Installing Domestic Refrigeration and Air-Conditioning (DomRAC) Unit

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Self-Check #1.2-5

LO 2. INSTALL ELECTRICAL CIRCUIT.
Electrical Conductors and Insulators

A. ESSAY:

Direction: Answer the following questions briefly

1. Define the following:
a. electricity
b. electron
c. conductor
d. insulator

2. List at least five good insulators.

3. List at least five good conductors.

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ANSWER KEY #1.2-5
Self-Check of #1.2-5

1.
1. Electricity is a flow of electron

2. Electron is a positive charge

3. Conductor is flow of electron easily

4. Insulator is a flow of electron does not travel easily.

2. Good conductors:
- Gold
- Aluminum
- Silver
- Copper
- Iron

Good insulators:
- Plastic
- Rubber
- Wood
- Glass
- Asbestos

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Information Sheet # 1.2-6

LO2. INSTALL ELECTRICAL CIRCUIT

Learning Objectives: In an refrigeration and air conditioning shop scenario,
the trainee will be able to select the appropriate types and sizes of electrical
conductor for installation.

Selecting Electrical Conductors for Installation:

1. Electrical wires are insulated with different types of insulators and they are
used to keep electricity from leaving the conductors it travels on.

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2. Ampacity is the current in amperes that a conductor can carry continuously
under the conditions of use without exceeding its temperature rating.

3. Allowable Ampacities of Insulated Conductors. (PEC Part I, Vol. 1, 2000)

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4. Factors that determine the conductor type and size are the following:
a. Full load current.
b. Number of conductors
c. Type of load served

Example:
Single motor requires conductors for 125% of full load ampacity [Section

5.30.2.2(a) PEC 2000]
d. Length of run
e. Ambient temperature
f. Voltage

Example:
Rooftop temperatures in summer approach the water boiling point of 100oC

(212oF)
Most conductors for general use are rated for 600V. Higher voltage ratings

are generally specified on a special order.

Example:
Select the appropriate conductor type and size of the motor nameplate

below. The nameplate indicates that the motor is rated 1.5 horsepower,
110/220V. Let us assume that the motor will be operated in 220V source and
50oC ambient temperature.

Full load current is determined through Table 4.30.14.2, this is the
provision in Philippine Electrical Code 2000 under Section _________.and not
through the motor nameplate FLA.

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Table 4.30.14.2 Full Load Current in Amperes,
Single Phase Alternating Current Motor

Thus, the full load current of 1.5 horsepower is 10 A as obtained
in the table above.

Single motor requires conductors for 125% of full load ampacity
[Section 4.30.2.2(a) PEC 2000]

Therefore;

Full Load Current = 10A X 125%
= 12.5 A

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Let us now find the size and type of conductor. We will be using
Table 3.10.1.16. Note that the ambient temperature is 50oC.

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ASSIGNMENT SHEET #1.2-6

LO2: INSTALL ELECTRICAL CIRCUIT.

Objective: In air conditioning shop scenario, the trainee will be able to select
the proper conductors for various ampacities and temperatures. This skill
requires that the technician be able to locate and read Philippine Electrical Code
tables.

A. Select Conductors for Various Ampacities and Temperatures

Directions:Select conductors for various ampacities and temperatures. Use
thePhilippine Electrical Code, Table 3.10.1.16. Use the ampacity
correctionfactor for temperature rating column that is the same
orthe next higherrating than the required temperature, and then
select the size ofconductor for the required or next higher
ampacity. Refer only to the sizes given for copper wiring.

Examples: What wire size is required for a load of 55 amperes at

30°C?

The answer is 14mm2 (#6 AWG). This is obtained by
referring to the 60°C column because the required
temperature is not above 60°C. You must then check

theampacity correction factor. The ampacity
correction factorrounder 26-30oC is 1.0.

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B. Select Conductors for Given Horsepower Rating of the Load

Directions:Select conductors for the given horsepower of the load. Use the
Philippine Electrical Code, Table 3.10.1.16. Use the ampacity

correctionfactor for temperature rating column that is the same
or the next higherating than the required temperature, and then

select the size of conductor for the required or next higher
ampacity. Refer only tothesizes given for copper wiring.
You can go over Information Sheet 6 again if you find some
difficulties in selecting conductor size and type.

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TASK SHEET 1.2-6

Title: Performing single outlet electrical installation for
window type air-conditioning unit. (Surface Non-
metallic Raceway)

Performance Objective: In air conditioning shop scenario, the trainee
must be able to select appropriate location for

the electrical components to be installed,
layout mounting location of the electrical
components based onworking drawing, install
wiring devices, install surface non-metallic
raceway and electrical wiring

Supplies/Materials: Pencil or Chalk, Installation plan or working
drawing, Flat head screw, ¾ in X 10, Fisher, #
6 (Tox), Plastic molding ¾ in X 8 ft., Surface
metal box (Amco Box), Mica tube, ¼ in. dia.,
Stranded wire, 2.0 mm2 TW, ACU outlet, 3
prong, Safety switch, 30 A

Equipment : Electric drill

Tools:Pull and push rule or any measuring device
suited for the activity, Steel meter
stick/Straight edge

Personal Protective Equipment: Gloves, mask, goggle, safety
shoes

Steps/Procedure:

Roughing-in activities of electrical installation deal with marking-
outlocations of electrical components, mounting of electrical boxes,
raceways and metal circuit protection enclosures.

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1. Identify the locations of the
components to be installed. There
are some provisions where we
need to consider like:

a. Distance of the convenience outlet
away from the unit and from the
ground. The outlet must be not more
than 1 meter away from the unit and
not less than 300 mm above finished
floor.

b. The fuse box (if installed separately
from the main circuit breaker) must be
installed at least 1.2 m –2 m above
finished floor

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2. After determining the exact
location of the components, start
mounting the safety switch. Hold
the safety switch on determined
location, level it and mark-out the
holes of the safety switch on the wall.

3. Mark the path where the moldings
will pass through

4. Install a mounting screw for the top
mounting hole and then the
remaining two bottom screws.

Note: If you are installing on
concrete walls, you have to
drill holes and insert filler
plugs before mounting any
components on the wall.

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5. Hang switch box on the screw.

Note: The hole in the upper middle
back of the housing should
slip over the screw head

6. Next component to be installed is
the base of surface metal box.
Disassemble the surface metal box
and mark-out the holes on wall.(as
what you did in procedure 3)

7. Mount the base of surface metal
box using 4 pcs of flathead screws.

8. Next is the backing of plastic molding.
Mark-out the holes of plastic molding
against the wall. Make sure that the
plastic molding is leveled horizontally
or vertically as the case may be during
marking–out procedures.

Note: Provide an ample space for
mica tube between the end of the
molding and safety switch.

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9. Install the backing of the plastic molding.

Note: Plastic molding is provided
with holes for screws, if you think the
holes provided are not enough to hold
the backing in place, bore additional
holes into it using gimlet or portable drill.

10. In angular turns, miter joints must be
used to facilitate comfortable laying
out of conductors.

11. Lay-out the conductors, insert 2-
5.5mm2 wires together with 1- 2.0mm2
wire for grounding conductor, if the length
of the conductor to be used is determined,
cut it, and make sure that you provide
ample allowance for splicing and terminating
to the wiring devices and circuit protection.
Provide ¼ inch mica tube to protect the
conductors from abrasions. Insert the backing
of molding in the slot provided.

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12. Lay-out the conductors carefully especially
in angle turns; be careful not to put too
much stress on the conductors bend so
that the insulation will not be damage.

13. Cover the molding; snap it by hitting the
capping slightly against the backing. Be
careful not to break the capping.

14. Install the cover of surface device box.

15. Secure the cover by tightening the
two screws located at the two sides of
the cover.

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16. Terminate the conductors on the
three-prong ACU outlet.

17. Install the 3-prong convenience outlet.
Make sure that the conductors are
Terminated properly. Be careful not to
interchange the connection of three wires,
the green screw is intended for grounding
conductor (green wire).

18. Fix the metal strap of the outlet to the
metal box.

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19. Install the plate cover of the convenience
outlet.

20. Connect the wires to the safety switch.
Harness the conductors properly inside
the box to reduce stress on the
conductor‟s insulation.

Note: Be careful not to break conductors
Insulation during harnessing. If the
insulation has been damaged due to
unavoidable circumstance, cover it
with vinyl tape.

21. Switch on the safety switch and check the
voltage in the convenience receptacle.

22. This is how your work should look like.

23. Have your instructor check your work.

Assessment Method:

Demonstration, Evaluate Using Performance criteria checklist

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Performance Criteria Checklist
Task Sheet #1.2-6
]

Task Sheet #1.2-6

Title: Performing single outlet electrical installation

for window type air-conditioning unit

CRITERIA YES NO

Did I..

1. Prepare unit and equipment/components ?

2. Select and safely install electrical cabling and wiring devices

of correct load carrying capacity ?

3. Install power wiring in line with the Philippine

Electrical Code (PEC)?

4. Position and level unit in line with manufacturer's

Instructions?

5. Install sealant to ensure an air tight seal around the

unit in line with manufacturer's instructions?

6. Install condensation drain ensuring free drainage of

condenser and to avoid water spillage?

7. Employ safe manual handling techniques in line with

enterprise OH&S procedures?

8. Clean work site and keep in safe state in line with

work instructions?

Assessment Result:

Competent Not Yet Competent

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Information Sheet # 1.3-1

LO 3. INSTALL DomRAC UNIT

Learning Objectives: In an refrigeration and air conditioning shop scenario,
the trainee will be able to demonstrate on how to mounted the air condition unit
in accordance with the prescribe procedures.

INSTALLATION

Complete step-by-step installation instructions arefurnished with your unit.
These instructions will be found on a separate page included with this manual
or in the mounting kit assembly. Follow these instructions carefully. Keep these
instructions with this manual for future reference. Your unit will be one of the
following designs:

Unit with a window mounting kit. These models are designed for mounting
through anopening in a wall. These units can be adapted towindow installation
by using the optional windowmounting kit supplied with your unit.

Unit without a window mounting kit. No window mounting kit is
supplied with the unit.These models are designed for mounting through an
opening in a wall. These units can be adapted to window installation by
purchasing an optional window mounting kit. Consult your dealer to choose the
kit that is appropriate for your model and installation.

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Title: TASK SHEET 1.3-1
Install Window Type Air Conditioning Unit

Performance Objective: In air conditioning shop scenario, the trainee
must be able to mount the window-type air-
conditioning unit, test window-type air-
conditioning unit for operation, provide
drainage for the window-type air-conditioning
system and demonstrate safety practices while
working.

Supplies/Materials : Installation plan or working drawing, Unit‟s
Manual, Fastener (wood screw, metal screw,

self threading screw, bolt and nut, concrete
nail, etc) Expansion bolt, Fisher (wall plug)

Equipment : Window-type air-conditioning unit, multi

meter, portable drill

Tools : Screw driver screw, Drill bit for concrete
hammer wood or metal, File, Wrench, Pliers, Ball peen

Personal Protective Equipment : Gloves, mask, goggle, safety
Shoes

Steps/Procedure:

Mounting housing of air-conditioning unit is a simple task. It
involves simple metal works and some alignments. Some of the

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important things to consider are:

a. The housing must be securely mounted to the cavity.

b. The housing should be tilted towards the drainage, so that the
condensate in the base plate will freely flow towards the drainage.

c. Steel brackets/frame must be used if the wall cannot support
theweight of the air-conditioning unit to be installed.

d. Electrical source should be compatible with the unit

6. Install steel brackets. Make sure
that the bracket is slightly, tilted
towards the direction of the drainage
to allow condensate to drain.

7. Mark the locations of the holes to
be drilled. You can use the housing as
reference. Consider the thickness of the
front cover before marking. The cover has
locks/screws connected to the housing.
If the housing is mounted inside the cavity,
the cover may never be mounted to the
housing. Therefore, the housing should be
mounted with at least 12 mm (or as stated
in the air-con manual) extension away from
the surface of the wall. Consider also the gaps
between the wall and the housing it should be
not less than 3 mm or as stated in the user‟smanual.

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8. Drill holes in the base part of the
cavity or/and in the bracket where
the housing will be screwed on.

Note: If the base part of the cavity
is wood, the hole must be smaller
than the screw. If the base part of
the cavity is steel or concrete, the
hole must be slightly bigger than
the bolt to be used in securing the
housing to the wall.

9. Place the housing inside the cavity

10. Screw the housing to the edge of the
cavityand bracket.

Note: If the base of the cavity is
concrete, you can use fisher (wall
plug) to ensure secure contact
between the wall and the housing
when screwed.

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11. Slide the unit into the housing until
it is firmly against the rear of the
housing. Care is required to
ensure the foam sealing strips on
the housing remain in position. Ask
help for this step. DO NOT ATTEMPT

TO LIFT THE UNIT ALONE!

12. Check the power source if it is
compatible with the unit. Do
corrective action in case the power
is not suited for the unit.

13. Connect the air conditioner in the
power. Coil excess cord beneath
the air conditioner base or
convenient outlet.

14. Engage chassis lock into the Date: Developed Date: Revised Page #
bottom of the housing rail and
secure to the base with the screw

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provided (this step is optional).

15. Switch the unit into fan mode.
Check if there is a vibration in the
installation. Check also if the fan
blade is rotating smoothly. If this
happens, pull out the unit again
then re-insert it until proper
alignment (no vibration and fan
blade is rotating smoothly) is
achieved.

16. Turn off the unit then fit the front
panel to the unit and make sure
that it is securely mounted (see
unit‟s manual).

17. Fit the drain chute to the housing
and run a drain line to a suitable
location if required.

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18. Seal gaps between housing and
casing by using rubber, foam,
plastic, silicone. This is to ensure
that the unit is air-tight.

19. Turn the unit into fan mode for at least three (3) minutes then
Switchto cool mode. Get the temperature and refer to the unit‟s

manual if thecondition of your unit is okay. Corrective action
should be done if the unit is found to be defective (refer to module in
troubleshootingwindow-type air-conditioning and domestic
refrigeration system)

Assessment Method:
Demonstration, Evaluate Using Performance criteria checklist

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Performance Criteria Checklist
Task Sheet #1.3-1

Task Sheet #1.3-1 YES NO
Title: Install Window Type Air Conditioning Unit

CRITERIA

Did I..

1. Mount securely the housing to the cavity?

2.Tilt the housing towards the drainage?

3.Use steel brackets/frame when the wall cannot support
the weight of the air-conditioning unit to be installed?
4Mark the locations of the holes tobe drilled?

5 Drill holes in the base part of the cavity or/and in the
bracket wherethe housing will be screwed on?
6 Place the housing inside the cavity?

7 Screw the housing to the edge of the cavity and bracket?

8 Slide the unit into the housing untilit is firmly against the
rear of the housing?
9 Check the power source if it is compatible with the unit?

10 Connect the air conditioner in the Power?

11. Engage chassis lock into thebottom of the housing rail and
secure to the base with the screw provided ?

12 Switch the unit into fan mode?

13Check if there is a vibration in the installation?

14. Check if the fan blade is rotating smoothly?

15. Turn off the unit then fit the front panel to the unit?

16 Fit the drain chute to the housing and run a drain line to a
suitable location ?
17 Seal gaps between housing andcasing by using rubber,
foam,plastic, silicone?
18 Turn the unit into fan mode for at least three (3) minutes?

19Switch to cool mode

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20 Get the temperature and refer to the unit‟s manual if the
condition of your unit is okay?
21Do corrective action when the unit is found to be defective?

Assessment Result: Not Yet Competent
Competent

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LO 3. ASSIGNMENT SHEET #1.3-1

INSTALL DomRAC UNIT

Install Window-type Air-conditioning Unit

After going through several activities in installing window-type air-
conditioning unit your task now is to look for an on the job training where in
you will be able to enhance the skills that you learned from this module.

1. Get permission from your trainer; inform him that you want to enhance
your skill in installing window-type air-conditioning unit. He may be able
to refer you into a Refrigeration and Air-conditioning service shop where
in you can practice installing window-type air-conditioning unit in a
concrete surface, wooden surface and window sills or he may provide you
with the job himself.

2. In every installation you have done in the shop where you are practicing,
fill-up an assignment report (worksheet 3) sign it and let your immediate
supervisor sign it.

3. After experiencing installing window-type air-conditioning unit in different
locations (preferably, concrete surface, wooden surface and window sills)
Return to your instructor and submit a copy of the assignment reports
signed by you and your immediate supervisor.

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ASSIGNMENT SHEET #1.3-2

LO 3.INSTALL DomRAC UNIT

Making Job Report

After reading the importance of making a job report and identifying the
different parts of a job report, your task now is to practice filling up a service
report.

1. Secure a copy of Worksheet 2: Service Report
2. Fill up the service record based on the scenario below. Your certification

number is your I.D. Number.
3. Let your trainer sign as your customer for the said job. Then let him

check your work.

Scenario:

You have installed a used window-type air-conditioning unit in a class
room. The unit was installed at the window sill in the back part of the room.

In the process of installing the unit, you have used hoses, sealant (foam),
metal screws (8 pcs) and steel brackets. The sealant was provided by the owner.
The rest of the materials were provided by your company.

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ASSIGNMENT SHEET #1.3-3

LO 3. INSTALL AIR CONDITIONING UNIT

Objective:In air conditioning shop scenario, the trainee will be able to enhance
the knowledge and skills in preparing a job reports.

Install Window-type Air-conditioning Unit:

After going through several activities in installing window-type air-
conditioningunit your task now is to look for an on the job training where in you
will be able toenhance the skills that you learned from this module.

1. Get permission from your trainer; inform him that you want to enhance your
skill in installing window-type air-conditioning unit. He may be able to refer
you into a Refrigeration and Air-conditioning service shop where in you can
practice installing window-type air-conditioning unit in a concrete surface,
wooden surface and window sills or he may provide you with the job himself.

2. In every installation you have done in the shop where you are practicing,
fill upan assignment report (worksheet 3) sign it and let your immediate
supervisor sign it.

3. After experiencing installing window-type air-conditioning unit in different
locations (preferably, concrete surface, wooden surface and window sills)
Return to your instructor and submit a copy of the assignment reports signed
by you and your immediate supervisor.

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Title: TASK SHEET 1.3-1C
Installing Window-type Air-conditioning Unit

Performance Objective: : In air conditioning shop scenario, the trainee
will be able to prepare tools and equipment, supplies and

materials for testing and running the system; install system
analyzer; hook up ammeter and run the unit; and take data

on temperature, pressure, amperage and voltage reading.

Supplies/Materials: Pencil or pen, paper

Instruments:Multi-tester, Ammeter, System analyzer/Gauge
manifold

Tools: Flat Screw driver, Philip Screw driver, Ratchet wrench

Personal Protective Equipment: Gloves, mask, goggle, safety
shoes

Introduction:

When the mechanical installation, electrical installation, piping
installation, leak testing, evacuating, charging were already
accomplished, the next work activity is to test run the system.

Procedure:

1. Backseat, suction service valve and discharge service valve.

Note: Always wear PPE.

2. Install system analyzer/gauge manifold.

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3. Crack off backseat and purge low side and high side hoses through
center fitting of system analyzer.

4. Run the unit and get data

CHECKLIST:

Note: Use the following checklist to ensure the installation is in good
order. Indicate
Yes or No.

1. Indoor Section Yes No
 Air filter in place
 Refrigerant piping in good order and insulated
 Electrical connection in the air handler tight
 Fan motor and wheel can be removed easily
 Face cover
 Control panel
 Control switch
 Capacitor
 Thermostat

2. Outdoor Section
 Condenser level
 A firm foundation under the condenser
 Service panel in correct location
 Airflow correct and not re-circulating
 Refrigerant piping in good order and insulated
 Electrical connections tight
 High voltage correct
 Low voltage correct
 Service valves open if any
 Noise reducer

3. Condensate Check Date: Developed Date: Revised Page #
 In a drywell
 On the ground
 In a drain

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4. Voltage Check (Fill the blanks)

 Line voltage to indoor fan section __________ V
 Line voltage to condenser __________ V
 Low voltage power supply voltage __________ V

5. Start the indoor fan motor and verify the voltage and current:

 Rated voltage ____________ V
 Actual voltage ____________ V
 Rated current ____________ A
 Actual current ____________ A
 Fan motor rated current ____________ A
 Actual current _____________ A

6. Start the condensing unit and verify the voltage and amperage

 Rated voltage ____________ V
 Actual voltage ____________ V
 Compressor rated current _____________ A
 Actual current ____________ A
 Fan motor rated current ______________ A
 Actual current ____________ A

7. Take pressure and temperature

 Suction pressure ___________ kpa
 Discharge pressure ___________ kpa
 Suction temperature ___________ ºC
 Discharge temperature ___________ ºC
 Evaporator room temperature ________ ºC
 Room temperature _______ ºC

8. After the test run, return tools and clean up mess.

Evaluation:
While performing the task, it is important for you to assess

your performance following the criteria below:

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1. Installed system analyzer properly
2. Correct amperage rating
3. Correct temperature reading
4. Correct pressure reading
5. Correct adjustment of low pressure service valve and discharge

pressure
service valve
6. Wore PPE
7. Observe safety while doing the job
8. Perform proper housekeeping

Assessment Method:
Demonstration, Evaluate Using Performance criteria checklist

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Title: Job Sheet #1.3-1 YES NO
Did I.. Installing Window-type Air-conditioning Unit

CRITERIA

1. Power circuit installed is tested using recommended line voltage
for the unit

2. Unit is tested in line with manufacturer's instructions

3. Report on installation and testing of unit is prepared in line with

enterprise procedures

Assessment Result:

Competent Not Yet Competent

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Information Sheet # 1.4-1

LO 4. CONDUCT PERFORMANCE TEST
Learning Objectives: In an refrigeration and air conditioning shop scenario,
the trainee will be able to check the suction and discharge pressure of the
system, the refrigerant charge, the temperature of the motor, condenser,
evaporator and the refrigerant circuit of the system

TASK SHEET 1.4-1

Title: Performing Maintenance Check-up

Performance Objective: : In air conditioning shop scenario, the trainee
will be able to maintain the unit, the temperature of the system, the
refrigerant charge of the unit and the pressure both discharge and
suction pressure.

Supplies/Materials: Refrigerant 22, air cond. unit

Instruments:Multi-tester, Ammeter, System analyzer/Gauge
Manifold, oxy-acetylene

Tools: Flat Screw driver, Philip Screw driver, Ratchet wrench,

Personal Protective Equipment: Gloves, mask, goggle, safety
shoes

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Introduction:

Performance Criteria Checklist

Task Sheet #1.4-1

CRITERIA YES NO

Did I..

*Test Installed unit for operation in line with prescribed

procedure?

*Install drainage system based on work instruction

*Prepare work documentation and submit per prescribed

procedure?

*Apply good housekeeping and safety practices line with job

requirements?

Assessment Result:

Competent Not Yet Competent

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INSTITUTIONAL ASSESSMENT

Test I.Multiple Choice: Choose the correct letter that best describe the
statement.

Write your answers in capital letter on your answer sheet.

1. Part of the component housing which is mounted with four screw into the
wall:
A. Junction box
B. Utility box
C. Receptacle
D. Plastic

2. Part of the component use for fastening the junction box into the wood.
A. Screw
B. Nail
C. Masking tape
D. Electrical tape

3. Is a kind of screw use for mounting the holes of the housing?
A. Wood screw
B. Round head screw
C. Flat screw
D. Metal screw

4. Is a kind of tool operated by hand and use for drill the wood?
A. Drill beat
B. Nail
C. Gimlet
D. Screw

5. Is a kind of tool use for marking the wall? Date: Developed Date: Revised Page #
A. Pencil
B. Chalk

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C. Center punch
D. Knife

6. Part of the service report that indicate the name of the customer, contact
number and others.

A. Customer data
B. Job done
C. Parts and Consumables
D. Readings

7. Part of the service record that indicate you tick on what service you are.
A. Customer data
B. Job done
C. Consumables

D. Readings

8. Part of the service report that indicates the consumable materials.
A. Customer data
B. Job done
C. Parts and Consumables
D. Readings

9. Part of the service report that indicates the lo side and hi side.
A. Customer data
B. Job done

C. Parts and Consumables
D. Readings

10. Part of the service report that indicates the authenticity of the document
A. Authentication
B. Reading
C. Job done
D. All are wrong

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Test II. Enumeration

1. List five types of over current protective devices.
2. Enumerate at least three PEC requirements concerning PVC Wire
Molding method.

3. List at least five good insulators.
4. List at least five good conductors.

Test III. ESSAY:

Direction: Answer the following questions briefly

1. Describe the operation of single element fuse

2. Describe the operation of dual element fuse.

4. Describe the differentiate between thermal trip and electromagnetic
trip type circuit breaker

5. How does the PVC wire molding method differ with the surface
metal racewaymethod?

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