Troubleshooting package-type air-conditioning units(PACU) / commercial refrigeration equipment (CRE)

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Assignment Installing Package-type Air
Sheet 1
Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 15 of 29

System

Cutting Hard Drawn Copper Tubes

After learning the procedure in cutting copper tubes, you will be cutting copper
tubes on your own.

1. Inform your instructor that you are ready to hard drawn copper tubes. He
will be providing you with the tubes to cut.

2. Cut the following sizes of hard drawn copper tubes
1. Tubes with ½ inch outside diameter
o 1 pc - 2.0 ft
o 1 pc - 3.5 ft
o 1 pc - 34 ft
o 2 pc - 1.0 ft
o 4 pcs - 0.25 ft

2. Tubes with ¾ outside diameter
o 2 pc – 2.0 ft
o 1 pc – 3.5 ft
o 1 pc – 24 ft
o 1 pc – 10 ft

3. When you finished cutting the tube, let your instructor check your work. If
your work passed the requirement, store it for later activities. If not, make
the necessary correction then submit it again.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Assignment Installing Package-type Air
Sheet 2
Conditioning Unit/ Commercial Page

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System

Annealing Copper Tubes

After learning the procedure in annealing copper tubes, you are to anneal
copper tubes on your own.

1. Request your instructor to allow you to use the oxyacetylene equipment.

2. When your request has been granted, prepare the oxyacetylene equipment
and gear yourself for annealing.

3. Retrieve from storage the 2 pc 1.0 ft x ½ inch Ø hard drawn copper tube
from previous activity.

4. Anneal the tube

5. When you’re finished, let your instructor check your work. If you pass the
requirement, store your work for later activity. If not, make the necessary
correction then submit it again.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Self Check 2 Installing Package-type Air

Conditioning Unit/ Commercial Page

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System

Test what you have learned about the different
types of fittings.

Direction: Read the questions carefully. Write the answer on the space provided.

1. What are the two types of connection commonly used in
refrigeration and air conditioning system?

2. What is the most common flare fitting used in refrigeration
which uses S. A. E. fine thread?

3. What type of fitting is usually used for plastic pipes?

4. What type of fitting is used to join tube or pipes of different
kinds?

5. What type of fitting is used with either soft or silver solder?

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Assignment Installing Package-type Air
Sheet 3
Conditioning Unit/ Commercial Page

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System

Preparing Flared Joints

After learning the procedure in flaring copper tubes, you are to prepare flared
joints on your own.

1. Retrieve from storage the 1 pc 1.0 ft x ½ inch Ø annealed copper tube
from previous activity

2. Prepare the tube as shown below:

Note: You can make necessary cutting of tube if required, the important
thing to consider is that the flared tube will measure as shown in the
figure.

½ inch Ø
1 pc

½ inch Ø
2 pcs

3. When you’re finished, let your
instructor check your work. If your work passed the requirement, store it for
later activities.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Assignment Installing Package-type Air
Sheet 4
Conditioning Unit/ Commercial Page

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System

Swaging Practices

After learning the procedure in swaging copper tubes, you are to swage
copper tubes on your own.

1. Retrieve from storage the 1 pc 1.0 ft x ½ inch Ø annealed copper tube
from previous activity

2. Prepare the tube as shown below:
Note: You can make necessary cutting of tube if required, the important
thing to consider is that the flared tube will measure as shown in the
figure.

½ inch Ø
4 pc

3. When you’re finished, let your instructor check your work. If your work
passed the requirement, store it for later activities.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Assignment Installing Package-type Air
Sheet 5
Conditioning Unit/ Commercial Page

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System

Soldering and Brazing Tube Fittings

After learning how to solder or braze tube fittings, you will perform soldering
and brazing on your own.

1. Retrieve from storage the 4 pcs 0.25 ft x ½ inch Ø copper tube that has been
swaged (assignment 4) and the 4 pc 0.25 ft x ½ inch Ø copper tube that has
been cut from previous activity (assignment 1).

2. Connect the swaged joint and braze it (see illustration).

3. After completion, let your trainer check your work.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Learning Refrigeration Equipment Piping System
Activity
Installing Package-type Air
2
Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 21 of 29

System

Install Piping System for PACU/CRE

Assessment Criteria:

The learning outcome stated above is attained if you
can demonstrate the following:

 Size and Length of tube used in installation is selected
based on work requirement

 Bracket used in installation is based on work requirement

 Insulator is applied on piping system following prescribed
procedure

 Piping system is laid out based on working drawing

 Tube is swaged following prescribed procedure

 Joining of pipes are carried-out based on work
requirement

 Installation of suction and discharge is carried out
following work requirement.

 Leak testing of piping system is carried out following
prescribed procedure

 Installation of drainage is carried out following work
requirement.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Learning Refrigeration Equipment Piping System
Activity
Installing Package-type Air
2
Conditioning Unit/ Commercial Page

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System

Reading Activity 1

Read: Information Sheet 4 Piping System
for the Learning
Element for
Installation of
refrigeration piping
system

o This is an informative sheet that discusses the different tips in
installing piping system.

Reading Activity 2

Read: Information Sheet 1 of Selecting Pipe Size
the Learning Element
for Installation of
refrigeration piping
system

o This is an informative sheet that discusses the technique in
determining the pipe size needed in installing piping system for
PACU/ CRE.

Practice Activity 1 p. 25

Perform: Assignment Sheet 1 Computing for Refrigerant

on this Learning Line Pipe Diameter

guide

o This activity aims to enhance your skill in determining pipe size

for a particular application.

Practice Activity 2

Perform: Operation Sheet 1 on Insulate Copper Tubing
the Learning Element
for Installation of
refrigeration piping
system

o This activity aims to enhance your skill in determining pipe size
for a particular application.

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Learning Refrigeration Equipment Piping System
Activity
Installing Package-type Air
2
Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 23 of 29

System

Reading Activity 3

Read: Information Sheet 4 of Brackets and Supports
the Learning Element
for tubing, piping
and fittings.

o This is an informative sheet that discusses different types of
brackets and support which can be used in installing refrigerant
piping system.

Reading Activity 4

Read: Information Sheet 3 of Different Leak Testing
the Learning Element Methods
for Installation of
refrigeration piping
system

o This is an informative sheet that discusses the different leak
testing method commonly used in detecting leak.

Practice Activity 3

Perform: Job Sheet 1 on the Installing Suction and
Learning Element for Discharge Lines for
Installation of Packages Air Conditioning
refrigeration piping Unit and Commercial
system Refrigeration Equipment

o This activity aims to guide you in installing suction and
discharge lines for PACU/CRE

o If you’re not familiar with the different leak detection devices
and system analyzer yet, supplemental information about halide
torch, electronic leak detector, system analyzer and evacuation
and vacuuming is located at the learning element for tools and
equipment used in refrigeration and air conditioning servicing
(LE 0002).

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Learning Refrigeration Equipment Piping System
Activity
Installing Package-type Air
2
Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 24 of 29

System

Reading Activity 5

Read: Information Sheet 4 Condensate Drain Piping
for the Learning
Element for
Installation of
refrigeration piping
system

o This is an informative sheet that discusses the condensate
drains applicable for PACU and CRE

Practice Activity 4

Perform: Job Sheet 2 on Installing Condensate Drain

Learning Element for Piping

Installation of

refrigeration piping

system

o This activity aims to guide you in installing condensate drain

piping for PACU/ CRE

Practice Activity 5 p. 26

Perform: Assignment Sheet 2 Installing Piping System of

on this Learning Package Air Conditioning

guide Unit and Commercial

Refrigeration Equipment

This activity aims to enhance your skill, knowledge and attitude in

installing piping system for PACU/CRE

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Assignment Installing Package-type Air
Sheet 1
Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 25 of 29

System

Computing for Refrigerant Line Pipe Diameter

After learning how to compute for the refrigerant pipe lines, you will compute a
sample pipe line on your own.

1. Given the working drawing below

2. Compute for the diameter of suction and discharge line
3. After completion, let your trainer check your work.

Unit Install Package-type Air Conditioning Unit/Commercial

Evidence Plan Refrigeration Equipment Piping System
Module
Installing Package-type Air

Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 26 of 29

System

Installing Piping System of Package Air
Conditioning Unit and Commercial Refrigeration
Equipment

After going through several activities in installing piping system for PACU/
CRE, your task is to look for On-the-Job Training where you will be able to enhance
the skills, knowledge and attitude that you have learned from this module.

4. Get permission from your instructor. Inform him that you want to enhance
your skill in installing piping system for Package Air Conditioning Unit and
Commercial Refrigeration Equipment. He may also able to refer you to
some service shop in the community.

5. In every installation you have done, you are to document your work by
filling-up an assignment report (worksheet 1).

6. After experiencing installation of pipes for PACU and CRE, submit your
report (signed by you and your immediate supervisor) to your instructor. If
you passed the standard, he will inform you that you can now that you are
ready to take the assessment.

Unit Install Package-type Air Conditioning Unit/Commercial

Evidence Plan Refrigeration Equipment Piping System
Module
Installing Package-type Air

Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 27 of 29

System

Worksheet for Assignment in Installing
Piping System for Package Air Conditioning
Unit and Commercial Refrigeration
Equipment

Name of Customer:

Address of Customer

Contact Number of Installation of piping system for PACU/ CRE
Customer:

Service Rendered:

Service Report No.

Unit Type: ( ) PACU ( ) CRE

Installed by: Signature
(Trainee’s Name and Signature
Signature) Date finished:

Inspected by:
(Supervisor’s Name
and Signature)

Date started

Unit Install Package-type Air Conditioning Unit/Commercial

Evidence Plan Refrigeration Equipment Piping System
Module
Installing Package-type Air

Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 28 of 29

System

The table below is the plan which includes criteria (right column) and
assessment methods (interview, demonstration with questioning, and observation
with questioning presentation.) Any of the five assessment method can be used to
gather evidence in 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]

Question/Interview
Demonstration with questioning
The evidence must show that the candidate
can….

Select location for piping installation based on client
and units requirements
Pipe hangers and supports are fabricated in
conformity with job design and specifications.

Brackets and support are securely installed to plan

Refrigerant piping is laid-out in accordance with job
requirements
Refrigerant piping is installed in line with
manufacturer specification
Pipe joint brazing is performed ensuring leakage
and quality finish in accordance with manufacturing
standards
Correct insulating/sealing/ahhesive materials are
use in accordance with manufacturer specifications
Install drainage system for condensate based on
work plan

Perform housekeeping based on work requirements

Tools and equipment are selected in accordance
with job requirements

Items with*is/are critical aspects of competency

Unit Install Package-type Air Conditioning Unit/Commercial
Module
Refrigeration Equipment Piping System

Key-to- Installing Package-type Air
Correction
Conditioning Unit/ Commercial Page

Refrigeration Equipment Piping 29 of 29

System

Answer key to Self-Check 1

1. Soft drawn copper tube
2. Type L
3. Decreases
4. PVC
5. Stainless Steel Tubing

Answer key to Self-Check 1

1. Flared connection and soldered connection
2. 45 ° flare fittings
3. Glued fittings
4. Adaptor
5. Soldered fittings

Information Sheet 1

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

Information Sheet 1

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.

HP Rating Staring Capacitor Run Capacitor
¼ MFD (µf)/VAC MFD (µf)/VAC

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 Tecumse 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.

Information Sheet 1

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:

µft= µf1 x µf2
µf1 + µf2

For example, using the value of capacitor above if connected in series, the total
capacitance rating would be:

µft= 15µf x 45µf
15µf + 45µf

Self-Check 1

Identifying Capacitors

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?

Answer Key 1

Identifying Capacitors

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 1

Testing capacitor using ohmmeter (Running and
Starting Capacitor)

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

o Identify grounded, shorted, open and leaky capacitor.
o Discharge capacitor safely.
o Observe safety precautions in testing capacitor.

Equipment: - 1 unit
o Multi meter
- 1 pc
Materials: 1 pc
o Running capacitor
o Starting capacitor - 1 pc
1 pc
Tools: 1 pc
o Phillips screw driver 1 pc
o Flat screw driver 1 pc
o Lineman’s pliers
o Long nose pliers - 1 pair
o Diagonal cutting pliers - 1 pc

Personal Protective Equipment:
o Gloves
o Goggles

Operation Sheet 1

Procedure:

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.

Operation Sheet 1

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.

Operation Sheet 1

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.

7. Have your instructor check your work.
8. Perform housekeeping.

Operation Sheet 2

Replace Capacitors

Objectives : When you have completed this job sheet, you will be able to:
 Replace defective capacitor
 Follow safety practices in replacing defective capacitor

Equipment: - 1 unit
o Multi meter - 1 unit
o Domestic Refrigeration/Air conditioning
- 1 pc
Unit - 1 pc
- 1 pc
Materials:
o Rag - 1 pc
o Wires - 1 pc
o terminal lugs - 1 pc
- 1 pc
Tools: - 1 pc
o Phillips screw driver
o Flat screw driver - 1 pair
o Long nose pliers - 1 pc
o Diagonal cutting pliers - 1 pair
o Lineman’s pliers

Personal Protective Equipment:
o Gloves
o Goggles
o Safety shoes

Operation Sheet 2

Procedures:
1. Wear appropriate PPE

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.

7. Have your instructor check your work
8. Connect the unit to electrical power

Operation Sheet 2

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.
13. Perform housekeeping.

Job Sheet

Replace Filter Drier

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

Materials, Tools and Equipment:

Materials: - 1 pc
o Filter drier - 1 cylinder
o Refrigerant
- 1 set
Tools
o Wrenches - 1 unit
- 1 unit
Instrument
o System analyzer - 1 unit
o Leak detector - 1 unit

Equipment
o Vacuum pump
o Recovery/recycling Machine

Personal Protective Equipment - 1 pc
o Goggles - 1 pair
o Globes - 1 pc
o Mask

* - Item is optional

Introduction:

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

Job Sheet

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

protective equipment.

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

2. Recover remaining refrigerant from
liquid line, evaporator and suction
line.

Job Sheet

3. Remove defective filter drier.

4. Install appropriate and new set of
filter drier.

5. Purge the system and test for leak.
Make sure that after purging the
liquid receiver valve is returned to
close position.

Job Sheet

6. Vacuum the unit till the gauge
reading reach perfect vacuum
(approximately 29 inch of mercury)

7. After vacuuming close the two valves
of the system analyzer.

8. Disconnect the center hose from the
vacuum pump and transfer to
refrigerant tank cylinder.

9. Open refrigerant cylinder valve and
purge the center hose. Then after
purging make sure that the fittings is
tightened.

Job Sheet

10. Open all valves to its normal
operation

11. Run the unit and observe its
operation. Add refrigerant if needed.

12. Have your job check by your
instructor

13. Perform proper housekeeping

Evaluation:

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

 The liquid receiver service valve is front seated properly with the use of proper tools
and equipment before replacing the filter drier

 The remaining refrigerant is recovered before replacing filter drier
 Filter drier has been replaced with the same specs
 The system is ensured to be leak-free
 The unit is charged with refrigerant when needed
 Safety and proper housekeeping is employed during the activity.

Job Sheet

Cleaning Condenser Unit

Objectives: At the end of this activity, the learner/trainee should be able to:
o Clean condenser
o Clean filter
o Clean fan blade
o Check condition of fan motor
o Demonstrate safety practices in checking and replacing circuit

breaker

Materials, Tools and Equipment:

Materials: 1 pc
o Soap - 1 bucket
o Water - 1 pc
o Shop towel
- 1 pc
Tools 1 pc
o Insulated side cutter 1 set
o Insulated pliers
o Screw driver - 1 pc
o Pin comb or Flat metal
- 1 unit
Instrument
o Clamp Ammeter

Equipment
o Pressurize washer

* - Item is optional

Introduction:

An inefficient condenser acts the same whether it is water cooled or air cooled. If the
condenser cannot remove the heat from the refrigerant the heat pressure will go up.

The condenser does three things and has to be able to do correctly, or excessive
pressure will occur.

1. De superheat the hot gas from the compressor
2. Condense the refrigerant
3. Sub cool the refrigerant before it leaves the coil

These three things are definitely affected once the condenser is dirty, because dirt
insulates the coil which will make it have poor heat transfer.

Job Sheet

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

protective equipment.
1. Remove all panel cover

2. Wrap the fan motor w/ plastic bag
3. Remove screw that hold the

condenser fan shroud
4. Spray water w/ soap into the

condenser. Continue spraying until
all dirt has been removed

5. Clean also the inner side of the
condenser, be careful, do not let the
water hit the electrical controls and
fan motor. To avoid short circuit.

6. Dry all electrical components w/ shop
towel

Job Sheet

7. Remove the bag that covers the fan
motor and check motor if it requires
lubrication or other maintenance.

8. Straightened fins

9. Replace the screw w/ hold the
condenser fan shroud.

10. Test the unit while monitoring the
current at the condenser fan motor

11. Restore the cover then measure the
air velocity of the unit. Refer to
troubleshooting guide if trouble
arises.

12. Have the instructor check your job
13. Clean up and put away tools and

instrument

Job Sheet

Evaluation:

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

 Condenser is cleaned following prescribed procedure
 Fan motor is protected from getting during the washing
 Fan blade is cleaned using prescribed procedure
 Fan motor is ensured to be in good running condition
 Units operation is tested following prescribed procedure
 Safety and proper housekeeping is employed during the activity.

Job Sheet

Cleaning Evaporator Unit

Objectives: At the end of this activity, the learner/trainee should be able to:
o Clean evaporator
o Clean filter
o Clean fan blade
o Check condition of fan motor
o Demonstrate safety practices in checking and replacing circuit

breaker

Materials, Tools and Equipment:

Materials: 1 pc
o Soap - 1 bucket
o Water - 1 pc
o Rag
- 1 pc
Tools 1 pc
o Insulated side cutter 1 set
o Insulated pliers
o Screw driver - 1 pc
o Pin comb or Flat metal
- 1 unit
Instrument
o Clamp Ammeter

Equipment
o Pressurize washer

* - Item is optional

Introduction:

Dirt insulates evaporator, thus hampers the heat transfer, An inefficient
evaporators does not absorb the heat into the system and will have low suction pressure.
The suction line may be sweating or frosting back to compressor. The evaporators can clean
by compressed pair, nitrogen and water w/ soap.

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

protective equipment.

Job Sheet

1. Remove cover of the evaporator unit

2. Remove air filter

3. Remove the electrical connection of
the blower unit

4. Remove the blower unit from
mounting

5. Detach the centrifugal blade from the
fan motor

6. Check fan motor if it requires
lubrication and other maintenance.

7. Wash the blade with soap and water.
Let it dry before installing it again

8. After installing it, restore the
electrical connection of the fan motor

9. Clean the evaporator using soft type
of brush and soap. Then rinse it with
water.

Job Sheet

10. Straighten flat and deformed fins

11. Remove the filter from the frame

12. Wash the filter with soap and water
while brushing it.

13. Let the filter dry before you install it
again.

Job Sheet

14. Test the unit for operation while
measuring the running current of the
system (refer to the nameplate for
comparison). If trouble arises, refer
to troubleshooting guide.

15. Restore the cover then measure the
air velocity of the unit. Refer to
troubleshooting guide if trouble
arises.

Evaluation:

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

 Evaporator is cleaned following prescribed procedure
 Filter is cleaned following prescribed procedure
 Fan blade is cleaned using prescribed procedure
 Fan motor is ensured to be in good running condition
 Units operation is tested following prescribed procedure
 Safety and proper housekeeping is employed during the activity.

Information Sheet

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.

Information Sheet

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).

Information Sheet

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

Information Sheet

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
Brown wire = Start lead
Yellow wire = Common or fan capacitor
Red wire = Low speed lead
Blue wire = Medium speed lead
Black wire = High speed lead

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

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

Operation Sheet

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

Operation Sheet

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

Operation Sheet

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 N - lowest resistance

Operation Sheet

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.

Brown wire = Start lead
White wire = Common lead
Black wire = High speed lead
Blue wire = Medium speed lead
Red wire = Low speed 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.

Maintenance of finned Evaporators
At the end of the practice the trainee must able to:

1. Clean evaporator by pressure washer
2. Clean evaporator by steam cleaner
3. Straightened bent fins

Tools and Equipment:
1. Fin comb
2. Pressure washer
3. Compressor air

Materials:
1. Soap
2. Water
3. Rugs

Procedures:
Dirt insulates evaporator, thus hampers the heat transfer, An

inefficient evaporators does not absorb the heat into the system and will have low
suction pressure. The suction line may be sweating or frosting back to
compressor. The evaporators can cleaned by compressed pair, nitrogen and
water w/ soap.

Procedures:
1. Set the pressure regulator of the compressed air or nitrogen at 6.90
kg./cm by turning the pressure regulator valve handle clockwise, as shown
by the arrow in the picture
2. Slowly work the spray up and down the fins
3. Direct the spray nuzzle so that it is parallel to the fins. Do not spray at
angle to the fins because they could be bent and may cause damage to
the coil.