Module 1: Fundamentals of Refrigeration and Air

Conditioning Systems
Principles of Refrigeration & Air Then lastly as shown in areas 3 & 4, with the heat
Conditioning removed from the refrigerant, it is circulated back
to the evaporator to repeat the process

When heat is moved, the temperature of the

substance it moved from drops, while the
A refrigerator is another example of how the heat
temperature of the substance it moves to rises
movement by refrigeration is related to space
temperature. To keep food cold and avoid
spoilage, heat must be removed from the food to
the air in the room. As in air conditioning example,
this happens in several steps too.

Looking on a living space cooled by a central

conditioning system, the heat must be removed
in order to cool the space.

First the heat is removed from the indoor air to

First, the heat moves from the food into the
the refrigerant circulating through the evaporator
surrounding cooler air. This increases the
which will allow the temperature of the air
temperature of the air and decreases the
moving over the evaporator to drop.
temperature of the food.
Second, when heat is absorbed by the refrigerant
Next, the heated air moves into the refrigerant
in the evaporator and is moved along to the
circulating through the evaporator coil. This
condenser. Then the heat moves from the
causes the temperature of the air coming off the
refrigerator to the outdoor air which causes the
coil to drop.
outdoor air temperature to rise as it flows over the
condenser.
That heat is then moved along by refrigerant
flow to the condenser coil (underneath)

4 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

where it is moved from the refrigerant to the
room air circulating over that coil. This causes the
room air temperature to rise.

In both examples, refrigeration moved heat, in

several steps, from the place where it wasn't
wanted to a place where it was less objectionable.
The result was a lowering of temperature in the
area from which heat was removed and a rise of
temperature in the area to which the heat was
transported.

Refrigeration Cycle It flows between components, through

refrigerant piping, in the direction indicated by
arrows. The order in which it flows through the
components is always the same for cooling
applications.

There are many types of mechanical refrigeration

systems. They come in a great variety of shapes,
sizes, component arrangements, and uses. If you
build your understanding of refrigeration by trying
to learn about each one, you will have a very long Refrigeration is defined in its simplest term as
and difficult task ahead. If, on the other hand, you cooling by removal of heat. In terms of heat
work hard at learning the basics of refrigeration transfer, refrigeration is the transfer of heat from
presented earlier. The principles of mechanical a place where it is not wanted to a place where it
refrigeration and essential components of a is less objectionable.
system are the same, no matter how big or small
the system, and no matter how the system is
packaged.

So let's begin about learning the things all

refrigeration systems have in common. Then you
will find it easy to sort out the details that make
one system different from another. Here is a
schematic diagram of a mechanical refrigeration
system. You will recall that there are four
components. A fluid (a liquid or gas), called
refrigerant, is circulated through each component
for the purpose of moving heat.

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The normal strategy in mechanical refrigeration is devices to move heat. It has neither a compressor
first to get the heat into the refrigerant. Then, the nor a metering device. Heat naturally flows a
refrigerant is pumped to a place where the heat warmer to a cooler temperature. Here, the
can be removed from it. The refrigerant makes refrigerant picks up heat from the outdoor air and
this heat transfer possible. rejects that heat to the indoor air. The space will
soon reach the same temperature as the outdoor
For, practical purposes, a refrigerant is a fluid that air. What is really needed is a way to move heat
picks up heat by evaporating at a low temperature from a lower temperature area (the indoor air) to
and pressure and gives up heat by condensing at a higher one works against the laws of nature
a higher temperature and pressure. and, therefore, requires mechanical energy.

Most of the heat transfer in mechanical Notice also that this closed cycle refrigeration
refrigeration system takes place because the system has the outdoor coil evaporating liquid
refrigerant changes state. The liquid refrigerant refrigerant into a vapor, while the indoor coil
passes through an evaporator that absorbs its condenses vapor refrigerant into liquid. We need
latent heat of vaporization, and in the process to rearrange temperatures and pressures within
changes from a liquid into a vapor. the refrigeration system so that just the opposite
occurs. The indoor coil must evaporate liquid
refrigerant into a vapor by absorbing heat from
the indoor air. It will cool the indoor air in the
process. The outdoor coil must condense gas
refrigerant into a liquid by transferring heat from
the refrigerant to the outdoor air.

Adding a compressor and a metering device

solves the problem by making it a mechanical
refrigeration system. These two components will
allow us to do two things that were impossible
without them. First, the compressor allows us to
add mechanical energy to the refrigerant so that
The gas refrigerant passing through the heat can be forced to "uphill". Secondly, they
condenser rejects its latent heat of vaporization, allow us to create two pressure zones in the same
thus changing from a gas the refrigerant from a system. Our system needs to absorb heat from
liquid into a gas, and then from a gas back into a the indoor air in order to keep it cooler indoors
liquid, is what moves heat to the desired place. than outdoors. The refrigerant in a system
absorbs heat when it evaporates (boils). We need
The system shown here illustrates why closed a system that will evaporate refrigerant at low
refrigeration systems must have mechanical enough temperature that heat will flow from the

6 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

indoor air into the refrigerant within the air-cooled condenser when it is 95F outdoors is
evaporator. In a comfort air conditioning system, about 120F. As in the evaporator, proper
a normal saturation temperature for the pressure will cause the refrigerant to change
refrigerant in the evaporator 40F. state at the desired temperature. For R-22, a
saturation temperature of 120 occurs at a
pressure of about 263 PSIG.

Heat will flow downhill from the 75F air flowing

The compressor and metering device work
over the coil to the 40F refrigerant within it. Since
together to create a high-pressure zone and a
pressure and boiling points are directly related for
low-pressure zone in the same system. They
all fluids, the refrigerant can be made to
allow the same refrigerant that evaporates at 40F
evaporate at a desired temperature simply by
to condensate at 120F.
adjusting its pressure to the proper level. For R-
22 a saturation temperature of 40F occurs at a These two devices mark the dividing points
pressure of about 69F PSIG. between the high-pressure side and low-pressure
side, or simply high side and low side of the
refrigeration system.

Looking at the system diagram, we will review the

components on the high side and low side the
system. Locate each item mentioned in the
diagram as it is discussed.

The compressor takes in refrigerant gas at low

pressure and temperature (about 40F) and
compresses it. The discharge of the compressor
is on the high side of the system.

Our system also needs to reject heat from the

refrigerant to the outdoor air in order to move heat
out of the building and to make the refrigerant
reusable at the evaporator the next time it goes
around the system. The refrigerant rejects heat
when it condenses from a gas into a liquid. We
need a system that will condense refrigerant at a
high enough temperature that heat will flow from
the refrigerant within the condenser coil into the
outdoor air flowing over the coil. A normal
saturation temperature for the refrigerant in an

7 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

The compressor is on the high side of the system. Piping is used to interconnect these components
The compressor has raised the pressure to about and to keep the refrigerant closed off from
263 PSIG and the temperature to 170F. Also, on contamination by the environment outside the
the high side is the interconnecting tubing ("line") system. Many accessories are available for the
that carries the hot gas from the compressor to refrigeration system, but they are not absolutely
the condenser coil is on the high side as is the essential to its operation. They will be covered in
liquid line which connects the condenser to the a separate module. Now let's take a closer look
metering device. Refrigerant enters the metering at each of these four basic components.
device at a high-pressure and temperature, but
leaves at a low pressure and temperature.

The four basic components can be divided into

two groups, each containing two items. The first
The inlet of the metering device is on the high group is heat exchangers; these transfer heat.
side, but the outlet is on the low side of the The evaporator and condenser make up this
system. The evaporator coil also is on the low group. The second is mechanical devices which
side of the system, as is the suction line regulate refrigerant pressure and flow within the
connecting the evaporator with the inlet to the system. The compressor and liquid metering
compressor. The suction, or inlet, side of the device belong to this group..
compressor is the last item on the low side
Molecules, Heat, and Temperature
system.

In summary, the basic, essential components of

a mechanical refrigeration system are:

1. An evaporator to absorb heat into the

refrigeration system
2. A condenser to reject heat from the
refrigeration system
3. A compressor to establish the
pressures necessary to force heat to
flow "uphill"
4. A liquid metering device to regulate The refrigerant R-22 changes from a liquid to a
the flow of the refrigerant, and in the vapor at 40F and a pressure of 69 PSIG, for
process, to establish two pressure example. Therefore, as we continue to heat the
levels. R-22, it will eventually turn into vapor or gas.
Notice how much farther the molecules are
separated as a 40 F gas than they were as 40F
liquid. There has been a huge change in density
during this latent heating process. The R-22

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molecules will be about 52 times farther apart as the latent heat in a gas is greater than the
a gas than as a liquid. This separation causes the sensible heat. For that reason, it is important in
density to decrease about 98% from what it was refrigeration that we measure total heat. This
as a 40F liquid. The change of state causes a big
measurement is expressed in BTU's.
change in spacing and arrangement but very little
change in the velocity of the molecule.

Technically, anything above about -460F

A great deal of heat is required to achieve this (absolute zero) contains some heat. Cold,
new spacing and arrangement of molecules, but therefore, is really a relative term. From a human
it doesn't show up on the thermometer. This heat viewpoint, ice feels cold to the touch because skin
remains in the refrigerant as long as it is a vapor. temperature is about 92F and the ice is 32F or
Temperature does not measure the spacing and below. The ice is only cold in comparison with a
arrangement molecules within a substance. finger.

The heat that can be measured by the

temperature can be sensed by a thermometer,
and is called sensible heat. The heat that cannot
be measured by temperature, likewise cannot be
measured by a thermometer, and is called latent
heat. Latent heat is the amount of heat that is lost
or absorbed into substance such as R-22 in order
to change its state.

Likewise, from the viewpoint of the outdoor unit

on a central air conditioning system, 95F air is
relatively cool. The R-22 refrigerant circulating
through it tubes is about 120F, which is much
warmer than the outdoor air. Since the goal in
mechanical refrigeration is controlling the
movement of heat, the right question to ask is,
"How much heat energy does it contain?" rather
than, "How cold is it?"
The total heat contained in our sample of R-22
gas at 40F is equal to its sensible heat plus its
latent heat. This is true of any substance. Often

9 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

Temperature and outdoor temperatures are the same. no heat
will flow. There is neither heat loss from the
space, nor heat gain into it.

Temperature is the measure of the intensity of het

in a substance. It can also be thought of as the
degree of heat of a substance. It does not
If the refrigerant temperature is equal to that of
measure the heat energy which was required to
the air flowing over the coil, there is no heat
change the state of a substance form a solid into
transfer, and therefore no cooling capacity is
a liquid or from a liquid into a vapor. In other
provided by the coil.
words, temperature measures sensible heat, but
not latent heat.

If the air temperature is lower than that of the

refrigerant in the coil tubes, heat will flow from the
The two scales used in refrigeration service work refrigerant inside the coil to the air moving over
for measuring temperature are Fahrenheit scale the coil. Since the air is heated, we can say that
(expressed in degrees F) and the Centigrade the coil provides heating capacity in this scenario.
scale (expressed in degrees C). The boiling point
for water at sea level is 212F or 100C. Its freezing Methods of Heat Flow
point is 32F or 0C. A comfortable 75F room is
about 24C. Since Fahrenheit is the most Heat is transferred by conduction, convection,
commonly used temperature scale. and radiation. We'll look more closely at each of
these by first defining the term and then by
Heat Transfer viewing each method as it occurs in three
settings: first, in nature; second, as it appears in
In an occupied space in a cold climate, heat will a space - as load; and finally, as it applies to
flow out. This is a heat loss. When it is hot equipment as capacity. In nature, we don't see
outside, heat flow from the hotter outdoor air into the forms neatly separated. They are generally
the cooler indoor air. This is a heat gain. If indoor mixed together.

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 If one end of an iron bar is kept in a flame,
conduction eventually will cause it to become too
hot to hold. Conduction through roofs, walls,
windows and doors is what allows heat to enter a
tightly-sealed house as cooling load.

Conduction is also what allows a cooling coil to

provide the capacity to the air. Heat from the air
moves into the cold refrigerant by being
conducted through the cooling coil.

Conduction is the transfer of heat from molecule

to molecule through a substance by chain
collision. Heat added at one place causes the
temperature of the substance being heated to go
up because the molecules move about more
rapidly.

Convection is heat transfer by the movement or

flow of molecules within a flowing medium such
as air carry their heat directly to a new area. In a
forced air heating system, for example, air flowing
through the conditioned space carries heat by
convection.

These high velocity molecules near them. The

chain reaction moves throughout the material.
While conduction takes place in gases and
liquids, it works best when molecules are closely
packed, as they are in solids.

Convection currents are easy to see in a pan of

water being heated on a stove, especially just
before boiling begins.

Natural convection currents like these are also

called "density currents" because their movement
is caused by differences in fluid density, which are
a result of temperature differences. Less dense
fluids tend to rise, while more dense fluids fall.

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 understood because radiant heat can't be defined
in terms of colliding and moving molecules.

In cold climates, convection causes heavy, cold

air to form a downdraft off outside walls and
especially windows. As new air rushes in behind
that which falls off the windows, heat is Radiant heat usually behaves as a wave form of
transferred from above the windows down to the energy but also possesses some qualities of
windows, where it becomes heat loss (heat load) energized, moving particles.
for the space. In this case, convection causes
discomfort because of the cold "puddle" of air
which builds up on the floor.

Radiant heat has the ability to pass one place to

another without heating up the area in between.
For example, a camper sitting in front of a fire on
Convection can also be at work as heating a cold night can get warmed even though the air
capacity when a baseboard heater is installed between him and the fire remains cold. This is
below a cold window. As the less dense, heated because radiant heat can only heat what it hits.
air moves upward, it takes heating capacity to the As a result, the camper's front side is warmed but
load at the window, wall and ceiling. As the air his back remains cold.
molecules lose their heat energy, they become
colder and denser, falling toward the floor. Cold Radiant heat can only heat material into which it
air moves into the heater to make up for the warm is absorbed. The camper will get warmest by
air moving up; this solves the downdraft and cold wearing dull, clack clothing and will remain
puddle problem. coldest by wearing reflective clothing - other
things being equal. This is why people in hot,
Radiation is the most common, and least sunny climates tend to wear white clothing.
understood, method of heat transfer. It is most White is a good reflector of the sun's radiant
common because most of the heat energy of our heat energy.
planet comes from solar radiation. It is least

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Solar radiation comes through windows in a Materials which help heat move by conduction
building, strikes walls, floors, furniture and are called conductors. Those which retard it are
people, and is absorbed by them. As it is called insulators. Good insulators make poor
absorbed, it heats up the space and becomes a conductors and vice versa.
cooling load which may need to be removed by
cooling equipment.

We use good conductors when we want heat to

be transferred. We use good insulators when we
Radiant heat is sometimes used to provide want heat to stay where it is. For example, we put
heating capacity from overhead as a method of fiberglass insulation in our attics to help keep heat
warming people or products, without heating the from escaping.
air in between, or the entire area. Radiant heat is
almost always seen in combination with other
forms of heat.

Materials
Heat transfer can be greatly affected by the
materials selected in constructing buildings and
heat transfer equipment. Conduction, convection,
and radiation are all affected by materials, but we
will focus our attention on conduction because it
affects us in a major way in refrigeration load and
equipment.

As a general rule, materials that conduct

electricity well will also be good thermal
conductors. Metals are good conductors. Silver

13 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

and gold are excellent, but not very practical for found between the panes of a double glass
use in heating and refrigeration equipment. window. Corkboard and wood products,
Copper is nearly as good a conductor as silver especially soft woods, are also good insulators.
and has the advantage of being much less
expensive. Aluminum, among other common
metals, is also an excellent conductor and is
relatively inexpensive. That's one reason most
heat transfer coils are made of copper tubes with
aluminum fins. This arrangement speeds heat
transfer from the air into the refrigerant within the
cooling coil, or from the fluid within a heating coil
into the air flowing over it.

Since insulators slow down heat transfer by

conduction, they are used in buildings both above
and below ground, as shown by the arrows in this
diagram. The cabinet of cooling coils is often
insulated to prevent the casing from becoming so
cold that water in the air condensed on the
outside, causing "sweating". The casings of the
furnaces are often insulated to prevent the
outside from becoming so hot that it is dangerous
Since copper and aluminum tend to melt under to people or the building.
intense heat, steel or cast iron is often used for
heat exchangers on direct-fired heating Kinds of Heat
equipment like the furnace shown here. A good
conductor speeds the heat transfer from the
flame to the air flowing over the outside of the
heat exchanger.

For practical purposes, all material possesses

heat energy. As we have already seen, this
energy exists in two forms. Sensible heat is the
energy of molecular motion. It is measured by
temperature and always causes a temperature
Trapped air is one of the very best insulators change in substance heated.
available. Examples include expanded
For example, when a pan of water at 32F is
polystyrene foam board, fiberglass and cellulose
placed on a stove and heated so that the
insulation, and dead air spaces such as those

14 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

temperature climbs from 32F to 212F, it is a it boils, the temperature stays at 212F. This is a
sensible heating process. latent heating process. The temperature does not
change, but the state changes from liquid into
gas. As we saw earlier, much energy will go into
separating and rear-ranging the water molecules
to make the liquid a gas.

A characteristic of a refrigerant is its ability to boil;

that is, to change from a liquid to a gas at a low
temperature.

The temperature has changed, but the state

(liquid) has not. No boiling has occurred.

The total heat of a material is equal to its sensible

plus latent heat. The total heat of any material will
change if either its temperature or state changes.
Liquids and gases contain both sensible and
latent heat.

Latent heat is the energy of molecular separation

and arrangement. It cannot be measured with a
thermometer. A latent heat change causes a
change of state at a constant temperature.

For example, the water a 32F contains the

sensible heat needed to warm solid water (ice) to
its melting point (32F). It also contains the latent
heat needed to melt the 32F ice int 32F water.
Both sensible and latent heat enter spaces and
If the pan of water at 212F is further heated, it will become a cooling load which must be removed
begin to boil. As heat is added, it will continue to by refrigeration equipment in order to maintain
boil until all the water turns to steam (gas). While comfort.

15 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 a liquid and condenses on the cold surface. This
is the same thing we observe when water vapor
condenses on the outside of a glass of iced tea.
The air coming off the coil is not only colder, but
is also drier than when it entered. The process
allows the air to absorb both sensible and latent
heat when it enters the space.

When it is 95F outdoors, heat is conducted from

outdoors to indoors through the roof, ceiling,
walls, windows and doors of a building. This adds
sensible heat to the indoor air, raising its
temperature.

Radiant heat also adds sensible heat to the air as

sunlight enters through windows and is absorbed
by objects inside. Sensible heat is also added to Heating coils add sensible heat to indoor air. In
the air by people, lights and cooking. Latent heat such cases, the coil provides heating capacity.
is added by anything that turns water into vapor - For example, air returning from the heated space
cooking, for example. Even though such latent at 70F id heated to 95F as heat from the fluid
heat additions don't raise the indoor air inside the coil is conducted to the cooler air
temperature, they increase its relative humidity. flowing over the coil.
The total heat entering a space is the total cooling
load for that space. It contains the sensible heat
(sensible cooling load) plus the latent heat (latent
cooling load).

Latent heat transfer is the main way mechanical

refrigeration systems move heat. This close up
look of a cooling coil shows how cooling of the air
is accomplished.
Sensible heat in a warm house moves into the
cold refrigerant of a cooling coil as the air flows Liquid refrigerant in the indoor coil tubes boils at
over it. The coil is providing sensible cooling a fairly constant temperature. As the refrigerant
capacity as it removes sensible heat from the air, flows back and forth through the coil tubes, more
reducing the air temperature from 80F to 53F. and more liquid refrigerants boil away until it is all
This process also removes latent heat from the gas. The latent heat required to boil this
air as the water vapor in the air changes state to refrigerant is taken from the air into the

16 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

refrigerant, thus cooling the air. This boiling • In case of a spill, evacuate the area
process is called evaporation in the refrigeration immediately, and procure the required
business. The coil where evaporation takes place breathing apparatus before returning to
is called the evaporator. The latent heat transfer the area
process happens at a low temperature because • Do not puncture cylinders or drums and
of the nature of the refrigerant and low pressure follow all precaution for handling and use
in this part of the system. of compress gas cylinder. When used
indoors provide sufficient air exchange or
use local exhaust in work room.
• Ensure adequate earthing because liquid
refrigerants transferred between
containers and from system can result in
static charge generation which can lead
to an explosion.

Storage of New and Used HCFC Refrigerants

• Cylinders containing HCFC refrigerants

should be stored upright in original
containers or other approved containers.
Refrigerant in the outdoor coil condenses (from a • They should be stored at or below a
gas into a liquid) at a fairly constant temperature. temperature of 50C. If stored at or below
As the refrigerant flows back and forth through the 50C, they should never be more that 80%
coil, more and more of it condenses from a gas filled. If the cylinders are exposed to
into a liquid until it becomes completely liquid. temperature above 50C, they should not
be more than 60% filled.
The latent heat required to condense this gas is • Never apply steam or direct flame to the
rejected from the refrigerant into the air, thus cylinder
heating the air. In the refrigeration into the air, this
• All HCFC refrigerants vapor are heavier
process is called condensation. The coil where
than air, therefore, they should be stored
condensation takes place is called condenser.
above ground level in well ventilated
The temperature at which condensation happens
area.
is higher than the temperature for evaporation
• If stored inside, the area should be dry
because the pressure in the condenser is higher
and properly ventilated, refrigerant leak
than it is in the evaporator.
detector should be installed to monitor
RAC Safety Rules indoor air quality.
Handling of New and Used Refrigerants • Cylinders should be protected from salt
and other corrosive chemicals.
• All refrigerants should be handled in • HCFC refrigerants react violently with
accordance with good industrial hygiene alkali or alkali earth metals such as
and safety practices sodium, potassium, barium in the free
• Wear personal protective equipment to state. The reaction might be explosive if
protect against contact with skin, eye and the metals are in the fine-grained or
clothing. powered state. Therefore, they should be
• Do not breathe vapor or spray mist and stored in separate areas.
avoid all contact with skin, eye and • Recovered refrigerants should only be
clothing. When handling HCFC stored in approved recovery cylinders
refrigerants do not eat, drink or smoke. painted gray with the top shoulder portion
painted yellow.

17 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 • Recovery cylinders should be properly cylinder on its base or lay it down to roll
labeled on its side.
• Storage cylinders should be inspected • A forklift truck should be used to move
periodically for damage or deterioration large containers of refrigerant on pallets.
of condition during storage. During • Never strap or lift cylinder by the valve or
inspection examine the valve assembly valve cover.
for leakage, damage or tampering.
Inspection should be carried out at least Electric Hazards & First Aid for an Electric
once every six months. Shock Victim
• Most of the cylinders used for HCFC
Hazards Associated with Electricity
refrigerants are steel cylinders and are
under pressure, therefore, they should be Electricity is widely recognized as a serious
handled carefully and all guidelines for workplace hazard, exposing employees to
handling compress gas cylinders electric shock, burns, fires, and explosions. Some
observed. have been killed or injured in fires and explosions
• Never drop cylinders whether empty or caused by electricity.
full or hit with a hammer or other sharp or
blunt object. How is First Aid administered for Electric
Shock?
Transportation of New and Used HCFC
Refrigerants • First Aid tips for an Electric Shock:
• Eliminate contact with the electrical
• Vehicles used for transporting cylinders source immediately: Turn the switch off,
should be open, the use of cars, vans, or or turn off the circuit breaker, or using a
any other enclosed vehicle is extremely non-conducting material, such as a
dangerous, and should be avoided. If this wooden plank, firm cardboard, or a piece
cannot be achieved the vehicle should be of plastic item (or even a piece of
properly ventilated. furniture, like a chair), as a conduit, push
• A 2kg fire extinguisher is required on all the person away from the electrical
vehicles carrying gas cylinders to fight source. DO NOT touch the person, until
engine and cab fires this is accomplished
• All compressed gas cylinders should be • If the electrical source is a high voltage
secured from movement during line, avoid approaching the affected
transportation and should not project individual, but call 9-1-1 immediately.
beyond the sides or ends of the vehicle. Only the electric power company can turn
Cylinders that can move may open off high power lines; but you may try to
accidentally, or roll off the vehicle into the push the person away from the electrical
path of oncoming traffic. source, using a non-conducting material
• Always install the protective cap on the (made of wood, plastic, or cardboard), if
cylinders when they are being it is available
transported. If the cylinders were not • If the individual has trouble (or stopped)
designed to accept a protective cap over breathing, perform cardiopulmonary
the valve, special care must be taken to resuscitation (CPR) immediately
prevent the valve from damage or • Prevent shock, by making the individual
opening during transportation. lay down with legs raised above their
• When moving cylinders within the work heart-level, and cover him/her with a
site, they must be firmly strapped onto an blanket
appropriate wheeled device. Never roll a

18 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 • If there are minor external burns, these right hand use) or facing right (for left-
should be cooled with running water (and hand use).
NOT ice), or soak for 10 minutes, until the
burnt area cools down. Then, cover the
affected area with a sterile gauze or cloth
• Seek help from a medical professional,
as early as possible

Safety Information for Oxy-acetylene Welding

Apparatus 5. Check torch handle to make sure it is
1. Before you begin, perform Hover Test.
closed by gently turning knobs counter
Place the back of your bare hand close to
a work surface or tool before touching or clockwise to open and then clockwise to
setting down something heat sensitive. completely close.
Welding tables, stationary equipment,
tools, and scrap material might not
appear hot, but may be hot enough to
injure you or damage equipment.

2. Take enough hose off hanger carefully

so the mixer reaches the welding table
without creating a tripping hazard
6. Check regulator keys to make sure they
are backed out (disengaged) and
approximately ½ inch of threads are
exposed.

3. Inspect the hose for wear or damage by

making your way from the torch handle to
the regulators.
7. Standing to the side of regulators,
open both oxygen and acetylene shut-off
valves slowly by turning counter-
clockwise until fully opened, then close ½
turn clockwise.

4. Install tip into mixer, hand tighten nut

on top with touch tip facing to the left (for

19 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 8. Open acetylene (red) and oxygen General Rules for Shop Safety
(green) mixer valves ¼ turn while
directing welding tip towards exhaust. 1. Learn to operate each machine properly.
Turn regulator key clockwise until 5 psi 2. Know the entire procedure before
registers on regulator gauge, always starting a job
3. Do not rush or take chances.
reading in red. Then close mixer valve.
4. Use only properly guarded and safe
equipment.
5. Use proper attire in the shop
6. Never work in the shop if you are tired
7. Ask for assistance when necessary.
8. Do not engage in horse play in the shop.
9. Check the machine set-up before
operating.
10. Observe cleanliness and orderliness in
the shop.

9. Before the torch is lit, put on welding Steps for Safe Lifting
gloves and oxygen-acetylene goggles.
Jobs that require heavy lifting are hard on the
back, especially for employees who have not
been trained to lift properly. Proper lifting
techniques can minimize back strain and on the
job injuries. Follow these six easy steps to lift a
heavy object.

1. Test the Weight of the Item. Judge the weight

of the item to be picked up by nudging it with one
foot or picking up the corner of the item.
Determine if you can pick it up and carry it
yourself, or if you will need a dolly or other lifting
assistance.

2. Figure Out the Route You Will Take. Know

ahead of time what route you will take and make
sure there will be nothing in your way. Do this
even for short distances.

3. Stand Close to the Object to be Lifted. Stand

close to the object you are going to lift, with your
feet shoulder width apart. Bend your knees and
keep your back and neck straight. Continue
looking ahead while you grasp the object.

4. Bend at the Knees and Push Up with Your

Heels. Don’t lift the object using your back.
Instead, keep looking straight ahead and push up
with your heels and your leg muscles. Your back
should not be bearing any of the weight at all
during lifting.

20 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

5. Move the Item. Take deep breaths and go 2. Box End - used for tightening or
slowly as you move the item to its designated loosening hex head bolts, nuts, or
location. If you have to turn while you are carrying screws, but less likely to slip off
the object, make sure to move your feet instead 3. Combination - used for tightening or
of twisting your spine. loosening hex head bolts, nuts or
screws
6. Set the Item Down. When you set the item Adjustable Open End - used for
down, you will simply reverse how you picked it tightening or loosening various size of
up. Don’t bend your back – instead, bend your hex and square head nuts, bolts, and
knees while keeping your back straight and screws.
looking straight ahead. Pipe - primarily used for tightening or
loosening round pipe or other rounded
What to Do When Injuries Happen Anyway?
surfaces.
Even the most cautious of lifters can experience Flare nut - used for tightening or
work injuries. It’s highly likely that your job will loosening a flare nut; it can be slipped
cause back strain over time or acute back injuries over the tubing
if you lift heavy objects throughout your shift.
C. Pliers
When you experience an on the job injury, the first
thing you need to do is get medical assistance. 1. Slip Joint - used for holding or turning a
Whether you suspect your injury has part where marring of the surface is not
accumulated over time or you are in significant a problem
pain after a sudden injury, it’s crucial that you are 2. Slip Groove - used for the same purpose
evaluated by a medical professional as soon as as slip joint but the jaws will generally
possible. open wider and the handles provide
more leverage
Refrigeration Tools, Devices and Equipment
3. Long nose - used for holding or reaching
for Installation, Troubleshooting and Repair
small items
Hand Tool Use 4. Diagonal cutters - used for wire
5. Plier Wrench - used for an excessively
A. Screwdrivers tight grip; it has a locking lever to
prevent slipping
1. Standard slot - used for tightening or 6. Pinch-off - used for crimping
loosening bolts and screws with a slot refrigeration tubing to prevent the loss of
type head refrigerant while it is being soldered or
2. Phillips -used for tightening or loosening brazed
bolts and screws with a Phillips type
head D. Hammers
3. Clutch Head - used for tightening or
loosening a clutch head bolts or screw. 1. Ball Peen - used for hammering on
4. Stubby - used for working in close metal tools such as punches and chisels
places where a jonger blade would fit 2. Soft Face - used for hammering on or
5. Offset - used for working extremely driving materials that a steel face
close places hammer would mark or break
3. Sledge - used for breaking and
B. Wrenches pounding; it is heavy, ling handled, and
has steel face
1. Open End - used for tightening or 4. Claw - generally used for driving and
loosening hex head bolts, nuts or pulling nails
screws

21 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

E. Punches, Chisels and Bars 5. Extension - rod that fits between the
socket and the drive handle to extend
1. Pin Punch - used for driving both the socket into hard to reach places.
straight and tapered pins or out of hubs 6. Speed Handle - drive handle used with a
and shafts socket to tighten or loosen bolts and
2. Center Punch - used for making nuts quickly that are easy to reach
indentations in metal for starting a drill 7. Universal joint - Fits between the drive
3. Flat Chisel - used for cutting bolt heads handle and the socket and bends in any
or splitting nuts direction enabling the socket to get to
4. Pry Bar - generally used for jobs that hard to reach nuts or bolts
require prying an object into alignment
5. Scratch Awl - generally for scratching a H. Tubing Tools
line on metal, making screw holes in
sheet metal, and for aligning screw 1. Flaring Tools - used for forcing a 45
holes. degrees cone into the end of a piece of
tubing being held by a flaring block
F. Files which created a flare on the tubing
2. Tubing Reamer - used for removing the
1. Flat - used for smoothing metal surfaces burr from the inside of tubing after it has
it is a double cut file been cut.
2. Half Round - used for filing rounded 3. Flare Block - used for holding the tubing
surfaces on metals while it is being flared or swaged
3. Round - generally used for enlarging 4. Tubing Cutter - used for cutting the
holes in metal tubing by tightening it onto the tubing
4. Point - used for filing contact points; it is and rotating it at the same time
a small, thin file 5. Double Flare - device which is placed in
5. Slim Taper - generally used for cleaning the tubing and forced down, which
up damaged threads causes the end of the tubing to roll-in,
6. File Handle - wooden handle placed on which makes a flare with double tubing
the end of the file to prevent it from thickness
gouging one's hand
I. Special Tools
G. Socket Sets
1. Refrigeration Gauge Set - used for
1. Ratchet - used to permit tightening or charging, evacuating and checking
loosening with very little swinging room, pressures on refrigerant systems.
it is a drive handle that sockets fit onto 2. Leak Detectors - used for locating
2. Socket - used for tightening or loosening refrigerant leaks
a hex head bolt or nut; used in a. Soap Solution
conjunction with a drive handle b. Halide Torch
3. Deep Socket - socket with an extended c. Electronic
wall for reaching recessed bolts and 3. Drill Motors
nuts that have bolt extending through a. Straight - used for drilling holes
them so far that the standard socket will in metal or wood
not fit over them b. Offset - used for drilling holes in
4. Hinge Handle - drive handle that is used metal or wood in limited working
with sockets when more force is needed space
to break loose or tighten a nut or bolt 4. Drill Bits
a. Twist - used for drilling metal
b. Wood - used for drilling wood

22 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 c. Masonry - used for drilling humidity changes which gives a
concrete and stone meter reading
5. Bench Grinders - used for grinding metal c. Humidity Recorder - used to
edges record humidity changes on a
6. Vises time chart
a. Bench - used for holding object 11. Vacuum Pumps
secure when being drilled, filed, a. Low Vacuum - used for
sawed or electrically tested evacuating a refrigeration
b. Pipe - used to hold pipe or system and used in conjunction
conduit secure when being cut, with gauge manifold
threaded or reamed. b. High Vacuum - used for
7. Pullers evacuating a refrigeration
a. Wheel - used for removing system and used in conjunction
pulleys and bearings from motor with a human vacuum gauge
shaft manifold and micron gauge
b. Bearing - used for removing or 12. Vacuum Indicators
installing bearing and bushings a. Compound Gauge - indicates
in motors vacuum accurately to 25 inches
c. Gear - used for removing small of mercury
pulleys or gears from motor b. Mercury Manometer - indicates
shafts an accurate vacuum reading
8. Thermometers below 25 inches used with a
a. Pocket - used for checking the vacuum pump
temperature of components and c. Thermocouple Micron Gauge -
systems an extremely accurate vacuum
b. Remote Bulb - used for indicator, used in conjunction
checking temperatures in one with a high vacuum pump
area and reading the 13. Capillary Tube Cleaners
temperature on a dial in another a. Manual - used to force oil or R-
area 11 through a capillary tube
c. Flue and Stack - used for when the pressure handle is
checking the temperatures turned clockwise
created in gas flues and stacks b. Hydraulic - used to force oil or
d. Thermal Electric - used for R-11 through a capillary tube
measuring temperatures from - with thw use of hydraulic pump
50F to as high as +1,000F 14. Charging Cylinder - used for charging
9. Recording Thermometers the proper amount of refrigerant into a
a. Manual Wind - used to record system used with a gauge manifold set
temperatures on a time chart 15. Service Valves
b. Electric - used to record a. Hermetic Service Valve Kit -
temperatures on a strip chart allows the connection of
10. Hygrometers refrigeration gauges to some
a. Sling Psychrometer - wet bulb hermetic systems
and dry bulb temperatures will b. Access Core Type Valves -
be obtained by whirling the allows the refrigerant system
psychrometer for 15 to 20 pressures to be checked when
seconds the gauge hose depressed the
b. Dual Type - used to contain core.
human hair that reacts to

23 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 c. Process Tube Adapters - used a. Right-hand - used for cutting
to provide a gauge connection sheet metal in a right-handed
by fitting onto the end of the direction
charging stubs b. Left-hand - used for cutting
d. Line Piercing Valves - allows a sheet metal in a left-handed
gauge connection by tightening direction
onto a charging stub and 29. Double Cutting Snips - used for cutting
piercing it sheet metal where both pieces of metal
16. Scales - used for weighing the amount must lay flat.
of refrigerant during the charging 30. Hand Crimper - used for crimping the
process end of sheet metal pipe so that sections
17. Fin Combs - used for straightening the may be fitted together
heat transfer fins on condenser and 31. Refrigeration Ratchet - used for front
evaporators. seating and back seating service valves
18. Oil Pump - used for putting on into a and acetylene cylinder valves
compressor without the danger of 32. Swage Punch - driven into the end of a
contamination tube to enlarge it so that another tube of
19. Combustion Testing Kit - used for the same size may be placed in it and
servicing gas or oil furnaces to detect soldered.
CO2 content, draft, stack temperature, 33. Lever-Type Bender - Tubing is held
and smoke. securely against the bender and the arm
20. Air Meters is slid over the tubing forcing the tubing
a. Anemometer - measures the into the rounded end of the bender.
spread of the air being supplied 34. Bending Spring - Coil Spring which is
through a grille placed on the outside of tubing to keep it
b. Pitot Tube - determines the from collapsing while bending
speed by obtaining air pressure 35. Accessory Hand Tools
through a grille a. Wire Strippers - used to remove
c. Incline Manometer - used with a the insulation from electrical
pitot tube to determine air wire without damaging the wire
velocity pressure and static b. Drop Light - used to light in dark
pressure work areas; it has a protective
21. Appliance Truck - used for moving reflective shield and an
refrigerators and other heavy equipment electrical outlet in the handle.
22. Knock-out Cutter - used for making c. Oil Can - should have a flexible
holes in sheet metal spout for reaching difficult
23. Combination Pattern Snips - used for all places and a cap to prevent
general purpose cutting of sheet metal spillage
24. Hand Notcher - used for cutting notches d. Hack Saw - used for cutting
in the edge of sheet metal metals in installation and service
25. Hand Seamer - used for forming a seam work
on a piece of sheet metal by hand e. Screw Starter - used for starting
26. Riveter - used for riveting pieces of small slot or Phillips head
sheet metal together screws in hard to reach places
27. Riveting Hammer - used for forming f. Safety Glasses - serves as eye
sheet metal protection that should be worn
28. Aviation Snips on all jobs.
g. Nut Drivers - Hollow shaft
screwdriver with a permanently

24 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 attached socket for tightening o Annealed
and loosening hex head bolts o Hard drawn
and nuts. • Wall thickness
h. Level - used for checking the o K
o L
levelness of air conditioning and
o M
refrigeration units o DWV
i. Hex Key Wrenches - used for • Advantages
loosening or tightening socket o High thermal conductivity –
type set screws Silver is the only metal that has
36. Threading Tools a higher rate of conductivity, but
a. Taps - used for cutting threads due to expense itis not used
very often.)
inside of hole
o Easy to solder and braze
b. Dies - used for cutting external o Easy to bend and flared. High
threads on round stock resistance to corrosion
c. Handles - used for holding taps
and dies during the threading B. Aluminum
process • Types
o Coiled seamless tube
A. Copper Tubing o Thin wall
• Tube--Fluid carrying pipe which has a • Contamination prevention
thin wall o Internally cleaned
• Nominal size tubing--Type of tubing o Sealed ends
used refrigerant lines, drains, and in • Sizes--5/16" to 3/4" o.d.
other applications, but never in • Advantages
connection- with refrigerants o High thermal conductivity
• ACR tubing -- Tubing manufactured o Easy to bend
specifically for air-conditioning and o Easy to flare - A double flare is
refrigeration that is free of contaminants, recommended.
sealed, and is measured by outside • Disadvantages
diameter o Porous
• Annealed tubing--Tubing which has o Easily work hardened
been heat treated to soften it for easy o Creates corrosive action
bending • Connections
• Hard drawn- -Rigid copper tubing that o Aluminum flare nuts - The use
should not be bent of any other type of metal flare
• Flare--Enlargement at the end of a piece nuts would create a corrosive
of tubing which is made at a45° angle action.
and enables a. fitting to be placed on the o Special solder
tubing o Inert gas welding
• Sweat--Method of soldering tubing o Epoxy - When connecting
• Compression fitting--Tubing connector aluminum to copper, care must
consisting of a nut, sleeve, and union be used to prevent a corrosive
action.)
• Quick connect Fitting which permits fast
and easy connecting and disconnecting
C. Steel
df refrigerant lines
• Types
Kinds of Tubing o Thin Wall
A. Copper - is the most widely used tubing in this o Stainless
trade.) • Connections
• Type o Flaring
o Nominal size o Brazing
o ACR2.
• Temper

25 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

Applications of copper tubing for nominal size o Oil coolers – Steel lines are
and ACR used often on domestic
Nominal size refrigeration.)
• Type M • Absorption refrigeration--All refrigerant
o Underground water service carrying components must be steel
o Water distribution systems.
o Chilled water systems Tube and flexible refrigerant hose fittings
o Hot water heating and low- (Transparencies 1, 2, and 3)
pressure steam • Flared fittings
• Type L o Seal cap
o Underground water-service o Flare gasket
where coils are permitted o Cross
o Hydronic heating where coils o Union elbow
are used o Female elbow
o Water heating or condensate o Reducing union elbow
return o Female swivel elbow
• Type K o Short nut - This nut is also made
o Heavy wall tubing where self- with slits or holes to be used in
support is vital low-temperature applications
o Severe corrosion conditions which prevents the nut from
• Type DWV loosening due to expansion
o Drain waste pipes and- contraction. This type of
o Hot water heating where larger nut is called a frost-free nut.)
than 11.'4"is needed o Long nut
o Cap nut
ACR o Flare cap
• Air conditioning & Refrigeration o Nonheavy pattern
o Suction line o Plug
o Liquid line o Union tee
o Evaporator coils o Reducing tee--Small to large
o Condenser coils o Reducing tee--Large to small
o Discharge line o Union
o Female connector
Color coding of tubing cartons and tags o Female union
• Green--Type K o Tee--Female to male
• BlueType L o Reducing union
• Red--Type M o Reducer
• Yellow--Type DWV o Swivel
• Flare to pipe fittings
Applications of aluminum tubing o Male elbow
• Domestic refrigerators o 45° male elbow
o Evaporator o Male branch tee
o Suction lines o Male run tee
o Female coupling
• Central Air-conditioner condenser
o Male connector
• Automotive air conditioner
• Compression fittings
o Condenser
o Sleeve
o Liquid line
o Nut
o Receiver
o Union
o Evaporator
o Compression to pipe union
o Union elbow
Applications of steel tubing
o Union tee
• Compression refrigeration
o Female connector
o Condensers
o Female elbow - Compression
o Liquid lines
fittings are not suitable for
refrigerant lines.)

26 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1

 • Sweat fittings
o Coupling
o Coupling reducer
o Return bends
o Suction line traps
o 90° elbow''
o 45° elbow
o Street elbow – Sweat elbows
are available with either a long
or short-bend radius.)
o Cap
o Tee
o Sweat to pipe
o Sweat to flare
o Sweat to flare swivel
• Hose fittings
o Flare
▪ Male
▪ Female-
o Splice
▪ Tee
▪ Straight
• Quick connect fittings (Transparency 4)
o Cutter type - This type of fitting
is used on pre-charged
refrigerant lines and the
refrigerant charge will be lost
the line is removed after it has
once been installed on a
system.)
o Spring loaded seal -This type of
fitting is used on pre-charged
refrigerant lines and it may be
removed from a system without
losing the charge.)
• Flexible refrigerant hose (Transparency
5)
o Construction
▪ Outer core heat
resistant ventilated
neoprene
▪ Double layer rayon cord
▪ Soft dense refrigeration
guide neoprene inner
liner.
o Use
▪ Primarily automotive air
conditioning
▪ Central air conditioning
where complicated
bends might be
encountered
▪ Units that have a
tendency to vibrate
excessively

27 | MEEN 30052 REFRIGERATION & AIR-CONDITIONING SERVICING 1