioners
• As blowing agents in the production of
foams
• As propellant in aerosol sprays
• As firefighting agent in fire
extinguishers
• As industrial solvent for cleaning and
dry cleaning
The ozone layer can be saved only by

stopping the use of CFC’s halons and
other ozone depleting substances:

OZONE DEPLETING SUBSTANCES
• Chloroflourocarbons (CFCs)
• Halons
• Hydrochloroflourocarbons (HCFCs)
• Other mine chemicals
• Methyl Bromide
Note:
Dubbed as a miracle chemical, CFCs
were utilized in many industries—first as the
working fluid for refrigerators; then propellants
in aerosol cans; and more recently as solvents
in computers where it cleans the delicate
circuit without the plastic mountings; or used
as blowing agent in foams for various uses
from buildings and cars to fast food containers
Where are CFC and halons used?.

• Aerosols used in sprays
• Refrigeration and air-conditioning
• Industrial Solvent
• Foam for insulation and padding
• Fire extinguishers
• Tobacco fluffing and expansion
• Semi-conductor and electronics
Note:
By 1994, refrigeration and air-
conditioning service industry as well as foam
manufacturing in the solvent sectors are the
only remaining users of CFC in the country.

5. What is Greenhouse Effect and Global
Warming— Another environmental effect
of refrigerants is their possible contribution
to globalwarming.The theory of global
warming states that, due to mankind’s
activities, the concentration of certain heat-
trapping gases is increasing in the
atmosphere. This is believed to be causing
the mean temperature of earth’s
atmosphere to increase slowly.
Refrigerants may contribute to global

warming by way of a phenomenon called
the greenhouse effect.
Although the greenhouse effect is essential

for life, enhance global warming may have
severe consequences. Some other effect
that have been speculated include:
• Rising mean level of the seas. It has
been predicted that increase
temperatures will cause some ice that
is currently stored (e.g., in glaciers)
above sea level, to melt and flow into
the oceans, raising sea level globally.
• Climate. Models that are currently
used give average global estimates.
But changes in temperatures, rain,
sunshine, etc., vary enormously from
one point to another.
• Harvests. The larger CO2
concentration could benefit harvests of
certain crops, but the uncertainty
regarding the regional climate changes
does not allow us to predict which crops
will be able to adapt to the changes in
each zone.
• Eco-systems. Local ecosystems are
very sensitive to changes in
temperature, precipitation and ground
humidity. The increase in CO2, favors
plant growth. Some plant species and
animals may disappear in certain
regions if they are unable to adapt to
the new conditions or to migrate fast
enough to more favorable ecosystems.
II. What is NCPP Phase-out Plan?

The Montreal Protocol on substances that
deplete the ozone layer is an agreement
among 129 countries, including the
Philippines, that limits the production,
application and use of the most common
ozone depleting substances, like CFCs
and provides for the phase-out of these
chemicals.
Under the Montreal Protocol, the

Philippines is committed to phase out the National CFC Phase-Out Plan
country’s CFC consumption by:
Year Percentage
2005 50%
2007 85%
2010 100%
Through the Philippine Ozone Desk

(POD) of the Environmental Department of
Management Bureau (EMB) the National Environment
CFC Phase Out Plan(NCPP) was and Natural
established. Resources
The NCPP aims to phase-out CFC in the Environmental

country as stipulated under the Montreal Management
Protocol without creating adverse effect Bureau
in the economy.
PHILIPPINE OZONE DESK

The focus of the NCPP is to phase out the
remaining CFC consumption in the country
specifically in the following sectors:
Manufacturing Sectors:
1. Foam manufacturers
2. Tear gas producers
3. Refrigeration equipment manufacturers
Service Sectors;
1. Mobile air conditioners
2. Domestic refrigeration and
air conditioners
In order to achieve this target, the DENR

in cooperation with TESDA will train/certify S
at least 5000 service technicians
nationwide in order for them to recover/
recycle refrigerants.
Republic Act No. 6969 otherwise known

as the “Toxic Substances and
Hazardous and Nuclear Waste Control
Act of 1990”. Its main objective is to
monitor, regulate and keep an inventory
of imported, manufactured, or used
chemicals that presents unreasonable risk
or injury to health or to environment in
accordance with the national policies and
international commitments.
Republic Act No. 8749, known as the

“Clean Air Act of 1999”, RA 8749 is
intended to formulate a holistic national
program on air pollution. DENR is the lead
agency but cooperates with other
government agencies as well as with
industry and related non-governmental
organizations. The Clean Air Act’s primary
focus is on ambient air quality but it is
applicable to all other pollutants including
ODS.

Self-Check 11

QUESTIONS Satisfactory
response
The student trainee should answer the following questions YES NO

1. Refrigerants are believed to contribute to two major global
environmental phenomena. Name them:
1.
2.
2. Describe two methods by which ozone is converted into oxygen.
1.
2.
3. Name some possible effects of ozone depletion.
4. What is the name of the international treaty, which controls the

production of certain refrigerants due to their ability to reduce the
ozone layer?
5. Define ozone layer?
The student’s underpinning knowledge was:

Satisfactory Not Satisfactory
Feedback to student/trainee:
Candidate Signature: Date:

Instructor Signature: Date:

1. Ozone depletion and global warming
2. Ozone is naturally converted to oxygen (and vice-versa) by the sun’s UV

rays. Also, chlorine and bromine can act as a catalyst in the presence of
UV rays, converting ozone to oxygen.
3. Increase in skin cancer and cataracts; impaired immune systems;

decrease crops yields; decreased phytoplankton growth.
4. Montreal Protocol
5. Ozone layer —is a thin, fragile shield of kind oxygen in the stratosphere. It
envelops the entire earth and blocks off most of the harmful UV rays from
the sun from reaching the earth’s surface.

Identify Refrigerants
I. Refrigerants
A refrigerant is a fluid (liquid and gas)
which transfer heat away from one point
to another. In a typical vapor compression
system, the refrigerant changes phase.
That is, it changes from a liquid to a gas
when it absorbs heat and changes back to Methane
a liquid when it gives up heat. Most
chemicals have the ability to change from
a liquid to a gas, but only a few chemicals
do so in a manner that makes them good
refrigerants.
Ethane
Most refrigerants used today for vapor
compression air conditioning are called
halocarbons. A halocarbon is a
hydrocarbon molecule containing one or
more halogens. The halogen elements
most commonly used in refrigerants are
chlorine (CI) and fluorine (F). Refrigerants
used in centrifugal chillers are halocarbons
based on methane, ethane and propane Propane
molecules.
• A halocarbon can contain chlorine and

fluorine in place of hydrogen, in which
case it is a chlorofluorocarbon (CFC):
CFC-11 CFC-12
• It can contain hydrogen in addition to
chlorine and fluorine, in which case it
is a hydrochlorofluorocarbon (HCFC).
HCFC-22 HCFC-123

• Or, it can contain only hydrogen and
fluorine (no chlorine), in which case it
is a hydro fluorocarbon (HFC)
HFC-32
HFC-134a
Refrigerant Nomenclature—single component refrigerants have an “R-” designation of

two or three numbers, which reflect its chemical composition.
• The first digit (of a refrigerants with three numbers) is one unit lower than the number
of carbon atoms, the first digit is omitted.
• The second digit is one unit greater than the number of hydrogen atoms in molecule.
• The third digit is equal to the number of fluorine atoms in the molecule.
One less than the number of carbon
atoms (i.e., there are 1 + 1 = 2 carbon
atoms)
More than the number of hydrogen atoms (i.e.
there are 3 - 1 = 2 hydrogen atoms)
Number of fluorine atoms (i.e. there are 4
fluorine atoms)
The ‘a” indicates an isomer (i.e. a different

R - 134a arrangement of the same atoms) of R - 134
Physical and Environment Properties of Some Common Refrigerants
Even small changes in the makeup of these refrigerants can make a large difference in
their physical and environmental properties as shown in table below:
Heat of
Boiling Atmospheric
Vaporization ODP GWP
Point (C o) Life (years)
(kJ/kg-mol)
R - 11 23.82 24768 1.000 3400 60

R - 12 -29.79 19982 1.000 7100 130
R - 22 -40.76 20207 0.055 1600 15
R - 123 27.87 26005 0.020 90 2
R - 134a -26.16 22160 0 1200 16

Health and safety consideration—
TOXICITY
Another consideration for an acceptable
refrigerants is its effect on human health Class A: refrigerants with low
and safety. Many chemical, including toxicity, with a weighted TLV over time
refrigerants, can be dangerous if used higher than 400 ppm. That is, only
improperly. Two important categories of concentrations over 400 ppm over
health and safety concerns are toxicity and sustained period of time are concern.
flammability. Most toxic and flammable
Class B: refrigerants with higher
refrigerants gives off pungent odor.
toxicity with a weighted TLV over time
lower than 400 ppm.
FLAMMABILITY
Group 1: No flammability
Group 2: Low flammability
Group 3: High flammability
1. Refrigerants are identified through a

consistent numbering system.
a. So me common CFC are:
• R-11 or CFC-11
• R-12 or CFC-12
• R-114 or CFC-114
• R-115 or CFC-115
b. Common HCFC’s include:
• R-22 or HCFC-22
• R-123 or HCFC-123
• R-124 or HCFC-124
c. HF C’ s include:
• R-134a or HFC-134a
• R-125 or HFC-125
• R-32 or HFC-32

d. Some non-halocarbon refrigerants
that have been used include:
• Ammonia (NH), 3
designated as R-
717
• Water (H 0),
2
designated as R-718
Propane (C3H8) designated as R-
290
 Isobutene (C4H10) designated as
R-600a
• Carbon Dioxide (CO 2), designated
as R-44
e. So me Common Refrigerants and
their Uses
• CFC-11 low pressure centrifugal
chillers; (also for foam blowing)
• CFC-12 high pressure centrifugal
chiller; domestic and commercial
refrigeration; automobiles
• HCFC-22 Unitary air conditioning;
mid-temperature refrigeration
• HCFC-124 low pressure centrifugal
chillers
• HFC-134a high pressure centrifugal
chillers;domestic and commercial
refrigeration;automobiles.
2. Standing Pressure
The temperature/pressure relationship

of refrigerants. The pressure exerted by
a refrigerant gas is related to the
temperature of the refrigerant. Using
gauge manifold, thermometer, and
pressure temperature chart, you can
identify an unknown refrigerant. With many
type of refrigerant at present, PT chart is
not as reliable as before in identifying
refrigerants as shown:

3. Color Code —Refrigerant manufacturers • R-11 Orange
have voluntarily established a color code • R-12 Grey/White
system to identify their products, with both
• R-22 Medium Green
disposable and reusable cylinders painted
or otherwise distinguished by the following • R-502 Orchid
common refrigerant colors and • R-500 Yellow R- 13 Pale Blue
identification: • R-503 Aquamarine
• R-114 Dark Blue
• R-113 Purple
• R-717 (NH3) Silver
4. Portable Refrigerant Identifier
The instrument is housed in a rugged

portable high-density polyethylene case.
The case will store the instrument itself as
well as required hose assemblies, power
cord and adapter fitting. This type of
refrigerant identifier can identify R-12, R-
22,R-134a HC and air.
5. Refrigerant Stamped on Data Plate

a. Ref r i ger a nt can be identified on
the back label of refrigerant unit

b. Stamped can also be found on
compressor label, or
c. On a soldered steel plate in the

Compressor.
6. TEV/TXV for specific refrigerant.

Identify Refrigerants Using Identifier
1. The Refrigerant Identifier
Sample Hose
Control Panel
Power Cord
Sample Inlet
Port
Air Intake Port

System Pressure Gauge
Sample Filter
Printer Port
Back View of the Identifier

Goggles
2. Tools and Personal Protective
Equipment needed when using refrigerant Gloves
identifier:
• Goggles
• Gloves
• Rachet wrench
• Adjustable wrench
Adjustable
Wrench
Rachet
Wrench
3. When using the identifier, the following should be considered:

• Always wear eye and skin protection when working with refrigerants.
• Always work in a well-ventilated area, avoid contact with refrigerant. It can cause
frostbite and blindness.
• If working with hydrocarbon, extreme care must be considered because of its
flammability.
4. Before proceeding in identifying refrigerant, the following should be considered:

• Always place the identifier on a flat and sturdy surface
• Do not utilize other hose than those supplied with the instrument
• Always verify that the refrigerant to be tested does not contain or will emit heavy loads
of oil or liquid
• Never admit any sample into the instrument in excess of 30 psig.
Pre-Operational Procedure
1. Open the case and inspect the sample filter for signs of red spots or discoloration
anywhere on the white outside diameter of the element. If any red spots or discoloration
are noticed, REPLACE THE FILTER BEFORE USING THE INSTRUMENT!
Warning: When red spots or discoloration begin to appear on the white outside diameter
of the filter element, THE FILTER MUST BE REPLACED. Failure to properly
maintain the sample filter may result in severe instrument damage that will
not be covered under warranty repairs.
2. Select the R12 or R13a sample hose for use in the specification. Inspect the hose for
signs of wear and as cracking, frying or kinks. Verify that the hose is not obstructed
and that no oil is present internal to the hose. If the hose shows signs of wear, obstruction
or oil IT MUST BE REPLACED (OR CLEANED) BEFORE USING THE INSTRUMENT!

3. Install the selected sample hose into the inlet of the instrument. The hose connector
needs only to be tightened to achieve a gas-tight seal.
4. Inspect the air intake port, sample exhaust port and case vent ports of the instrument
to verify they are clear and unobstructed.
5. Inspect the sample port of the refrigerant storage cylinder or vehicle air conditioning
system to be tested. Verify that the port is the LOW SIDE or VAPOR port.
Procedure:
Step 1. Plug the power cord of the instrument into a SUITABLE RECEPTACLE. The instrument
will display various parameters of the instrument and begin the warm up period.
During the warm up period the user has the option to enter the local elevation above sea
level into the instrument memory. The instrument is sensitive to elevation changes of 500
feet (152 meters) and the local elevation must be entered into the instrument memory
upon initial use. Normal barometric variations will not effect the performance of the
instrument. After the local elevation has been entered into the instrument memory there is
no need to enter it again unless the instrument is moved to a new elevation. To enter the
elevation into the memory, follow the procedure presented by the instrument display as
stated below:
a. During the warm up period depress and hold the “A” and “B” buttons simultaneously
until the display reads, ‘USAGE ELEVATION, 400 FEET”. This is the factory setting of
400 feet fee (122-meters) elevation.
b. Use the “A” and “B” buttons to adjust the elevation to the nearest 100-foot (30-meter)
increment. Pushing the “A” button will increase the elevation setting by 100-foot (30
meter) increments. Pressing the “B” button will decrease the elevation setting by 100-
foot (30 meter) increments. The setting is adjustable from 0-9000 feet (0-2743 meters)
and will be displayed while adjusting.
c. When the correct setting of local elevation has been achieved, allow the instrument to
sit for approximately 20 seconds while not pushing either of the buttons. The instrument
will automatically return to the warm up period and the elevation setting will be stored
in the memory.
Step 2: Calibration. A buzzing sound will be

heard during the self calibration of the
instrument. W hen it is already
calibrated the control panel display
reads “READY: CON. HOSE PRESS
A to START” as shown in the
illustration.

Step 2: Connect the sample hose to the vapor
port of the tank or unit and the other
end of the sample hose to the
identifier.
Note: When connecting the sample hose

to the cylinder and identifier, make
sure that it is finger tight only.
Sample hose connected to

the vapor port of the tank.
The other end of the sample

hose connected to the identifier.
Step 3: Open the cylinder slowly and allow

approx. 9-15 psi of refrigerant to enter
the instrument, then close the cylinder
and press “A” as indicated in the
control panel.
The instrument will read “SAMPLING

IN PROGRESS” while a small
refrigerant sample is analyzed to
determine the concentrations of R12,
R134a, R22, hydrocarbons and air.

Step 4: Check the type of refrigerant based
on the display result screen.
Note: In case error occurs, unplug and re-

plug the identifier to reset it.
Warning: Disconnect the service end of the

sample hose from the refrigerant
source immediately when so directed
by the instrument. The instrument is
not equipped with an automatic shut
off device and refrigerant will continue
to flow through the sample hose as
long as it is connected to the source.
Failure to immediately disconnect the
sample hose from the refrigerant
source when directed will result in
excess refrigerant loss to the
atmosphere.
Step 5: Unplug and return the instrument to

its proper arrangement.

Self-Check 12
response
The student trainee should answer the following questions YES NO

1. What is the family name for the common refrigerant based on
methane, ethane and propane?
2. What are the methods of identifying refrigerants?

1.
2.
3.
3. What is the best method of identifying refrigerants?
4. What is the cylinder color code for R-22?
5. What are the personal protective equipment required when using

refrigerant identifier?
The student’s underpinning knowledge was:

Candidate Signature: Date:

Instructor Signature: Date:

Part II : Part of portable identifier:
Instructions: Identify the different parts of the refrigerant identifier. Write your answer
on the numbered blank lines below.
7
1
6
2
5
3
4
1. 5.
2. 6.
3. 7.
4. 8.

Part I.
1. Halocarbons
2. Different methods of identifying refrigerants
• Refrigerants stamped on unit data plate
• TEV for specific refrigerant (Thermostatic Expansion Valve)
• Standing pressure
• Refrigerant identifier
3. Use refrigerant identifier
4. Medium Green
5. Gloves and goggles
Part II.
1. Power cord
2. Air intake port
3. Sample filter
4. Printer port
5. Sample hoses
6. Control panel
7. Sample inlet port
8. System pressure gauges

Job Sheet 13
Identify Refrigerant Using Identifier
Equipment/Instrument: Tools:
• Refrigerant identifier • Service valve ratchet wrench
• System analyzer • Tap line valve
Materials:
• Unlabeled refrigerant tank with content Safety Protective Devices:
• Labeled Refrigerant tank with content • Gloves
• Goggles
• Safety clothes
Ob servatio n
Pro ced u re Ch ecklist
Yes No N/A
1. Prepare identifier. (Set up instrument correctly)
2. Apply safety measure (Safety measure were applied)
3. Warming up and calibrate
4. Connect the sample to the vapor port of the tank or unit.
5. Open the cylinder slowly and allow approx. 9 - 15 psi of

refrigerant to enter the instrument.
6. Close the cylinder and press "A" as indicated in the control

panel.
7. Check the type of refrigerant based on the display result

screen.
8. Unplug and return the instrument to its proper arrangement.

Job Sheet 13
Identify Refrigerant Using Pressure

Temperature Method
Equipment/Instrument: Materials:
• System analyzer • Unlabeled refrigerant tank with content
• Labeled Refrigerant tank with content
Tools:
• PT Chart
• Service valve ratchet wrench
• Tap line valve Safety Protective Devices:
• Adjustable wrench • Gloves
• Goggles
• Safety clothes
Observatio n
Proced u re Ch ecklist
Yes No N/A
1. Instruments, materials were prepared in accordance with job

requirements (Set up instrument correctly)
2. Apply safety measure (Safety measure were applied)
3. Gauge manifold was connected to the refrigerant cylinder

correctly
4. Ambient temperature was taken using thermometer(
Refrigerant was identified correctly according to pressure and
temperature chart)

Set up Recovery/Recycling System
I. Good Service Practices
1. The following list of service practices may be helpful in establishing your own service
practices:
DO:
• Think CFC conservation and safety
• Follow and use recommended procedures and equipment for handling
refrigerants.
• Replace, tighten, and seal caps on all valves after servicing.
• Shut down system and make repairs when leaks exist.
• Use close loop refrigerant transfer equipment when removing, charging,
and storing refrigerants.
• Recover vapor and liquid refrigerant from charging hoses.
• Maintain refrigerant use logs for all equipment.
• Leak tests all charging hoses and refrigerant handling equipment.
• Install service isolation valves to limit refrigerant losses during servicing
and purge operation.
• Eliminate unnecessary mechanical joints. Use welded or brazed joints.
• Establish proper leak testing routine.
• Follow the published leak test procedures.
• Use industry-accepted tools/equipment for leak testing.
• Confirm overall leak tightness by using a standing vacuum test.
• After major service, evacuate and dehydrate to a minimum 757 mm using a
deep vacuum or triple evacuating method.
• Use only approved cylinder/drums/tank for storing refrigerant.
• Install charging valve quick connects.
• Recover all refrigerants for recycling/reclaiming.
• Use non-CFC gas as tracer gas when conducting leak tests.
• Add refrigerant carefully to avoid overcharging.
• Dispose used refrigerant container properly.
DON’T • Use refrigerants as cleaning solvent.

• Open the refrigerant side of system unless absolutely necessary.
• Use CFC for leak testing.
• Operate equipment with Vent/blow off (noncondensable

• gasses/refrigerant) to the atmosphere.
• Blow off refrigerant “empty” tanks, drum, or containers.
• Throw away any refrigerant.
• Contaminate recovered refrigerants with other refrigerants, solvents, oils, or
other materials.
• Exceed manufacturer’s recommend pressure when leak testing.
• Overfill refrigerant containers, tank, drum, recovery units, and receivers.
Etc.
• Refill disposable cylinders.
• Substitute alternative refrigerants into old system without approval.
II. Recovery/Recycling Equipment

1. Two types of recycling equipment are on the market. The first is referred to as single pass.
The other is a multiple pass.
Control
A/C System
Condenser
Evaporator
Multiple pass

Control
A/C System Condenser
Evaporator
Single pass
2. Typical equipment available in the market

in the Philippines is as shown
• Recovery/recycling machine—this type
of machine can service both the
refrigeration and airconditioning and
mobile air-conditioning equipment.
• Recovery/recycling machine for

domestic refrigeration and mobile air-
conditioning. It can onlybe used for R-
12 running equipment.

III. Identifying Recovery/Recycling Equipment Parts and Functions
1. Part of a typical recovery/recycling equipment is as shown:
Pressure Gauge Oil Outlet Port

Oil Inlet Port
Recovery Tank
Refrigerant Inlet Port
Refrigerant Outlet Port
2. Major parts and functions:
• Pressure gauges — indicators of refrigerant pressure from the unit and to the recovery
tank.
• Recovery tank — a cylinder for recovery/recycling of refrigerants.
• Oil outlet port— is where foreign particles and acids are drained out
• Oil inlet port -- is where refrigerant oil is pumped in to add the lubricants of the
compressor.
• Refrigerant inlet port -- is where the refrigerants passes from the refrigeration and
air-conditioning equipment being recovered.
• Refrigerant outlet port -- is where refrigerants comes out from the refrigeration and
air-conditioning equipment being recovered.
IV. Prepare the right tools, supplies and materials

When setting recovery/recycling equipment you must prepare the following tools,
supplies and materials, instrument:
1. Safety protective devices

• Gloves
• Goggles

2. Hand tools
• Ratchet wrench
3. Supplies and materials

• Rugs
• Tape
• Pen
4. Instruments
• Gauge manifold
• Weight scale
• Thermometer
V. General procedure in setting recovery/recycling equipment

1. Procedure:
• Prepare required materials, equipment,
tools and personal protective
equipment.
• Ask for Manufacturer’s Manual of a
recovery/recycling machine.
• Evacuate recovery/recycling machine
• Evacuate recovery tank
• Connect recovery/recycling machine to
the unit to be recovered
• Perform housekeeping

2. Shown below is the recovery/recycling equipment connected to a refrigeration unit.
Refrigeration
System
Recovery/Recycling
Equipment
Recovery
Cylinder
V. Procedure in setting recovery/recycling equipment
1. Prepare required materials, equipment,

tools and personal protective
equipment.
Gloves
Goggles
Adjustable Wrench Adjustable Wrench

2. Evacuate recovery/recycling machine
Getting Started Recovery/Recycling Machine

• Make sure recovery/recycling machine Pressure Gauge
is connected to proper voltage.
• Hook vacuum pump to both inlet end
outlet fitting of recovery/recycling
machine and pull a vacuum for
approximate 5-7 minutes. Make sure
that the inlet and outlet valve are open.
The center switch must be in the pump
out position.
Vacuum Pump
Pressure Gauge
• After evacuation of the recovery/
recycling machine, close inlet and
outlet valves, unplug the machine and
place the center switch to recycle
position.
3. Evacuate recovery tank

• Evacuate the recovery tank for 5
minutes by connecting a vacuum pump
to the vapor and liquid valve of the
cylinder.
• The recovery tank is now ready to
accept refrigerants.
• Turn off machine
• Clean machine
• Return tools, instruments and supplies
to proper place.

Set up Recovery/Recycling Equipment
response
The student/trainee should answ er the follow ing questions YES NO
1. Before operating any equipment a new technicians must first read the
Manufacturer's Manual. Why?
2. Identify at least two types of recovery/recycling equipment
3. Before set-up of equipment, it is good practice to prepare the right

tools, supplies and materials needed, instruments requirement. List the
most important tools, supplies, materials and instruments.
4. Enumerate at least three good service practices.
5. Enumerate at least three don'ts in good service practices.
The student's underpinning know ledge w as:

Candidate Siganture: Date:
Instructor's Signature: Date:

Identify Parts of Recovery/Recycle Equipment and
Accessories
Instructions: Label the illustration below by writing the right description of the parts
numbered blank space.
Part II : Part of recovery/recycling equipment
1 3
2
5
1. 4.
2. 5.
3. 6.

Identify Parts of Recovery/Recycle Equipment and
Accessories
Part I.
1 Specific technical instructions, setting guide, on how to use the equipment can be
found in the manual. Therefore it is a good practice that before operating a machine
one has to read the manual.
2 Types of recovery/recycling equipment:
• Multiple-pass
• Single-pass
3 Tools, supplies and materials, instruments:
Tools:
• Valve key/service wrench
• Tap line valve/piercing valve
• Goggles
• Gloves
• Safety shoes
• Working clothes
Instrument:
• Gauge manifold
• Electronic weighing scale
• Electronic leak detector
4. Good practices (at leat 3 items)
• Shut down system and make repairs when leaks exist.
• Use close loop refrigerant transfer equipment when removing, charging,
and storing refrigerants.
• Recover vapor and liquid refrigerant from charging hoses.
• Maintain refrigerant use logs for all equipment.
5. Don’ts in good safety practices (at least 3 items)
• Use CFC as tracer gas for leak testing.
• Operate equipment with leaks.
• Refill disposable cylinder.
• Vent/blow off air (non-condensable gasses/refrigerant) to the atmosphere.

Part II
1. Pressure gauges
2. Recovery Tank
3. Oil outlet port
4. Oil inlet port
5. Refrigerant inlet port
6. Refrigerant outlet port

Set up Recovery/Recycling Machine
A. Equipment: C. Tools:
• Vacuum pump • Valve key/service wrench
• Recovery & recycling machine set • Tap line valve/piercing valve
• Recovery tank
D. Personal Protective Equipment:
• Refrigerant tank
• Goggles
B. Instrument: • Gloves
• Gauge manifold • Safety shoes
• Electronic weighing scale • Working clothes
Ob servatio n
Pro ced u re:
Ch ecklist
YES NO N/A
1. Ask for Manufacturer's Manual of a recovery/recycling machine
2. Prepare required materials, equipment, tool and personal protective

equipment.
3. Evacuate recovery/recycling machine
4. Evacuate recovery tank
5. Connect recovery/recycling machine to the unit to be recovered
6. Apply safety measure

Application of Recovery/Recycling
I. Recover/recycling refrigerant of different systems
1. Recover/Recycling Refrigerant from a Refrigeration and Window Type Air-

conditioning Unit. It is possible to recover refrigerant from a hermetically sealed system,
which has no service valves. A line-tap valve (piercing valve) should be fitted to the system.
Procedure:
• Following the manufacturer’s instructions, and a recovery unit used to remove the
refrigerant from the unit via the line-tap as with the larger system.
• Line-tap valves should never be lea permanently in place, but removed after use if
placed on the process tube.
• It is recommended to install tap-valves on both high and low pressure side.
Note: Figure below shows a recovery unit is connected to a refrigerator with a typical
tap-valve (piercing valve). Because of the small charge of refrigerant, only vapor
recovery is needed.
Piercing
Tube
Evaporator
Valve Core
Nut
Pierced
Tube
Condenser
Refrigerant
Outlet Port
Recovery/
Recycling
Recovery Machine
Tank
Compressor
Scale
Refrigerant
Inlet Port

2. Recover from air-conditioning system(Liquid transfer)
Procedure
• Discharge side recovery unit to the suction pipe on the air-conditioning system
If there are available valves on the systems receiver (high pressure side) the recovery
discharge side could be connected here as well. Liquid flows now from the liquid side
of the air-conditioning system and into the cylinder.
• The recovery unit will keep the pressure inside the cylinder lower than in the air-
conditioning system and keep up the liquid flow.
Figure below shows a typical condensing unit for air-conditioning installations
OUT

Perform Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine
Equipment: 4. uncoded tank/cylinder
1. refrigerant identifier 5. thermometer
2. refrigerant 6. PT chart
3. unlabeled tank/cylinder 7. Operator Manual
CAUTION: Never mix refrigerants. Be sure unit is set up for the refrigerant you are
about to recover.
WARNING: Use only authorized refillable refrigerant tanks. Use of other tanks could
cause personal injury and void the warranty.
Getting started:
1 Make sure that the R/R machine is connected to proper voltage.

2 Hook the vacuum pump to both inlet and outlet fitting of R/R machine and pull a vacuum
for approximately 5-7 minutes. Make sure that the inlet and outlet valves are open. The
center switch must be in the pump out position.
3 After the evacuation of the R/R machine, unplug the machine and place the center
switch to recycle position and close inlet and outlet valves.
4 Evacuate the recovery tank for 5 minutes by hooking a vacuum pump to the vapor and
liquid valves of the cylinder.
5 The R/R machine and recovery tank is now ready to accept refrigerant.
Note: Always evacuate R/R machine and recovery tank if you will recover/recycle
another type of refrigerant
Operational procedure:
1 Plug in R/R machine to proper to proper voltage.
2 Connect hose to inlet valve of the machine and the other end to the source. Use a
gauge at the source as this will show when source is empty.
3 Attach the yellow cable to recovery tank. Connect other hose to outlet valve of the R/R
machine and the other end of the hose to the vapor port of the recovery tank.
4 Turn compressor and recycle switch on and open inlet valve half turn. If recycling
liquid regulate suction gauge pressure to 20-25 psi for 2-3 minutes, open the inlet
valve fully.
5 Open outlet valve of R/R machine. Open vapor valve of recovery tank.

6 When source is empty of liquid, turn vapor switch on. Leave on until source and R/R
machine have equalized at 3-4 psi.
7 When equalized, turn vapor switch off and unit will pump down to approximately 5"
vacuum. If additional vacuum is required, use the compressor momentary contact.
8 Pump out to clear unit by closing inlet valve, center switch to pump out and vapor
switch on and outlet valve open. Unit will pump down to 5" vacuum and shut off.
9 Turn compressor off and use the compressor momentary switch to pull R/R machine
into 10" vacuum.
10 Close the outlet valve, put center switch to recycle and turn vapor switch on. Unit will
equalize. If positive pressure remains after equalize, repeat pump out procedure.
Perform oil out procedure:

The oil out procedure is very important. By performing oil out frequently, you will keep
the separated oil below the level of the chamber entry point and assure that the oil/moisture
will be purged out of the R/R machine.
1. Close inlet valve and let machine pump down and shut off.
2. Turn compressor switch off and by using the recycle/pump out switch, add 2-3 psi to
suction gauge. Do this by flipping switch to pump out position and returning to recycle
position.
3. Put a container under the oil out valve and slowly open valve.
4. When oil stops draining, close the oil out valve.

Method of Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine
Liquid Recovery Method
ALTERNATIVE CONNECTION
FOR “PUSH - PULL”
OUT

OUT

Troubleshooting Guide: Recovery Operation
SYMPTOM CAUSE REMEDY
1. Recovery compressor • Power cord not plugged • Plug in cord, check circuit
does not start in or no power at plug for power
Recycle switch is on or
• Be sure recycle switch is
main power switch is off
off and main power is on
• Tank full light is on • Change tank

• Recalibrate weight
platform
• High pressure light is on
• Check valves on tank to
• Bad components—start be sure they are open
switch, relay,
compressor, etc. • Check scale calibration
• Call factory
2. Runs a short time, but • Tank valves not open • Open both tank valves
does not complete
recovery • Low oil level in • Call factory
compressor
• Bad components, • Call factory
compressor, relay, etc.
3. Runs but won’t shut • Leak In vehicle system • Pressure must be present
off in manifold gauges before
starting recovery
• Oil drain valve not operation
closed
• Bad components, • Close both valves
vacuum switch, etc.
• Call factory

RECYCLING OPERATION
SYMPTOM CAUSE REMEDY
1. Refrigerant pump • Power cord not plugged • Plug in cord, check circuit
does not appear to in or no power at plug for power
be running
• Main power switch off • Turn on
• Tank valves not open • Open valves
• Faulty components, • Call factory
pump, switch, etc.
2. Bubbles will not clear • Tank valves not open • Open valves
in moisture indicator • Not enough refrigerant • Recover more refrigerant
in tank—must have 15 before recycling
Ibs. minimum
3. Moisture indicator wilt • Wet or plugged filter • Remove and replace filter
not turn green after 3 cartridge cartridge. Be sure to pull
hours of recycling a vacuum
• Not enough refrigerant
in tank—must have 15 • Recover more refrigerant
Ibs. minimum before recycling
• Faulty moisture • Remove and replace
indicator moisture indicator

Troubleshooting (VAN Steenburg Recycling Machine)
PROBLEM SOLUTION
1. Unit won’t accept refrigerant • Check inlet ball valve

• Check that cable is attached to recycle
cylinder
• Make sure recycle cylinder is not full
• Check valves in hoses
2. System “Pulls Slowly” • Checked to ensure you are hooked to

liquid side of source
• Low ambient temperature, apply heat
to source
• Check hoses for restrictions
• Connecting hose to source to long
3. Oil in lines • Oil out operation has not been

completed on a regular basis.
Separator chamber is full and oil has
migrated though system

Recovery/Recycle Refrigerant Using Van Steenburgh
Recycling Machine in Domestic Refrigeration and
Window Air Conditioner
I. Equipment, instruments, tools and material needed.
1. Equipment: 3. Tools:
• Domestic refrigeration unit • Tap line valve/piercing valve
• Window air-conditioning unit • Access valve
• VS recovery machine (VS-220) • Tubing tools
• Vacuum pump
4. Materials:
• Oxy acetylene equipment
• Appropriate refrigerant cylinder
2. Instruments: • Appropriate recovery tank

• Weighing scale
• Gauge manifold
Observation
A. Recovery and Recycling Procedures: Checklist
YES NO N/A
1. Prepare the required materials, equipment, instruments, tools
and personal protective equipment.
2. Set-up recovery and recycling machine
Note: Pls. Refer manual of recovery and recycling machine.
3. Connect recycler to proper voltage
4. Attach hose to ¼” flare fitting labeled inlet.
5. Attach other end to the source and purge. Note: Use a gauge
at the source as this will show when source is empty.
6. Attach cable to recycle cylinder and one end of hose to ¼” flare
fitting labeled outlet. Attach other end of hose to vapor part on
cylinder.

Observation
A. Recovery and Recycling Procedures: Checklist
YES NO N/A
7. Attach cable to recycle cylinder and one end of hose to ¼” flare
fitting labeled outlet. Attach other end of hose to vapor part on
cylinder.
8. Turn compressor switch and recycle switch on and open inlet
valve. If recycling liquid regulate suction gauge pressure to 20-
25 psi, 2-3 minutes before opening the valve fully.
9. Open outlet valve and purge hose. Open vapor valve on
recycle cylinder.
10. When source is empty of liquid, turn vapor switch on. Note:
Leave on until source and recycler have equalized at 3-4 psi.
11. When equalized turn vapor switch off and unit will pump down
to approximately 5” vacuum. If additional vacuum is required
use the compressor momentary switch.
12. Pump out to clear unit by closing inlet valve, counter switch to
pump out and vapor switch on and outlet valve open. Note:
Unit will pump down to 5” vacuum and shut-off.
13. Turn compressor off and use the compressor momentary
switch to pull recycler into 10” vacuum.
14. Then close outlet valve, put center switch to recycle and turn
vapor switch on. Unit will then equalize.
Note: If positive pressures remains after equalize repeat pump out
procedure.
15. Then close outlet valve, put center switch to recycle and turn
vapor switch on. Unit will then equalize.
Note: If positive pressures remains after equalize repeat pump out
procedure.
16. Fill-up the worksheet form to complete the job.

Observation
Checklist
YES NO N/A
B Maintenance (Van Steen Burgh Recycling Machine)Oil

Compressor
Note:Recycle must be of “0” psi to check oil level and to add oil to
the compressor. If oil level is below bottom of sight glass of oil
must be added.
18. Locate the valve on the front of unit labeled comp. oil
19. Attach one end of hose to fitting and other end to oil supply
20. Hold compressor momentarily switch down until a small
vacuum is indicated on suction gage.
21. By opening comp. Oil valve oil will be pulled into compressor.
Proper oil level is from bottom of the sight glass to ¼ full.

NAME: Date:
COMPETENCY: Recovery/Recycling of Refrigerants TEST ATTEMPT

1ST 2ND 3RD
OVERALL EVALUATION
DIRECTIONS LEVEL
ACHIEVED PERFORMANCE LEVEL
• Ask instructor to assess 4

CAN PERFORM THIS SKILL WIITHOUT SUPERVISION AND WITH
ADAPTABILITY TO PROBLEM SITUATIONS
your competencies of the 3
CAN PERFORM THIS SKILL SATISFACTORILY WITHOUT ASSISTANCE
OR SUPERVISION.
critical performance CAN PERFORM THIS SKILL SATISFACTORILY WITH SOME
2 ASSISTANCE & SUPERVISION
criteria listed below.
CAN PERFORM PARTS OF THIS SKILL SATISFACTORILY WITH FULL
1 ASSISTANCE.
• You will be evaluated
0 CANNOT PERFORM THIS SKILL
using the guide on the
INSTRUCTOR W ILL INITIAL LEVEL ACHIEVED
other side
PERFORMANCE
PERFROMANCE STANDARD LEVEL
YES NO N/A
1. Identify refrigerants using identifier

• Relevant data is gathered on unit to be recovered recycled
• Unit is determined whether to be subjected to refrigerant recovery/recycle.
• Apply safety measure
2. Set up equipment for recover/recycling

• Prepare, instruments, tools and accessories based on job requirements
• Set up equipment, instruments and tools according to manufacturer’s
recommendations
3. Recover/recycling refrigerants
• Observe safety measures in recovering/recycling of refrigerants
• Achieve optimum recovery/recycling of refrigerants
• Identify and label recovered refrigerant in the tank prior to recycling
• Perform refrigerant recovery/recycling according to manufacturer’s

recommendations
• Remove contaminants from the system as a result of recycling based on

instrument readings
• Operate and maintain recovery/recycling machine in accordance with

manufacturer’s recommendations

Introduction
Retrofitting is the replacement of the refrigerant towards alternatives. It may require
replacing specific parts of the equipment. For older refrigeration and air-conditioning systems,
it may be more cost-effective to replace rather than retrofit. In addition, new equipment will be
more energy and cost efficient.
This module covers the knowledge, skills and attitudes in retrofitting process of preparing
refrigeration and air-conditioning system for use with a replacement refrigerant and lubricant.
This also includes the selection of alternative refrigerant, lubricant components and
accessories, basic principles of retrofitting, costing your work and good servicing practices.
Learning Outcomes
; Asses unit for retrofit
; Retrofit the unit
; Test performance of retrofitted unit.
Performance Criteria
After completion of the lessons in this unit, the student should beable to:
• Explain the advantages, disadvantages and procedures of retrofitting to
customer in layman’s terms
• Estimate the cost of retrofitting based on manufacturer’s recommendations
• Select alternative refrigerants & lubricants according to manufacturer’s
recommendations
• Select system components and accessories for retrofitting according to
application
• Perform retrofitting according to manufacturer’s recommendations
• Observe safety measures during retrofitting
• Monitor and check operating pressures, current, temperatures for
conformance with manufacturer’s operating manual
• Analyze and interpret recorded data based on manufacturer’s
recommendations
• Perform adjustment of controls and devices on pressures, current and
temperature in accordance with manufacturer’s recommendations

Conditions
The trainee must be provided with the following:
1. Learning materials
• Module 2: Retrofitting RAC & MAC Systems
• Operators Manual
2. Equipment and Materials
• Recovery/recycling machine
• Vacuum pump
• Standard tools and devices
• Adequate supplies and materials.
3. Learning Environment
• RAC or MAC unit for servicing
• Workshop or workplace
• Training facilities
Prerequisite
Before commencing this module, you should have already completed the following
module:
• Module 1: Recover/Recycling Refrigerants
• Module 2 : Perform Processing of RAC System
• Good Practice in Servicing R & R System
References
A. Books
• Good Practices in Refrigeration Training Manual. UNEP, December 1994
• Modern Refrigeration and Air-conditioning. Althouse/Turnquist/Brancciano.
Copyright 1992
B. Curriculum guides
• HVAC Competency Standard
• HVAC Competency-based Curriculum
C. Manuals
• Service Manual

Assess Unit for Retrofit

I. Basic Consideration for Retrofitting
1. Retrofitting is the process of preparing
a refrigeration and air conditioning
system for use with a replacement
refrigerant and lubricant. The basic idea Materials
of retrofit is to replace the refrigerant Compatibility Capacity
and refrigerating machine oil.
2. Retrofitting would appear to be a simple
matter since it involves replacing an old
refrigerant with a new one in an existing
system. However, because many other Cost
factors are involved, it is not generally Power
a simple process. Requirement
3. Other economic factors must be

Repla c ement with insta lla
Hermetic
considered. These factors include:

Open or
• The estimated equipment life,

tion c ost total
• Current performance,
100%
% of Replacement Cost
• operating requirement, and

Drive line retrofit
• The cost of equipment and

Open Only
60 - 80%
equipment room modification,

Open Only w/ gea r
40 - 60% Simp le
maintenance, refrigerant and

or imp eller
electrical power. Comparison of cost

20 - 30%
of chiller upgrade is as shown.

Saving s
Best Efficiency

4. In the refrigeration sector, often times
ODS-based equipment can be replaced Original CFC Possible Retrofit
with transitional refrigerant such as Refrigerants Refrigerant*
HCFCs, or alternative substances. The CFC - 11 HCFC - 123
most commonly used non-ozone
depleting refrigerants are HFC(which CFC - 12 HFC - 134a
have zero ODP, but contribute to global
warming) and HCs (which have zero CFC - 114 ???
ODP and zero global warming potential,
but are flammable and require specific R - 500 HFC - 134a
safety precautions). * Approved by the U.S. Environment Protection
Agency
5. Replacement of end-of-live ODS

equipment may be the most economical Advantages Disadvantages
option taking into account the energy
saving which may be realized by Alternate May reduced
modern technology. The advantage refrigerant is system
and disadvantage of retrofitting are ozone friendly efficiency
as shown. can be more
System is expensive in case
overhauled compressor and
other components
needs
Commercial replacements
Toxicity and
availability at
flammabilit
reasonable
y
6. A retrofit can usually performed at the cost
same time as a system overhaul. An
overhaul ordinarily consists of:
• Repair leaks
• Cleaning system tubing
• Charging t h e r e f r i g e r a n t
a n d lubricant to the proper levels,
• Adjusting controls.

7. Finally, the decision for retrofitting is the
end-user, but as technicians you can
advice the owner on the best option.
Guide in making your advice is shown
below.
BASIC CONSIDERATION FOR RETROFITTING

• Consider the expected energy efficiency, performance and operating costs of the
retrofitted system in addition to the direct retrofit costs.
• Consider the properties of the alternative refrigerant such as flammability, toxicity and
its global warming potential; some of these properties may require additional safety
measures.
• Consider retrofitting when major damage of the existing system requires expensive
repair work.
• Consult the system manufacturer for the appropriate alternative refrigerant/lubricant
system and the necessary replacement of system components, such as compressor,
filters, drier etc., before retrofitting.
• Consult the system manufacturer for the appropriate retrofitting procedure, which is, in
general, equipment-specific.
• Investigate the operating parameters and performance data of the existing system before
retrofitting.
• Investigate the operating parameters and performance data of the system and control
settings after completion of the retrofit.
• Re-label the retrofitted system and components to reflect the refrigerant and lubricant
change and to indicate future service needs.
• Record the retrofitting procedure in the service logbook.
Note: Observe local regulations concerning the collection, transport, storage

and. destruction of hazardous waste; contact refrigerant suppliers,
refrigeration associations or appropriate government institutions.

II. Retrofit Factor and Costing
1. The decision to replace or convert
existing equipment should be made
only after carefully considering the total
costs of both scenarios. To minimize the
cost, if timing permits, it is best to Cost Vs. Efficiency
undertake a retrofit operation around a
major maintenance period. Many of the
components would normally be replace
during a major maintenance overhaul.
Note: Retrofits when compressor

has failed and will be
replaced is much more cost
effective
2. Many air-conditioning and refrigeration
system running on CFC will be
retrofitted to ozone friendly HFCs (i.e.
134a etc.) refrigerants. This will require
flushing the mineral oil from the
systems and replacing it with synthetic
ester lubricants. To be able to perform
such a task the service contractor
needs to be well aware of the retrofit
performance and what to consider.
3. Several factors should be

considered when approaching a
refrigerant retrofit:
• Alternative refrigerant cost.
• Availability of alternative refrigerants
in the present and the future.
• Expected life of existing equipment.
• Refrigerant leak history of
equipment.

4. As a service technician, it is your work
to advice equipment owner the best
way to minimized cost, and at the same
time maximizes the efficiency of the
equipment. Example on costing is
shown below:
Example of costing retrofit
No. Measure Unit Cost/Unit Hours Cost/Hour Cost
1 Assessment 1 100 100
No Recovery to change oil -
3 Change oil 3x1L 800 3x2 100 3000
1 Recovery to change refrigerant 2 100 200
1 New refrigerant 3 kg 300 1 100 1000
1 New filter 1 pc. 500 500
1 Commissioning 1 100 100
Total cost of retrofit 4900
III. Alternative Refrigerants and

Lubrication
1. In selecting ozone-compatible
alternatives for CFCs, two molecular
concepts are to be used:
• Eliminate (or at least minimize) C-
Cl bonds, and
• Include C-H bonds
This is in addition to maintaining
the desirable physical and physiological
properties already ascribed to the CFCs.

2. With these criteria set forth, the major
CFCs producers, such as DuPont,
Solvay, and ICI, searched the tables of
known fluorocarbons in an attempt to
match these properties. From these
tables, which are extensive only a few
compounds approximate the physical
properties of the existing CFCs.The
following table identifies these
compounds:
List of Alternative Refrigerants
Replaceme Alternative
ODP Main Application
nt for Refrigerant
R - 11 R - 123 0.02 Water chillers
R - 12 R - 134a 0 Domestic and Commercial

Refrigeration(medium
temperature), fixed and vehicle air-
con, water chiller
R - 409A 0.05
Commercial and transport
R - 404A 0 refrigeration
Commercial and transport
R - 502
R - 408A 0.026 refrigeration
Retrofit of existing R - 502 systems
R - 22 0.055 Air-conditioning
R - 407C 0 Stationary air-conditioning

R - 22
R - 410A 0 Stationary air-conditioning
R - 404A 0 Refrigeration
R - 500 Blends Commercial and Industrial
R - 114 HCFC 124 Chiller application, marine
R - 115 HFC 125 0 Low temperature
R - 12/ R - 22 Hydrocarbons 0 Domestic/Air-conditioners
R - 114 HCFC - 142b Refrigeration

3. The factors that have to be considered in choosing an alternative refrigerant are:
• The refrigerant’s atmospheric lifetime
• The ozone depletion potential (ODP)
• The total equivalent warming index (TEWI) in the intended application
• The refrigerant toxicity and flammability
• The pressure under which the refrigerant operates
• Its heat transfer characteristics
• Its compatibility with materials used in the system
• Miscibility and compatibility with lubricants
IV. Oils for Alternative Refrigerants
1. An important consideration in the development of hydro chlorofluorocarbon (HCFCs)
and hydro fluorocarbons (HFCs) as alternative refrigerants is the testing of oils for
solubility, stability, lubricity with the refrigerant, and compatibility with materials of
construction. Testing will determine which lubricants can be used in current systems
and what changes are required.
2. In general the ternary blends and HCFCs can be used with oils that are commercially
available; however, some development work may be required to optimized performance.
Applications with HFCs require the development of new oils. The desirable properties
for developmental use are:
• Acceptable solubility with the refrigerant (ideally, single phase over a broad
temperature range);
• Acceptable lubricity;
• Good thermal stability for the refrigerant/lubricant combination;
• Acceptable compatibility with system materials (elastomers, metals and plastics);
• Low toxicity; and
• Commercial availability at a reasonable cost.
3. Listed below are the refrigeration lubricating oils and their characteristics:
Mineral Oil (MO)
• Designed for and miscible in CFC/HCFC
• Very soluble in HC (higher viscosity/superheat can be required
Alkylbenzene (AB)
• Designed for and miscible in CFC/HCFC
• Low viscosity AB is also used in rotary compressors for R-407C
Polyol ester oil (POE)
• Designed for HFC compatibility
• Soluble in CFC/HCFC/HFC/HC
• High solubility in CFC/HCFC/HC must be considered

Polyalkylene glycol (PAG)
• Designed for HFC compatibility
• Not considered suitable with CFC/HCFC
HFC Oils
Polyol esters (POE) and Poly alkylene Glycol (PAG)
PAG oils are developed for Mobile air conditioning (MAC).

• These oils are extremely sensitive to humidity and will absorb moisture from air if
exposed to ambient
• Should always be kept in well-sealed cans
• PAG oil in cans that have opened and not protected with dry nitrogen should not be
used in system
• Humidity will drastically reduce stability and reduce lifetime of system
• Careful evacuation and use of nitrogen are essential for long term reliability
POE oils are developed for stationary refrigeration and air conditioning (RAC)
systems but are also used by some auto manufacturers for retrofit as they are more tolerant
to contaminations than PAG.
• POE oils are sensitive to humidity and will absorb moisture from ambient air if
exposed
• Humidity will drastically reduce stability and reduce lifetime of system
• Careful evacuation and use of nitrogen are essential for long term reliability
Low viscosities Alkylene Benzene (AB) are used in rotaries for R407C and R410A.

Self-Check 14
Satisfactory
QUESTIONS
Response
The student/trainee should answer all the following YES NO
questions
1. What is the importance of retrofitting?
2. What are the advantages and disadvantages of retrofitting?
3. What lubricants are suited for HFC refrigerants?
4. What are the alternative refrigerants for R - 12?
5. In selecting ozone-compatible alternatives for CFCs, two

molecular concepts are to be used. What are they?
6. What are the factors to be considered when approaching

refrigerant retrofit?
7. Define retrofitting
The students underpinning knowledge was:

Date:
Candidate Signature:
Date:
Instructor Signature:

1. The unit will be ozone-friendly.
2. A. Advantages
a. alt er nat iv e refrigerant is ozone friendly
b. System is overhauled
c. c o m m e r c i a l availability at reasonable cost
B. Disadvantages
a. ma y reduced system efficiency
b. can be more expensive in case compressor
and other components needs replacements
c. T o x i c i t y and flammability (in case of hydrocarbons)
3. Polyolester oil, Polyalkylene oil
4. R – 134a, R- 409A, Hydrocarbon
5. a. Eliminate (or at least, minimize) C-Cl bonds,

b. Include C-H bonds
6. 1. Alternative refrigerant cost

2. Availability of alternative refrigerant, in the present and future.
3. Expected life of existing equipment.
4. Refrigerant leak history of equipment.
7. Retrofitting is the process of preparing a refrigeration and air conditioning

system for use with a replacement refrigerant and lubricant. The basic idea
of retrofit is to replace the refrigerant and refrigerating machine oil.

Retrofit the Unit
I. Retrofit Systems
1. After all refrigerant decisions have been made, the implementation of a refrigerant
retrofit program is best accomplished in a methodical, organized manner. Every system
has unique operating conditions. It is important to remember that all current practices
for refrigeration system services still apply with the alternative refrigerants. The basic
refrigeration cycle still applies, and changes that accompany the alternative refrigerants
involve additional service practices that must be followed. The accompanying retrofit
checklist may be used as a guide during the preliminary assessment of an existing
system. Remember that a successful retrofit begins with a thorough analysis of the
existing system. This is done before any retrofit procedures.
2. Generally, a successful retrofit should be prefaced by the following steps:
• Assess existing equipment and examine the system for potential problem areas
(low point, poor piping, etc.)
• Determine the service and operational history of the equipment.
• Carefully record all information regarding the existing system components (i.e.,
compressor, valves, heat transfer surfaces, piping, etc.).
• Establish existing system operating conditions (pressures, temperatures, amperage,
etc.) to determine the baseline operation. This step is essential in determining whether
or not the existing system is actually producing the desired refrigeration effect.
• Cross-reference all existing components to the intended alternative refrigerant. Many
components are likely to be acceptable; however, some system components may
need to be changed.
• Material compatibility is best determined by the OEM. Be sure to consult the OEM
recommendation for retrofits—this is especially important for older systems.
• Once the equipment selections have been made and all preliminary investigation is
complete, a thorough leak-check of the system should be performed. Remember
that the genesis of this CFC problem is in a large part of result of excessive leakage.
• Further, the leak characteristics of some of the alternatives mandate the need for
“very tight” systems.
• After all preliminary work is complete, the retrofit procedure

II. Safety requirements:
Low- and high-pressure refrigerants need to be handled as compressed gases, and
refrigerant containers are pressure vessels, which require particular safety considerations.
Specific Safety Practices:

DOs:
• Use specific colors for containers for different refrigerant types (see document 14 in
Annex G).
• Comply with mandatory safety precautions for systems retrofitted with alternative
refrigerants, such as hydrocarbons or ammonia, which might be flammable or toxic
(these are beyond the scope of this Guidebook).
• Properly label all cylinders using country-approved hazard labels where applicable.
• Use proper protective caps over refrigerant valves to prevent damage to the valve on
top of the cylinder.
• Recover refrigerant prior to servicing.
• Use nitrogen in cleaning refrigeration piping.
• Use non-CFC as gas tracer.
• Thoroughly leak test system before changing.
DON’Ts
• Do not substitute refrigerant with drop-in alternatives without consulting the system
manufacturer.
• Do not exceed the manufacturer’s recommended pressure or system strength test
pressure when leak testing.
• Do not overfill refrigerant containers, tanks, drums, recovery units, receivers, etc.
• Do not refill disposable cylinders.
• Do not use an open flame on any refrigeration system that has not been properly
evacuated for servicing.
• Do not service refrigeration systems unless wearing protective clothing, including goggles
and gloves.
• Do not attempt to service equipment unless fully trained in the safe handling of
refrigerants.
• Do not work with refrigerants in a confined space lacking ventilation.
• Do not blow off a piping system with air or oxygen to remove welding, brazing or cutting
debris, because this may cause contamination and the risk of explosion; only dry nitrogen
should be used for this task.
• Do not pressurize refrigeration or piping systems with air or oxygen.
• Do not use CFC as gas tracer.

III. Retrofitting Procedure
1. Ensure that the system is leak tight
2. Recover the refrigerant into a clean cylinder.
3. Drain the mineral oil from the system and replace it with correct quantity of
appropriate polyolester lubricant.
4. Recharge the system with the previously recovered refrigerant.
5. Run the system for long enough to “flush” the system mineral oil residues.
6. Stop system and recover the CFC refrigerant again into the clean recovery cylinder.
7. Drain the oil mixture and recharge the system with fresh polyolester lubricant.
8. Recharge the system with recovered CFC refrigerant.
9. Run the system for long enough to “flush” the system mineral oil residues.
11. Drain the polyolester mineral oil mixture and test it with an appropriate test kit. The
target mineral oil/polyolester lubricant concentration is 5% mineral oil 95% polyolester
lubricant. (Preferably less than 5% mineral oil.)
12. If the mineral oil residue is higher than 5% then repeat the flushing procedure until
its lower.
13. Once the mineral oil concentration is below 5% then recharge the system with fresh
polyolester, change the drier, test for leak, and if system is free from leak, evacuate
the system.
14. Now charge the system with alternative refrigerant in accordance with the
manufacturer’s instructions/recommendation.
15. Run the system and make any adjustment as required.
16. Thoroughly leak test system and ensure that all valve caps are in place and tight.
Note: Although HFC refrigerant will give acceptable performance in the CFC/
HCFC system, some of the materials may not be compatible and this can
lead to component failure and leakage. It is advisable to consult with the
manufacturer before changing system refrigerant.
II. Alternative refrigerants

Replacement refrigerants are gradually becoming available, but the earliest ones are
either blends of HCFC-22, and thus have a limited life expectancy, or consist of blends of new
“ozone friendly” (non-ODS) refrigerants that are undergoing the the last stages of toxicity
testing. However, several blends are now available, that are based upon HFCs only, such as
R-404 and R-410.

There are three categories into which replacement fluids can fall. These are:
• DROP-INS — fluids that can be substituted into an existing system without any
work being required apart from very minor servicing such as the replacement of a
refrigerant filter dryer.
• RETROBITTABLE FLUID —fluids that can be substituted into an existing plant but
only after certain changes are made, such as substitution of new type of lubricating
oil or a modification of compressor speed.
• NON-RETROFITTABLE FLUID — fluids that cannot be used in existing equipment
even with major modifications, because of different operating pressures materials
incompatibility and other potential problems.

Retrofitting Using “Drop in” Replacement
Another type of retrofitting is the use of “drop in” replacements. “Drop in” replacements
need no change of lubricants and other accessories of the unit except for the filter drier which
is mandatory practice in servicing.
There are number of “drop in” replacements available now. It must be noted that if you
will use “hydrocarbons” drop in replacement, outmost care must be taken into consideration.
A technician should possess a special training when dealing with hydrocarbon because of its
flammability and explosiveness.
Procedure to retrofit a system with “drop in” replacement

1. Check system for leaks
2. Recover CFC refrigerant into appropriate containers and label it.
3. Record weight of recovered CFC
4. Change liquid line drier
5. Evacuate system to 500 microns (If you will use hydrocarbons, all spark producing
mechanical and electrical components must be replaced, repositioned or enclosed)
6. Charge the replacement “drop in” into system in accordance with manufacturer’s
instruction (i.e. for weight in liquid phase from the cylinder)
7. Start system and observe the operation of the unit, make adjustment if necessary to
expansion valve, Hi switch pressure and Lo pressure switch cut outs etc.
8. Leak test the system
9. Label the system with the new refrigerant type and remove the old labels to prevent
confusion in the future.
Note: Wear personal protective equipment and work in a well ventilated area.

The general procedure used to retrofit a system from CFC to HFC refrigerant is as
follows:
1. Check the system for leaks
2. Recover/recycle the CFC refrigerant into a clean cylinder
3. Drain the mineral oil from the system and replace it with the correct quantity of appropriate
polyolester lubricant.
4. Recharge the system with the previously recovered CFC refrigerant
5. Run the system for long enough to flush the system mineral oil residues.
7. Drain the oil mixture and recharge the system with fresh polyolester lubricant.
8. Recharge the system with recovered CFC refrigerant.
9. Run the system for long enough to flush the system mineral oil residues.
11. Drain the polyolester/mineral oil mixture and test it with appropriate test kit or
refractrometer. The target mineral oil/polyolester lubricant concentration is 5%
mineral oil 95% polyolester lubricant. (Preferably less than 5% mineral oil).
12. If the mineral oil residue is higher than 5% then repeat the flushing procedure until it is
lower.
13. Once the mineral oil concentration is below 5% then, recharge system with fresh
polyolester lubricant, change drier and evacuate the system thoroughly.
14. Now charge system with HFC refrigerant in accordance with the manufacturers
instruction.
15. Run system and make any adjustment as required.
16. Thoroughly leak test system and ensure that all valve caps are in place and tight.
NOTE: Although HFC refrigerant will give acceptable performance in CFC/HFC

system, some of the materials may not be compatible and this can lead to
component failure and leakage. It is advisable to consent with the manufacturer
before changing system refrigerant. Wear personal protective equipment.

Satisfactory
QUESTIONS
Response
The student/trainee should answer all the following questions YES NO
1. How do you apply safety measure in retrofitting the system?
2. What precautions must you take in handling refrigerants?
3. What would you do if something in the system malfunction? What

action should you take?
4. What should we not leave lubricant uncovered?
5. What are the three categories in which replacement fluids can fall?
6. Give the standing pressure and temperature of the following

refrigerant.
Refrigerant Pressure Temperature
a) R - 12
b) R - 22
c) R - 134a
The students underpinning knowledge was:

Date:
Candidate Signature:
Date:
Instructor Signature:

1. a. always wears protective clothing
a. al wa ys work in a ventilated area
b. nev er apply heat to a system with pressure in it.
c. N e v e r use air or oxygen in cleaning the
system.
2. a. always wears gloves and goggles in handling

refrigerants b. always cover the valve spindle of
refrigerant cylinder
c. a l w a y s secure refrigerant cylinder.
d. D o not vent refrigerant in the atmosphere
3. Stop retrofitting. Troubleshoot the unit. Recover refrigerant , if necessary.
4. It will absorb moisture from the atmosphere.

5. a. Drop-ins
b. ret r of it t ab le fluid
c. n o n -retrofittable fluid
6. The standing pressure of the following refrigerant:
Refrigerant Pressure Temperature
a) R - 12
b) R - 22
c) R - 134a

Retrofit with Alternative Refrigerant
Equipment:
• Gauge manifold set
• Vacuum pump of adequate size
• Alternative refrigerant
• Alternative lubricant
• Recovery and recycling machine
• Leak testing device
• Nitrogen
• Oxyacetylene set
Observatio
Procedure n
Checklis
YES NO N/A
t
1. Recover refrigerant
2. Drain oil
3. Perform flashing of mineral oil
4. Change unit with alternative refrigerant and oil
5. Label the unit with new refrigerant type
6. Safety measure are applied

Retrofit with a “Drop in” Replacement
Equipment:
• Gauge manifold set
• Vacuum pump of adequate size (spark free)
• Soap suds solution
• Valve key and suitable spanners/wrenches
• Appropriate hydrocarbons.
Observation
Procedure Checklist
YES NO N/A
1. Pressure test system with nitrogen
2. Soap (bubble) test joints-repair leak if appropriate
3.Release nitrogen safely
4. Evacuate and dehydrate system - prove vacuum tight
5. Retrofit with a "drop-in" replacement
6. Record operating conditions
Note: This should only be given to those with evidence of knowledge, skills and
attitude in dealing with hydrocarbons.

Test the Operating Performance of Retrofitted Unit
Equipment: Retrofitted Unit
Instrument: Thermometer, System analyzer, Clamp Tester
Ob serv atio n
Pro ced u re Ch ecklist
YES NO N/A
Test the operating performance of retrofitted unit using the following
steps
1. Prepare the unit and instruments required for testing retrofitted unit
such as; system analyzer, clamp-on ammeter and retrofitted.
2. Connect the unit to the analyzer.
3. Clamp the ammeter in one of the two lines of the power supply
chord.
4. Run the retrofitted unit for thirty minutes.
5. Take reading of:
o
P a. Suction pressure/temperature psi/kpa C/oF
o
b. Discharge pressure/temperature psi/kpa C/oF
c. Running current amperes
5. Analyze and interpret the above readings based on the
recommended operating pressure, temperature and current. Make
necessary adjustments if needed until normal operating pressure is
attained.
6. For retrofitted unit (time tested/time of operation)
Time Started
Time Ended
Total Time
No te: See specifications recommended by the manufacturer.
7. Inspection form fully accomplished.
8. Make recommendations for further maintenance action.

Forms and attachments
Comparative Data between the system before and after retrofitting
* RECOMMENDED
BEFORE AFTER VALUE
RETROFITTING RETROFITTING (RETROFITTED REMARKS
UNITS)
Suction Pressure
(PSI/Kpa)
Suction
Temperatur
e (? F/? C)
Discharge
Pressure
(PSI/Kpa)
Running
Temperatur
e (? F/? C)
Running Current
(AMP)
Cabinet
Temperatur
e (ºF/ºC)
Type of
Refrigerant
Superheat
(ºF/ºC)

Cabinet temperatures are fairly standard. The table below shows the recommended
fixtures (cabinet) temperatures for some common fixtures (cabinets).
Fixture (Cabinet) Temp oF Temp. oC

Back Bar 37 - 40 3-4
Beverage Cooler 37 - 40 3-4
Beverage Pre cooler 35 - 40 2-4
Candy Case (Display) 60 - 65 16 - 18
Candy Case (Storage0 58 - 65 15 - 18
Dairy Display Case 36 - 39 2-3
Double Display Case 36 - 39 2-3
Delicatessen Case 36 - 40 2-4
Dough Retarding Refrigerator 34 - 38 1-3
Florist Display Refrigerator 40 - 50 4 - 10
Florist Storage Case 38 - 45 3-7
Frozen Food Cabinet (Closed) -10 to -5 -23 to - 21
Frozen Food Cabinet (Open) -7 to -2 -22 to - 19
Grocery Refrigerator 35 - 40 2-4
Retail Market Cooler 34 - 39 1-3
Pastry Display Case 45 - 50 7 - 10
Restaurant Service Refrigerator 36 - 40 2-4
Restaurant Storage Cooling 35 - 39 2-3
Top Display Case (Closed) 35 - 42 2-6
Vegetable Display Refrigerator (Closed) 38 - 42 3-6
Vegetable Display Refrigerator (Open) 38 - 42 3-6

Recommended fixture (Cabinet) temperature.
Application Temp oF Temp. oC
Service 34 - 38 1-3
Meats 30 - 34 -1 to 1
Bananas 60 - 65 16 - 18
Fresh Meats 28 - 32 -2 to 0
Aging Room 30 - 34 -1 to 1
Chill Room 35 - 39 2-3
Curing Room 32 - 36 0-2
Freezer Room -15 -26
Poultry 30 - 34 -1 to 1
Vegetables, Fresh 36 - 42 2-6
Ice Cream Hardening - 25 - 32
Ice Cream Storage -20 to -10 -29 to - 23
Plants and Flowers 38 - 50 3 - 10
Fur Storage 33 - 37 0-3
Locker Room -5 to 0 -21 to -18
Recommended temperatures for various refrigeration applications.

• Normally, the refrigerant will be 10oF (6oC) colder than the evaporator temperature
when the unit is running. The refrigerant and evaporator will become the same
temperature during the off cycle.
• The evaporator surface temperature depends on its size and the rate at which heat is
being removed from the fixture.
• The temperature of a typical frosting type evaporator (domestic type) will vary from 0
O
F to 25 OF (-18 OC to 4 OC), and the refrigerant temperature will be about 10 OF (6 OC)
lower than this or in range of -10 OF to 15 OF (-23 OC to -9 OC) while the unit is running.
Refrigerator Temperature
• The low side pressure in a refrigerating system determines the temperature in the
evaporator.
• One must first determine the temperature that is wanted in the cabinet or fixture, then
adjust the motor control until this temperature is maintained. However, there are many
cases where both a certain evaporator temperature and a cabinet temperature
relationship should exist.

Cross Reference Table for Single Phase, 220 Volts Compressor Motor
HP NLA FLA LRA

1/20 0.1 0.3 1.0
1/12 0.2 0.6 4.0
1/10 0.6 0.9 7.0
1/8 0.8 1.2 10.0
1/6 1.4 1.8 13.0
1/5 1.8 2.0 15.0
1/4 2.0 2.5 17.4
1/2 2.8 3.0 21.6
3/4 2.0 3.1 18.0
1 ¾ 6.8 34.0
1¼ 3.2 6.4 38.0
1½ 3.3 7.6 45.6
1¾ 5.1 10.20 61.2
2 6.0 12.0 72.0
2½ 7.5 15.0 90.0
Legend:
HP - Horsepower
NLA - No Load Amperage
FLA - Full Load Amperage
LRA - Lack Rotor Amperage

Name Date
Test Attempt
Competency: Retrofit Refrigeration an d Air-Conditioning 1st 2n d 3rd
Systems
OVERAL L EVAL UATION

Directions: LEVEL
PERFORMANCE LEVEL
ACHIEVED
1. Ask instructor to assess your
Can perform the skill without supervision and with adaptability
competencies of the critical 4
to problem situations
performance criteria listed Can perform the skills satisfactorily without assistance or
3
below. supervision
Can perform this skill satisfactorily with some assistance and
2. You will be evaluated using 2
supervision
the guide on the other side 1 Can perform parts of this skill satisfactorily with full assistance
0 Cannot perform this skill
INSTRUCTOR WILL INITIAL LEVEL ACHIEVED
PEFORMANCE
PERFORMANCE STANDARDS L EVEL
YES NO N/A
1. Assess Un it to b e Retro fitted
1.a Estimate cost of retrofitting based on manufacturer's
recommendation
1. a.1 Select alternative refrigerants and lubricants
according to manufacturer's recommendation.
2. Perform Retrofitting Process
2.a Select system components and accessories for retrofitting
according to application;
2.b Perform retrofitting according to manufacturer's
recommendation; and
2.c Observe safety measures during retrofitting.
3. Monitor and check operating pressures, current
3.a Temperatures for conformance with manufacturer's
operating manual
3.a.1 Analyze and interpret recorded data based on
manufacturer's recommendations
3.a.2 Perform adjustment of controls and devices on
pressures, current and temperature in accordance
with manufacturer's standards

Definition of Terms
Code No. Installing Window Type Air-conditioning Date: Developed Date: Revised Page #
Units 282 of 287
Air Cleaner - Device used to remove airborne impurities
Air conditioner - Device used to control temperature, humidity, cleanliness, and
movement of air in a confined space
Air Conditioning - Control of temperature, humidity, cleanliness, and movement of air in
a confined space
Alternating - Electric current in which direction of flow alternates or reverses. In 60
Current (AC) cycles (Hertz) current, direction of flow reverses every 1/120 th of a
second
Amperage - Electron or current flow of one coulomb per second past given point
in circuit
Ampere - Unit of electric current equivalent to flow of one coulomb per second
Anemometer - Instrument of measuring the rate of airflow or motion
Circuit - Tubing, piping or electrical wire installation which permits flow to and
from energy source
Circuit breaker - Safety device which automatically open an electrical circuit if
overload
Cold - The absence of heat; a temperature considerably below normal
Compression - Term used to denote increase of pressure on a fluid by using
mechanical energy
Compressor - Pump of a refrigerating mechanism which draws a low pressure on
cooling side of refrigerant cycle and squeezes or compress the gas
into the high-pressure or the condensing side of the cycle
Condensate - A fluid formed when a gas is cooled to its liquid state
Condensing Unit - Part of the refrigerating mechanism which pumps vaporized
refrigerants from the evaporator, compress it liquefies it in the
condenser and return it to the refrigerant control
Conductivity - Ability of a substance to conduct or transmit heat and/or electricity
Conductor - Substance or body capable of transmitting electricity or heat
Direct Current - Electron flow which moves continuously in one direction in circuit
(DC)
Energy - Actual or potential ability to do work
Evaporator - Part of refrigerating mechanism in which the refrigerant vaporize and
absorb heat
Evaporator fan - Fan which increases air flow over the heat exchange surface of
evaporator
Fan - Radial or axial flow device used for moving or producing flow of
gases
Fuse - Electrical safety device consisting of strip of fusible metal in circuit
which melts when circuit is overloaded
Gas - Vapor phase or state of substance
Ground wire - Electrical wire which will safely conduct electricity from a structure
into the ground
Heat - Form of energy which acts on substance to raise their temperature;
energy associated with random motion of molecules
Liquid - Substance whose molecules moves freely among themselves, but do
not tend to separate like those of gases
Motor - Rotating machine that transforms fluid or electric energy into a
mechanical motion
Ohm - Unit of measurement of electrical resistance. One ohm exist when
one volt causes a flow of one ampere
Ohmmeter - Instrument used to measure resistance
Ohm’s Law - Mathematical relationship between voltage, current and resistance in
an electric circuit
Power - Time rate at which work is done or energy is emitted; source or
means of energy
Pressure - Energy impact on a unit; force or thrust on a surface
Refrigerant - Substance used in refrigerating mechanism. It absorbs heat in
evaporator by change of state from liquid to gas, and release its heat
into the condenser as the substance returns from the gaseous state
to the liquid state
Resistance - An opposition to flow or movement; a coefficient of friction.
Superheat - Temperature of vapor above its boiling temperature as a liquid at that
pressure; The difference between the temperature at the evaporator
outlet and the lower temperature of the refrigerant evaporating in the
evaporator
Temperature - Degree of hotness or coldness as measured by a thermometer;
Measurement of speed of motion of molecules
Thermometer - Device for measuring temperature
Thermostat - Device which senses ambient temperature conditions and in turn,
acts to control a circuit
Timers - Clock operated mechanism to control opening and closing of an
electrical circuit
Velocity - Quickness or rapidity of motion, swiftness, speed
Voltmeter - Instrument used to measure voltage
Watt - Unit of measurement for power

Evidence Plan
Before you can take the assessment, take your time to study the evidence plan. An
evidence plan describes the ways of gathering evidence to prove that you are competent
enough in this module. Below are definitions of terms which will help you understand what is
contained in the plan.
 Critical aspect of competency means that you should have a passing rate for that
particular criterion in order to pass the assessment.
 Interview is an assessment method which is a form of questioning orally or in written

form.
 Demonstration with questioning is an assessment method wherein you will prepare a

scenario where in you will demonstrate the skills that you have learned from this
module while you are being interviewed to confirm that you also learned the required
knowledge and attitude
 Observation and questioning is an assessment method wherein you will be observed

by your instructor while you are actually doing your job in the work site.
 Presentation of final product is an assessment method wherein you will be asked to

show your installation output for evaluation. This supplement the result of your
performance assessment.
 Third party report Is an assessment method wherein your direct supervisor, previous
clients will be asked to rate your performance. This supplement the result of your
performance assessment.

The table below is the plan which includes criteria (rightmost column) and assessment
methods (interview, demonstration with questioning, and observation with questioning
Presentation of final product and third party report). Any of the five assessment method can
be used to gather evidence in a particular criterion. Study them carefully and solicit
clarification from your instructor if needed. When you are ready, make a schedule for
assessment with your instructor.
Ways in which evidence will be collected :

( tick the column )
Presentation of Final
Demonstration with
Third Party Report

Observation with
Questioning
Questioning
Interview
Product
The evidence must show that the candidate can
….
*Selected appropriate wiring diagrams, charts and
manuals are in line with the equipment tested
*Tested window-type air conditioning and
refrigerator electrical and mechanical controls and
its components/accessories as per standard
procedures.
*Performed leak test as per standard procedures
*Selected and used appropriate processes, tools,

materials and equipment to carry –out task.
*Demonstrated compliance with safety regulations
applicable to worksite operations.
*Identify faults and problems and made necessary
action to rectify in line with the SOP.
Communicate effectively with others where
applicable to ensure safe and effective work
operations
Completed troubleshooting as to specifications.
Perform housekeeping based on work requirement
Items with * is/are critical aspects of competency


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COMPETENCY BASED LEARNING MATERIAL

Technical Education and Skills Development Authority

Summary of Learning Outcomes:

On completion of this module you should be able to:

 Plan and prepare for troubleshoot.

 Manufacturer's nameplate rating are properly identified

 Correct testing procedures in the components are applied

 Components faults and problems are identified and diagnosed

 Remedial action is undertaken on the identified faults and problems

 HVAC code of practice and safety guidelines on troubleshooting and repair

 Test unit pressure and temperature are performed in accordance to work

 Completed report on trouble shooting and repair of electrical system are

Code No. Date: Developed Date: Revised Page #

 Mechanical parts and functions are identified and described

 Troubleshoot and repair procedure of mechanical system are performed in

 Operating procedures are performed in accordance to unit's manual

 HVAC code of practice and safety guidelines in troubleshooting of

 Test unit pressure and temperature are performed in accordance to work

 Work documentation is prepared and submitted as per prescribed

 Good housekeeping and safety practices is applied in line with job

Code No. Date: Developed Date: Revised Page #

The trainee must be provided with the following

Code No. Date: Developed Date: Revised Page #

 Althouse A. D., Turnquist C.H., Bracciano A. F. MODERN REFRIGRATION

 Institute of Integrated Electrical Engineers. PHILIPPINE ELECTRICAL

 CODE OF PRACTICE FOR REFRIGERATION AND AIR CONDITIONING

Code No. Date: Developed Date: Revised Page #

The instruction sheet may be in a form of:

 Job Sheet - This instruction sheet is designed to guide you

 Operation Sheet - This instruction sheet will guide you in

 Assignment Sheet - The assignment sheet is a guide used to

Code No. Date: Developed Date: Revised Page #

If you have questions, please don’t hesitate to ask your technical

Recognition of Prior Learning (RPL)

Code No. Date: Developed Date: Revised Page #

Reading Activity Self Check

Use Computer Answer Key

Code No. Date: Developed Date: Revised Page #

Read: Information Plan and Prepare Troubleshooting

Practice Activity 1 p.41

Perform: Job Sheet 1: Troubleshooting Refrigeration/Air

Reading Activity 2 p.42

Read: Information Hermetic Motor Compressor

o This is to self-evaluate what you have learned about the basic

Code No. Date: Developed Date: Revised Page #

Perform: Assignment Sheet Identifying Hermetic Compressor

o This is a practice activity in identifying hermetic compressor terminal

o This is to self-evaluate what you have learned about identifying

Practice Activity 3 p.49

Perform: Operation Sheet 1: Determining Hermetic Compressor

o This is a practice activity in determining hermetic compressor terminal

Reading Activity 3 p.50

Read: Information Hermetic Compressor Electrical

o This is an informative sheet that discusses about different types of

Code No. Date: Developed Date: Revised Page #

Practice Activity 4 p.57

Perform: Operation Sheet Connecting Hermetic Compressor