REFRIGERATION AND AIRCONDITIONING

What Is This Module About?

Welcome to the world of REFRIGERATION AND AIR-CONDITIONING SERVICING

(Dom RAC)!

This Module is an exploratory course which leads you to Refrigeration and

AirConditioning (Dom RAC)

Prepare Materials and Tools;

1) Perform Mensuration and Calculation;
2) Maintain Tools and Equipment; and
3) Perform Housekeeping and Safety Practices

These 3 common competencies are covered separately in 5 Lessons. As shown below,

each Lesson is directed to the attainment of one or two learning outcomes:

Lesson 1 – Prepare Materials and Tools

LO1. Identify materials and tools
LO2. Request materials and tools

Lesson 2 – Perform Mensuration and Calculation.

LO1. Select Measuring Instrument.
LO2. Carry out Mensurement and Calculation.

Lesson 3 – Interpret Technical Drawings and Plans

LO1. Analyze signs, symbols and data.
LO2. Interpret work plans.

Lesson 4 – Maintain Tools and Equipment

LO1. Check the conditions of tools and equipment.
LO2. Perform basic preventive maintenance.

Lesson 5 – Perform Housekeeping and Safety Practices

LO1. Sort materials, tools and equipment.
LO2. Clean workplace area, materials, tools and equipment.
LO3. Systematize dispensing and retrieval of materials, tools and equipment.
 LESSON 1

Prepare Materials and Tools

LEARNING OUTCOMES:
At the end of this Lesson
, you are expected to
do the following:

LO 1. identify materials and tools; and

LO 2. request materials and tools.
 Definition of Terms

Aluminum Tubing - usually used for evaporating units in air conditioning for home &
automobile

Clutch Head - used for turning with a clutch head bolt or screw

Copper Tube - use in refrigeration and air conditioning unit.

Document - written information

Flare Hose Fitting - includes assorted nylon fittings suitable to refrigerant hoses

Flaring Block - used for holding tubing according to its size so that it can be flared.

Hard Drawn Copper Tubing - used in Commercial refrigeration and air conditioning
applications

Job Order - the scope of the work to be done

Pipe Cutter - the adjustable clamp-type device with sharp-edged rollers that cut the pipe as
they are tightened and turned

Ratchet Handle – used to drive handle socket that fits on so that the tightening or loosening
motion can be limited to a short back and forth motion.

Requisition Form - a formal written order request for equipment, tools and materials.

Service Report describes the work done in a process

Soft Copper Tubing - used in domestic and some commercial refrigeration and air conditioning
work, because it is easy to bend and flare.

Soldered or Brazed Tube Fitting - used in most tubing and fitting connections that are either
by soldering or silver brazing
Different Types of flare fittings
 LEARNING OUTCOME 1
Identify materials and tools

PERFORMANCE STANDARD
S

 Job requirements are identified

 HVAC materials , tools are identified
 Quantity of each material to be used is determined or specified
 Correct quantity and quality of materials are determined as per job
requirements

Materials

Materials
• BALLPEN
• CAPACITOR
• COPPER TUBE
• ERASER
• FILTER DRIER
• FITTING USED IN RAC
• FLUX
• JOB ORDER FORM AND REQUISITION FORM
• OVERLOAD PROTECTOR
• PAPER
• PENCIL
• REEFRIGERANT OIL
• REFRIGERANT GAS
• RELAY
• SILVER ROD
• THERMOSTAT CONTROL

TOOLS
• ADJUSTABLE WRENCH SIDE CUTTING PLIERS
• SOCKET RATCHET HANDLE
• SOCKET WRENCH
• SPARKER LIGHT
 • SPIRIT LEVEL
• SWAGING TOOLS
• SYSTEM ANALYZER OR GAUGE MANIFOLD
• TUBE BENDER OR SPRING BENDER
• TUBE CUTTER
• ALLEN WRENCH
• BENCH VISE
• BLOW TORCH OR MAPP GAS
• BOX WRENCH
• CHAIN VISE
• CLAMP METER
• CLAW HAMMER
• COMBINATION PLIERS
• CONBINATION WRENCH
• FLAT SCREW
• HACK SAW
• LONG NOSE PLIERS
• MULTI-TESTER
• PHILIP SCREW
• PINCH OFF PLIERS
• PINCH OFF PLIERS
• PIPE WRENCH
• PLUMB BOB
• PORTABLE ELECTRIC DRILL
• PULL PUSH RULE
• SETS OF FLARING TOOLS

What Do You Need To Know?

Read the Information Sheet 1.1 very well then find out how much you can
remember and how m uch you learned by doing Self - check. 1. 1

Information Sheet 1.1

Use of Copper Tube in Refrigeration and Air-Conditioning Unit.

Installation of pipes and fittings in a refrigeration system is impossible without the

necessary tools and materials.

Copper Tubing
 The tubing that carries the refrigerant to various components is considered to be a vital
part of the refrigeration system. Copper tubing is the most common materials in the refrigeration
piping circuit. It is used to connect the major parts of the refrigeration system such as
evaporator coil, the compressor, the condenser coil and the expansion valve, most copper
tubing is available from 1/8 inch to ¾ inch of a diameter. The end are capped or plugged to
keep the inside of the tubing clean and dry. It is also available in soft and hard types.

Copper tubing is available in three types. Type K, L and M. Type K tubing is used for
heavy duty purpose because of its thick wall. Type L tubing is used for Six interior plumbing and
heating. It is the common types used in HVAC system (Heating Ventilation and Air
conditioning.)Type M is used for light duty work like refrigerator and window type air
conditioning.

L-type tubing in HVAC K type tubing

1. Soft copper tubing. This is used in domestic and some commercial refrigeration and air
conditioning work, because it is easy to bend and flare. Being bendable, this tubing must be
supported by suitable brackets or clamp in installation, so soft copper tubing is often used with
flared and soft soldering fittings. It is also sold in rolls of 1, 35, and 50 ft long.
2. Hard drawn copper tubing. This is used in commercial refrigeration and air conditioning
applications. Being hard and stiff, it needs few clamps to support it in installation. Hard drawn
copper tubing should not be bent so use straight lengths and fitting to form the necessary tube
connection. Hard- drawn refrigeration tubing joints should be silver brazed to eliminate leaks.

3. Steel tubing. This is a thin wall tubing used in refrigeration and air conditioning work, Its
size is practically the same as that of copper tubing, hence connections may be made on steel
tubing by using either flare joints or silver brazed joints.

4. Stainless steel tubing. This is a strong type of tubing that is very resistant to corrosion. It
is also easily connected to fitting by either flaring or brazing because of this qualities, stainless
steel is often required in food processing, ice, oven, manufacture, milk handling system, and
similar works .

5. Plastic tubing. This type of tubing with polyethylene is one of the most common
substances used in the manufacture of plastic tubing. The usual safe temperature is from 100
degrees centigrade (oC) to +175 degrees centigrade (oC) you should never use this tubing
where fluid temperature goes beyond this limit. Polyethylene tubing is not used in refrigerating
mechanism but in cold water lines in water cooled condensers.
6. Flexible tubing (hose). This is commonly used tubing in suction lines in many
refrigeration system and in commercial air conditioning application. This type serves to prevent
vibration in the mechanism. Air conditioning equipment for a motor vehicle requires the use of
flexible tubing since the vehicle is always moving.

7. Aluminum tubing. It is usually used for evaporating units in air conditioning for home
and auto-mobile. Commonly, it is used for evaporator (freezer) of the domestic refrigerators.
Special type of treatment for soldering or brazing is needed.

Fitting:
A fitting is a device used to connect tubes of different widths and lengths.
1. Flaring tube fitting. This is used in flared type connection to attach fittings in copper
tubing. There are many different fittings which are hexagonal in shape for wrench attachment.
These threaded fittings must be carefully handled to prevent damage. All fittings used are
based on the tubing size.

The common flare type fittings used in refrigeration and air conditioning works are the
following.
2. Flare hose fitting - This includes assorted nylon fittings suitable to refrigerant hoses.
Such as the following :
3. Soldered or brazed tube fitting - This type is used in most tubing and fitting connections
that are either by soldering or silver brazing. Soldered joints are used for water pipes and
drains. Silver brazed joints are used for refrigerant pipes and fittings.
Filter Drier

Soldered Type Filter Drier

Flare Nut
 Relay

In the above figure, shown 2 types of overloads protector and light its terminals with
the name of IN and Out. The (IN) means that we gave electric supply to this terminal and
(Out) means that we get electric supply for compressor or we can say that this point is
going to connect the compressor common terminal.
As have shown on this internal structure of overload in the above example diagram.
In the diagram, have shown the bimetallic strip metals with heating resistance with
incoming and outgoing supply. Whenever the compressor starts getting high current the
heating resistance heat up and creates an open electric circuit.
This one of the main reasons they use a thermal overload protector in refrigerator
compressor.

Watch the video to see where the overload protector place and how to replace.
(click the link below)

1. https://youtu.be/ItFs-tQ78OE - the circular type

2. https://youtu.be/IVjx922L4ME - the flat type

Filter Drier

What is a thermostat control switch?

A refrigerator thermostat is essentially the controlling component of a refrigerator

cooling system. It often looks like a dial or, in more modern appliances, a digital read-
out that tells owners how cold the appliance’s interior is and allows that temperature to
be shifted up and down. ( see figure 1)

Figure 1

A refrigerator thermostat controls the refrigerator cooling system which can be adjusted
using knobs. Usually located on the inside of a refrigerator.

Below is the actual image of a thermostat switch

Thermostat Control switch

TOOLS:

Types of screwdrivers and their uses:

a. Standard slot is a tool used for turning with a slot-head bolt or screw

b. Philips is a tool used for turning with Philips-head bolts or screw

c. Clutch head is a tool used for turning with a clutch head bolt or screw
 d. Torx head is a tool used for turning with a torx bolt or screw

e. Stub is a tool used for tightening or loosening in places where a longer blade will
not fit especially in narrow places.

f. Offset is a tool used for tightening or loosening in extremely close places.

Types of Wrenches and Their Uses
a. Open wrench is a tool used for working with hex-head bolts, nuts, or screws.

b. Box wrench refers to the tool with flat interior surfaces so that it is less likely to slip off
when working with hex-head bolts, nuts, or screws when added torque is applied.
c. Combination wrench is a tool with an open end and a box end. It is designed for the
convenience of an operator who may need an open end for speed tightening and
loosening while the box end is used for adding torque.

d. Adjustable open wrench is a tool used for working with hex-head bolts, nuts, and
screws of various sizes.

e. Pipe wrench is a tool used for working with pipe, pipe fittings, and other rounded
surfaces.
 f. Flare nut wrench is a tool used for working with hex-head nuts, bolts, or screws in
which the open end permits the wrench to slip over tubing.

Types of Pliers and Their Uses

a. Slip joint is a tool used for holding or turning a part where surface marring is not a problem.
b. Slip groove is a tool used on a wider surface and where more leverage may be required.

c. Long Nose is a tools used for holding small nuts, screws, or for reaching hard reached
places.

d. Diagonal cutter is a tool used for cutting wire only.

e. Self-locking pliers is a tool used for working where tight grip is needed. It also locks in place
to free operator to use another tool.

f. Pinch-off wrench is a tool designed especially to crimp refrigeration tubing to prevent loss of
refrigerant when a tube is being soldered or brazed.

Types of Hammer and Their Uses

a. Ball peen hammer is a tool used for hammering metal tools such as punches and
chisels.
b. Soft face hammer is a tool made of plastic, rawhide or material that will not mar or break
other tools or materials being hammered.

c. Sledge hammer is a tool made with a heavy steel head and a long handle for breaking or
pounding with substantial force.

d. Claw hammer is a tool used for driving or pulling nails

Punches, Chisels, Bars and Their Uses
a. Pin punch is a tool used for driving both straight and tapered pins into or out of hubs or
shafts.

b. Centre punch is a tool used for indenting metal to safely start a drill.

c. Flat chisel is a tool used for cutting off bolt heads or splitting nuts.
d. Pry bar is a tool used for a variety of jobs, but generally for prying equipment into alignment.
(Click the link below to see the video on how to used)
https://youtu.be/zDiwLYm5ofU

e. Scratch awl is a tool used for making on metal, making screw holes in sheet metal, and for
aligning screw holes.

Types of Files and Their Uses

a. Flat file is a tool used for smoothing metal surfaces; the surface is double-cut to help
promote even application.

b. Half round file is a tool used for fitting rounded surfaces.

c. Round File is a tool used for smoothing or enlarging holes in metal; because of the tapered
end, they are often called “rat-tail” files.

d. Point file is a tool used for cleaning up damaged threads or other “fine” work; it is sometimes
called a “saw” file.
e. Triangular file a tool used for working in tight places and “fine” finish work.

Socket Sets and Their Uses

a. Ratchet Handle is used to drive handle socket that fits on so that tightening or loosening
motion can be limited to a short back and forth motion.
b. Socket. Is a device that snaps onto a ratchet handle so the device can be used to work
on hex-head bolts or nuts.

c. Deep socket. Is a device that snaps on to a ratchet handle so the device can be used to
work on hex-head bolts or nuts that are in recessed places that a regular socket cannot
reach.
d. Extension. Refers to a rod that extends from the socket to the handle to extend the socket
into hard-to-reach places.

e. Torque wrench is a tool used for tightening hex-head bolts and nuts to specified limits
f. Speed handle is a tool used to drive by operating with both hands so that an operator can
loosen or tighten nuts and bolts quickly.

g. Universal joint refers to device that fits between a handle and a socket to permit the socket
to be turned to any one of several angles and to facilitate hard-to-reach nuts and bolts.

Tubing Tools and Their Uses

a. Tubing cutter is a tool used for smoothly cutting tubing with opposing cutting wheels that
are slowly tightened by a ratchet-like control as the cutter is turned around.
 Tubing cutter

b. Flaring block is a tool used for holding tubing according to its size so that it can be flared.

c. Flaring tool is a tool used for forcing a 45o cone into the end of a copper tube being held in
a flaring block.

d. Tube reamer is a tool used for cleaning burrs inside the tubing that has been cut; it is often
built into a tubing cutter.
e. Double flare punch is a tool used with a flaring block to bend tubing back and force it down
and roll it into the open tubing end to make a tube with double thickness.

f. Swage punch is a tool used for enlarging the end cut tubing so that another tube size can
be placed into the tubing and soldered
g. Lever-type bender is a tool used for bending tube in such a way that the tubing will retain
its rounded shape and not flatten out at the point of the bend.

h. Bending spring is a tool used for placement over the outside of the tubing to keep the
tubing from collapsing while it is being bent.

Threading Tools and Their Uses

a. Tap is a tool used for cutting inside threads in a hole.

b. Hand tap wrench refers to the handle used for threading inside threads with a tap.

c. T-handle tap Wrench refers to the handle with an adjustable holding device mush like
the chuck on a drill. Used with a tap to drill inside threads, especially smaller size
threads.
d. Round stock die is a tool used for cutting external threads on round stock and is
available in many sizes and specifications

e. Die stock refers to the handle that fits over a round stock die to secure it and facilitate
turning.

f. Pipe cutter refers to the adjustable clamp-type device with sharp-edged rollers that cut
into pipe as they are tightened and turned.
g. Pipe die is a tool used for cutting external threads on pipe.

h. Pipe die stock ratchet is a tool used for handle designed especially for speeding up the
cutting of external pipe threads.
Other Hand Tools and Their Uses
a. Wire stripper is a tool used for removing insulation from electrical wires without
damaging the wires.

b. Drop light is a tool used to provide light in dark or poorly-lit work areas. These lights
frequently have an electrical outlet in the handle, but because they are made of small-
gauge wire, they should not be used to power appliances such as refrigerators.

c. Oil can refers to a tool that has a long, flexible spout to reach hard-to-reach places, a
cap to prevent oil from dripping out.
 d. Hack saw is a tool used for cutting metals in installation and service work, but not
recommended for cutting refrigeration tubing because the fittings can contaminate a
system.

e. Screw starter is used for starting small slot or Philips head screws in hard-to-reach
places.

Prepared by:

ERWIN B. LUMILAN
Instructor