Servicing and Maintaining PACU and CRE

TRAINING PROGRAM
FOR GOTEVOT TRAINERS

Air Conditioning and Refrigeration
Module Title:
SERVICING AND MAINTAINING PACKAGE-TYPE AIR
CONDITIONING UNIT AND COMMERCIAL
REFRIGERATION EQUIPMENT
Technical General
Education and Organization of
Skills Technical
Development Education and
Authority Vocational
Training
TABLE OF CONTENT
AIR FILTERS-------------------------------------------------------------------1
CLEANING THE FILTERS AND FRONT PANEL--------------------3
SYSTEM OBSERVATION--------------------------------------------------6
DISMANTLING, INSPECTING AND REASSEMBLING SERVICE

VALVES------------------------------------------------------------------------12
CHECKING THE CONDITION AND LUBRICATION OF THE

BEARINGS--------------------------------------------------------------------20
POOR CONDENSATION IN PACU/CRE------------------------------22
MAINTAIN SECONDARY HEAT TRANSFER EQUIPMENT----25
TEST THE EFFICIENCY OF A COMPRESSOR--------------------31
CHARGE OIL IN THE COMPRESSOR--------------------------------33
EVACUATE THE SYSTEM-----------------------------------------------36
CHARGE REFRIGERANT IN THE SYSTEM (VAPOR

CHARGING)-------------------------------------------------------------------40
TEST LEAKS IN THE SYSTEM-----------------------------------------43
REMOVE AND REPLACE FILTER DRIER---------------------------48
REMOVE AND REPLACE OIL SEPARATOR-----------------------53
REMOVE, REPLACE OR CLEAN THERMOSTATIC

EXPANSION VALVE STRAINER---------------------------------------57
SERVICE COMMERCIAL REFRIGERATION SYSTEM----------60
BELT INSPECTION AND ANALYSIS----------------------------------63
ELECTRIC MOTORS-------------------------------------------------------67
HOW TO SERVICE MOTOR PROPERLY----------------------------72
FITTING AND REMOVING GAUGE MANIFOLD TO A SYSTEM73
CHARGE REFRIGERANT IN THE SYSTEM (LIQUID

CHARGING)-------------------------------------------------------------------88
DEEP EVACUATION-------------------------------------------------------90
TRIPLE EVACUATION-----------------------------------------------------93
LIQUID CHARGING OF REFRIGERATION--------------------------96
VAPOR CHARGING OF REFRIGERATION-------------------------99
Pumping Down a System-------------------------------------------------102

Information Sheet 1
 Filters Air filters

Option 1: Active carbon filter/Photo-catalyst filter
Option 2: Active carbon filter/Electrostatic filter
 Air filters eliminate dust and lint
 Optional active carbon filter/Photo-catalyst filter effectively eliminates odor and
cigarette smoke in the room air.
 Optional Active carbon filter/Electrostatic filter is particularly effective in eliminating
odor and microscopic dust.

Life Time of Filters
 The life of above filters varies according to the amount of cigarette smoke, room size and
the operating time.
 Air filters can be cleaned with a vacuum cleaner or rinsed under running water after
using a month.
 The life time of optional Active carbon filter is about 2 years and that of optional
Electrostatic filter is about 3 months. These filters cannot be recycled.
Air Filters
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Servicing and Maintaining Package Type Air Conditioning Unit and Commercial Refrigeration Equipment
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Information Sheet 1
 The life time of optional Photo-catalyst filter is about 2 years. This filter can be washed
under running water and can be refreshed by exposing under direct sunlight. Exposure
time is 6 hours after using for 3 months.
Note: Additional information for air filter.

Refer to Unit of competency: Service and Maintain Window-Type
Air-Conditioning/Domestic Refrigeration Units.
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Operation Sheet 1
Cleaning the Filters and Front Panel
Objectives: At the end of this activity, the learner/trainee should be able to:
o Clean filter and front panel
o Refresh the optional photo catalyst filter
o Wash front panel
Cleaning the Filters and Front Panel
 Turn off the unit and pull out the power plug.
 Clean the air filters once a month.
1. Lift the front panel and pull 1. Clean the filters with a 3. Rinse the filters under
the air filters downwards. vacuum cleaner. running water and dry
them completely, and then
refit them correctly into
their guides.
Refreshing the Optional Photo-catalyst filter
1. Lift the front panel and put 2. Blow off the dust from the 3. Expose under direct
the optional photo-catalyst filter with fresh air or wash sunlight for 6 hours and
filter downward. the filter under running refit correctly into its guide.
water.
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Washing the Front Panel
Note:
 Turn off the unit and pull out the power plug.
 Clean the front panel if it becomes dirty and spotted.
 Front panel is removable.
1. Lift the front panel up to 2. Rinse the panel under 3. Refit it correctly.
the top of the unit, then running water and dry it Installation procedure is
separate the front panel completely in a shaded reverse to the removal
from the unit. area. procedure.
Cleaning the Main Unit
 Use only a damp soapy towel.  Do not pour water onto the unit and do not
use petrol, solvents or abrasive powder
which may result in damage to the unit.
Note:
 When cleaning the unit, first turn it off and pull out the power plug.
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After-Season Care
1. Clean the filters and refit them into the unit. 2. If the unit to be switched off for an extended
period, run the unit on FAN only for two
hours to dry inside of the unit.
3. Clean the indoor and outdoor unit and wrap

the outdoor unit with a protection cover.
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System Observation
INTRODUCTION:
Refrigeration machinery may not require major regular maintenance when small problems
are detected and corrected before they become big problems. The reliability of the system
can be maintained through periodic inspection by a qualified refrigeration man. His services
must be utilized and his recommendation must be acted upon.
Shown below is a typical refrigeration system with a refrigeration man doing visual inspection
as a means of preventive maintenance or doing a maintenance check-up of the system.
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SERVICING EQUIPMENT
Some compressors are

equipped with suction
and discharge pressure
gauges which indicate
evaporator and
condensing pressures
respectively. However,
most compressors do
not have permanently
mounted pressure
gauges and in such
cases a particular unit
known as a GAUGE
MANIFOLD is used. The
service manifold is one
of the most versatile
instruments that the field
serviceman has utilized
to determine the
operating conditions of
the refrigeration system.
The manifold is connected to the suction service valve and the discharge service valve with
flexible lines. The actual connection shall be explained in time latter pages.
The service valves on the other hand, are fitted to the suction amid discharge ports of the
compressor and their construction is discussed in the following section. See illustration on
figure above for the location of service valves.
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COMPRESSOR SERVICE VALVES AND FITTINGS
Before gauges and service Nomenclature of service valve assembly

cylinders can be titled to the
system or any part removed
from a system, a knowledge
of the construction and
functioning of the valves is
essential. See figure.
There are three main service
valves:
1. Suction service valves

(SSV)
2. Discharge service valves
(DSV)
3. Liquid receiver service
valves (LRSV)
1. Flare nut 6. Seal cap
2. Union 7. Valve Body
3. Spindle 8. Gauge plug
4. Gland washer 9. Washer packing
5. Gland nut 10. Seal cap washer
The suction and discharge service valves have a front and a back seating arrangement, so
that the gauge manifold may be fitted to the system, while the liquid receiver service valve
usually has one seat.
The various positions of the valve spindle on both the suction and discharge service valves are
as follows:
Back Seated - this is when the spindle is turned

fully backwards closing the gauge
port.
Mid-seated - in this position the spindle can be

turn mid way of the valve allowing
the gauge port line connection
and compressor connection open.
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Front seated - this is when the spindle is turned
fully forward thus closing the line
connection.
SAFETY PROCEDURES IN HANDLING SERVICE VALVE
1. Always slacken off (loosen) gland packing nut before attempting to turn the valve stem.
2. Always use a ratchet spanner or key to suit the size of the valve stem.
3. NEVER FORCE the valve against its seat; this may score it or “freeze” the stem and seat
together.
4. Give the valve stein a drop of refrigeration oil occasionally.
5. Always back seat the service valve spindle before removing the gauge plug.
6. When service work is completed the gauge plug must be replaced, the gland nut
tightened and the sealing cap, complete the sealing washer inserted, replace on the
service valve tightened.
VALVE WRENCH AND SPANNERS
Service valve is the access point to refrigeration system. It serves as a key accessory in
servicing operation. Being one of the most important accessories in refrigeration system,
care should be taken in consideration. To handle the valve carefully, special access tools are
being used. These are:
a. Valve ratchet wrench
This is a special tool used mainly in

servicing operation. It is design for the
purpose of accessing service valve. The
wrench suit to the valve stem and fit it snugly
to avoid slippage that could wear or damage
it.
b. Adjustable wrench
This tool is not new to us, this is a universal

tool commonly used by a mechanic. The jaw
of this wrench can be adjusted to fit the size
of nut and/or flare cap. In servicing operation
this used particularly on opening of service
valve cap and service port cap.
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Information Sheet 2
THE COMBINATION GAUGE MANIFOLD
The combination gauge manifold is a necessary instrument for the serviceman, enabling him
to check and service refrigeration system. The gauge manifold is usually fitted to the
compressor service valves to obtain high and low side pressure in the system, and may be
used for nearly all service operations, such as adding or removing refrigerant, purging off air
or excess refrigerant, and by-passing pressure from high to low side of the system.
The combination gauge manifold should be given proper care, the gauges protected from
vibration and the threaded or flared ends should be provided with protective covers, it is
important to prevent entry of moisture and dirt into the hoses and manifold when not in use
and so avoid contaminating the refrigeration system. The gauges themselves should be
checked periodically so that so that accurate readings are taken at all times. A routine check
before using the compound gauge should be to see that the needle reads zero when the
gauge is open to the atmosphere.
CONSTRUCTION OF THE MANIFOLD
Basically the gauge manifold consists of compound amid

high pressure gauges mounted oil a manifold with hand
valves to isolate the common connection, or open it to
either side as desired. The construction of the valves
allows full flow of refrigerant to the gauge at all times.
Gauge manifold set
Flexible hoses
The two types of gauges are incorporated into the

manifold, these are:
1. Low Pressure Gauge:
The compound gauge indicates pressures above and

also those below atmospheric pressures (vacuum).
This is used to measure the low pressure or
Compound gauge
evaporator side of the system and is connected to the
suction service valves.
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2. High Pressure Gauge:
This gauge is used on the high pressure or condenser

side of the system and is connected to the discharge
service valves.
Pressure gauge
CARE IN HANDLING GAUGE MANIFOLD
1. Always blank-off (cover) the manifold lines when not in use to prevent entrance and
contamination of air.
2. Inspect the rubber of flexible hose before and after using it. If indication of wearing is
detected replace it at once.
3. Wipe-off oil and grease after using the gauge manifold. Remaining oil in it would catch
dust and forms heavy dirt. It is very hard to remove and unsafe to use.
4. Calibrate the gauge regularly before using.
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Operation Sheet 2
Dismantling, Inspecting and Reassembling

Service Valves
o Dismantle service valves
o Inspect service valves
o Dismantle service valves
o
TOOLS AND MATERIALS
Discharge line valve Ratchet wrench, 1/4 in.

Suction tine valve Graphite packing
Liquid line valve Packing gland
Service valve wrench, 1/4 in. Packing nut wrench
Adjustable end wrench
PROCEDURES
A. Two-way Service Valve

1. Obtain a two-way suction line valve from the instructor.
2. Remove the end cap with an adjustable wrench. Record your observations.
3. Remove the packing gland nut with the packing nut wrench.
4. Remove the valve stem using the 1/4-in, ratchet wrench.
5. Lay out the parts on a flat surface in the order of removal.
6. Proceed to clean all parts with dry rags.
7. Make a list of the parts in the table below and indicate the function of each part.
8. Reassemble the parts in their proper order.
B. One-Way Service Valve

Repeat steps 1 through 8 in port A.
C. Liquid Line Valve

Repeat steps 1 through 8 in part A.
Operating Data
These are the basics used by a refrigeration man in troubleshooting a system.
An example of operating data of a motor is shown below:
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Operation Sheet 2
1. Motors are identified from the
information in the rating plate. This
includes:
- Maker’s name or trade mark.

- Type of supply, e.g., 3-phase, 38-0
V, 50 cycles.
- Rated power, e.g., 5 Hp.
- Rating, e.g., continuous operation.
- Speed, e.g., 1450 rev/mm.
- Serial number of motor.
- Frame reference number.
- Additional information. Typical Rating Plate
Check Head or Suction Pressures
2. Install the gauge manifold set, as shown.
NOTE:
Refer to L.E. “Gauge and Manifold Set”

if necessary.
Head Pressure Test

3. Head pressure should not exceed 60
psi. (4.20 kg/cm2), as shown.
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4. If head pressure exceeds 60 psi (4.20
kg/cm2), it is possible that the condenser
is clogged and needs cleaning. Clean
the condenser as shown.
Refer to the L.E. on “Cleaning,

Removing and/or Replacing
Condensers” if necessary.
Check the Refrigerant Charge in the

System
5. A popular method to check for

refrigerant charge is to mount a glass
sight gauge in the liquid line, as shown.
6. Bubbles indicate that there is insufficient

refrigerant.
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7. Add refrigerant.
NOTE:
Refer to L.E. “Charging the System with

Refrigerant” if necessary.
8. Checking the Motor for Excessive

Temperature
NOTE:
Do not use your hand to check the

temperature of the motor.
9. Use a thermometer and check the

reading against the allowable
temperature shown on the name plate.
10. The temperature of the motor should not

rise more than 40ºC (72ºF) over room
temperature.
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Operation Sheet 2
Checking for Leaks in the Suction Valve and Discharge Valve
To test for leaks on the low pressure side oi

a compressor, such as at the gaskets, at the
suction service valve, or at the crankshaft
seal, one may use one of two methods:
11. Close the suction service valve and draw

as high a vacuum on the compressor as
possible. Then turn the discharge service
valve all the way in.
12. Keep the compressor running. If the

head pressure gradually rises, it means
that air is being drawn into the low side
off the system.
13. A better way is to balance the pressures

in the crankcase and turn the discharge
service valve all the way in, as shown.
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14. Remove the discharge service valve
gauge plug and connect a 250 mm
length of copper line, as shown.
15. Immerse the copper line into a glass

bottle partly filled with oil, as shown.
16. If the tube discharges gas continuously

as shown by air bubbles it means air is
being admitted to the low side of the
compressor.
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Operation Sheet 2
17. If there are no leaks, the bubbling will
stop immediately after the compressor is
started.
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Operation Sheet 2
Observation Checklist
CALL YOUR INSTRUCTOR who will observe you perform maintenance check-up.
Acceptability
Instructor’s checklist
Yes No
1. Obtaining operating data of the equipment ______ ______
2. Checking the head and suction pressure ______ ______
3. Checking the refrigerant charge in the system ______ ______
4. Checking motor for excessive temperature ______ ______
5. Checking for leaks in the suction valve and discharge valve ______ ______
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Information Sheet 3
Checking the Condition and Lubrication of the

Bearings
1. An increase iii temperature particularly at

the bearing housing section of the
equipment is an indication that the
bearing is excessively starved of
lubrication.
This can be checked by feeling with the

hands. A more accurate means of
checking would be to use a
thermometer.
2. A damaged bearing is indicated by

excessive noise while the motor is
running. Most often, this is accompanied
by an increase in temperature.
Checking the Shaft Seals for Leaks
3. A noisy seal will soon become a leaky

one if not attended to.
It may be remedied by the usual process

of lapping the seal, or it may sometimes
be repaired by tapping the seal box
lightly with a hammer.
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4. A leaky seal may be detected by the
usual test for leaks (ammonia for sulfur
dioxide).
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Poor Condensation in PACU/CRE
To determine what is responsible for a poor condensing condition proceed, as follows.
1. Install a gauge manifold, as shown. Refer

to L.E. on “Gauge and Manifold Set”, if
necessary.
2. Determine head pressure. The head

pressure should be 165-205 psig
1.14 x 10-4 Pa to
1.14 x 10-4 Pa at 100ºF
NOTE:
If the head pressure registered is more

than the range mentioned; then the
system has too much refrigerant, too
much oil or has a corroded interior.
Checking the compressor, condenser and the evaporator for excessive low or high
temperature.
3. Compressor
Compressors are checked by using

a thermometer, as shown.
Temperature range should be from
65ºF to 115ºF.
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4. Condensers
Condensers whether air cooled or

water cooled are installed to
remove heat. The condensers will
fail to do its job if the heat transfer
surfaces are inefficient.
Evaporators
5. Install a. thermometer on the

evaporator tube, as shown.
6. A reading of between 5ºF to 15ºF (-

15ºC to -45ºC) should be
registered.
NOTE:
If reading does not reach the range,

it means a lack of refrigerant. Add
refrigerant. Refer to L.E. “Charging
the system with Refrigerant”, if
necessary.
Checking the Condenser Cooling Water Flow Rate
7. Too much water flow will give a very

satisfactory refrigeration.
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8. Less water flow clue to leaky valves
or water lines gives unsatisfactory
refrigeration.
9. Adjust valve to control the flow rate

of water by turning the valve stem
clockwise or counterclockwise, as
shown.
10. Install the water flow meter or gauge
to determine the flow of water, as
shown.
Checking the Condition of Belts and Coupling
11. Fan belts need periodical checking

for its tension, as shown. Amount of
sag should not exceed 1/2” (12mm),
as shown.
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Maintain Secondary Heat Transfer Equipment
COOLING TOWER AND EVAPORATIVE CONDENSER
Heat from water cooled may be transferred to the surrounding through a cooling tower or
an evaporative condenser.
1. A cooling tower contains apparatus which sprays the condenser water through a blast of
air (some design rely on the wind created by spraying itself; others use fans). Some of the
water evaporates and loses the latent heat of vaporization. The remaining water dries to
the bottom and is returned to the condenser foil reuse. Chemicals may be needed to
control rust, algae fungus and the organism that causes legionnaires disease, which
grows inside the cooling tower. During operation, a cooling tower receives enough
condenser heat to keep it from freezing. The system must be able to empty itself of water
when not in use to prevent freezing.
2. An evaporative condenser also uses evaporation to remove heat. In this device, the
condenser water flows through a heat exchanger which is under a spray or drip of water.
Fan blow air across the condenser during operation. Build up of scale is visible in this
device.
Shell and Tube or Coil
In a shell and tube condenser is a large cylinder with a water manifold at each end. Water
recirculates through the large cylinder. Hot refrigerant vapor enters the inlet manifold and
flows through the cooling tubes and exits the discharge manifold.
A shell and coil is also a cylinder with two manifolds but the refrigerant flows through
coiled tubes instead of straight ones. Due to their shape, the coil must be cleaned with
chemicals not brushes.
Tube-Within-a-Tube
In this model, the outer tube contains refrigerant and the inner tube contains water. The
two fluids flow in opposite direction to the incoming cold water contacts the refrigerant that is
just about to flow to the receiver. This ensures the greatest temperature reduction in the
refrigerant. The wall between the two fluids may be shaped to increase its area and the rate
of heat transfer. The tube-within-a-tube type has too little space to store refrigerant and
cannot serve as a liquid receiver. Consequently, the tube-within-a-tube type is easy to
overcharge which reduces the space available for heat transfer and can cause erratic
cooling.
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WATER TREATMENT
All air-conditioning systems using water-cooled condensers require some form of water
treatment. This treatment is necessary because water (from any source such as wells, lakes,
and rivers) contains impurities in the form of minerals, gases, organic matter, algae, and
bacterial slime. These impurities act on the condenser water system in the following ways:
 Minerals cause the formation of scale on the metal surfaces.

 Guns In the atmosphere, such as carbon dioxide and sulfur dioxide, form acids when
they come into contact with the water. These acids eventually attack and corrode the
metal surfaces.
 Algae attach themselves to the surfaces of the system. Since algae are living plants,
they grow until the passages of the system are closed. Bacteria form slime and clog
the system in much the same way as algae.
Most of the Impurities found in water can be neutralized by chemicals which are prepared
to perform a specific function. For example, specific chemical compounds can suspend
minerals, dissolve scale, neutralize acids, coat the surface of the metal with a protective film,
or attack and kill algae and bacteria.
Some of the chemical compounds used to remove scale or neutralize acids can be
harmful to wood and to certain metallic and composition materials used in valves, valve
diaphragms, and cooling tower fill. Care must be exercised when these chemical compounds
are used in condensers and cooling towers. It is recommended that a water treatment
specialist be consulted for each system requiring some form of water treatment.
HARD AND SOFT WATER
Water is classified as hard or soft depending upon the amount of solid impurities
contained In the water. In general, water containing less than 200 parts per million (ppm) of
mold material is considered to be soft water. Hard water contains solids in amounts greater
than 200 parts per million (ppm). In terms of grains of hardness, 100 ppm to 200 ppm is
roughly equivalent to 6 to 11 grains of hardness per gallon of water; 200 ppm to 300 ppm is
equivalent to 12 to 17 grains of hardness pergallon of water; and 300 ppm to 400 ppm is
equivalent to 18 to 24 grains of hardness per gallon of water.
CONTROLLING SCALE
Scale formation is controlled by compounds called scale inhibitors. Some minerals tend to
accumulate and become more concentrated as the water in the system evaporates. An
inhibitor holds these mineral solids in suspension in the water. If the inhibitor is used in the
water and a water bleedoff is provided in the system, the suspended solids flow from the
system through the bleed pipe. Thus, the solids do not accumulate and the concentration of
solids is maintained at a minimum level. The amount of bleedoff can vary from four gallons
per hour for five-ton tmits to 360 gallons per hour far 100-ton units. For each unit size, the
bleedoff also varies according to the hardness of the water.
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Based on the specifications determined by a water treatment specialist, one water scale
treatment can maintain the amount of solids in the water at a safe level for three months or
more.
Removing scale through the condenser only.
REMOVING SCALE
To remove accumulated scale from a system, the services of a water treatment specialist
should be obtained. The specialist can determine the type of scale present. A suitable
chemical compound and the quantity of this compound necessary to remove the scale can
then be recommended. In most cases, the chemical should not be allowed to pass through
the cooling tower.
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Unless otherwise specified by the water
treatment specialist, the chemical should
pass through the condenser only, figure 1.
This precaution is recommended because
most scale removers are acid compounds
that can damage the materials in the cooling
tower. (However, the acid may be mild
enough that the water treatment specialist
considers it to be harmless to the materials
in the cooling tower.)
If the scale removing solution is

harmless to the materials in the cooling
tower, the solution can be added to the
system at the points shown in figure 2 for a
forced-draft tower. Part A in the figure is the
tower distributor plate. Part B is the tower
sump, and Part C is the water tank. For
natural-draft tower, figure 3, the solution is
added at the sump (Part B).
Figure 2. Forced-draft tower.
It is a good practice to clean the sump
before the scale remover is added. This
action is recommended because the sludge
in the sump Is likely to absorb some of the
cleaning strength of the remover.
CORROSION
Corrosion in a system can occur in the

following ways:
 Acids are caused by gases from the

atmosphere dissolving in the water.
These acids gradually increase in
strength until they begin to attack and
etch the metal surfaces in the
system.
Figure 3. Natural-draft tower
 One of the metals used in the system is dissolved by the action of electrolysis
resulting from the connection of two unlike metals. The two dissimilar metals set up an
electric current with the result that one metal dissolves and goes into solution. Some
combinations of dissimilar metals react faster than other combinations.
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 Oxygen enters the water from the atmosphere resulting in pitting of the metal surfaces
in the system.
CORROSION CONTROL
Corrosion can be controlled in the water system by the addition of chemically blended
polyphosphates or other similar compounds. The polyphosphate compound deposits a film
over the entire surface of the metal. This compound also protects the metal surfaces from
some of the milk acids that form from atmospheric gases.
Electrolysis can be prevented by following a few general rules.
 If dissimilar metals are joined in the system, the metals should be electrically insulated
from each other.
 If copper and steel are used in the system piping, large surfaces of copper and small
surfaces of steel result in rapid corrosion of the steel. Small areas of copper and large
areas of steel cause the steel to corrode, but at a rate which is much slower titan for
the previous case. A similar corrosive action will result when brass and steel are
combined.
CONTROLLING ALGAE AND SLIME
Algae and slime are controlled by the use of toxic compounds commonly called
algaecides. Chlorine is an algaecide. Since one type of algae vows best in daylight and
mater flourishes in darkness, one type of algaecide may be suitable and effective for indoor
cooling tower installations. Another type of algaecide may be more effective hr outdoor
installations where the tower ii exposed to daylight. In all instance, a water treatment
specialist should be consulted to determine the algaecide that is likely to produce the best
results. Algae treatment usually lasts one month or more depending upon the conditions of
the water and the atmosphere around the tower.
All algaecide compounds are toxic; therefore, the skin and eyes should be protected
when these compounds are handled.
The most important rule to be followed regarding water treatment or water treatment
problems is to obtain the services of a reputable water treatment specialist.
SUMMARY
 Cooling towers are designed to operate on the principle of -

1. natural draft where natural air currents cool the circulated water; or,
2. forced draft in which a fan blows or draws air through the tower to cool the
circulated water.
 In forced-draft towers, the discharge air should blow in the same direction as the
prevailing wind.
 To install a forced-draft tower:

1. Locate the tower
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2. Prepare a foundation
3. Install the Ian motor and belts
4. Install the water piping and pump
5. Connect the fan motor and water pump wiring
 To install a natural-draft tower:

1. Locate the tower
2. Prepare a foundation
3. Install the water piping and pump
 Water treatment is required in systems using water-cooled condensers because:
1. Minerals in the water cause scale formation on metal surfaces.

2. Atmospheric gases form acids in the water; these acids corrode the metal
surfaces.
3. Algae and bacteria clog the system passages.
 Hard water contains relatively large amounts of solid impurities; soft water has
relatively small amounts of impurities.
 Scale formation is controlled by inhibitors. Some systems are designed so that the
solids suspended by the inhibitor can be removed.
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Job Sheet 1
Test the Efficiency of a Compressor
General Instruction:
The compressor is the heart of a refrigeration system. The system efficiency depends mainly
on the perfect working of a compressor. So it is an essential part for the servicemen to test
the compressor efficiency before he proceeds to any repairing work. This worksheet will
guide the trainees to test the efficiency of a commercial compressor.
Tools, Equipment and Materials:
1. Gauge manifold set

2. Charging lines
3. Ratchet wrench
4. Adjustable wrench
5. Double ended spanner set
6. Soap and brush
7. Refrigeration oil
8. Clean cloth
9. Black tape
Procedure:
1. Prepare system
a. Loosen the service valve system cover by open ended spanner.
b. Check that the service valve stems are all the way out, i.e., backseated.
c. Remove the dead plugs from the half union at the gauge port of the service valve.
2. Connect gauge manifold in the system

a. Connect the compound gauge to the low pressure gauge port opening by means
of a charging line.
b. Connect the pressure gauge to the high pressure gauge port opening by means of
another charging line.
c. Slowly front seat the suction service valve stem.
d. Check oil level in the compressor.
e. Short the electrical terminals of the dual pressure cutout.
Caution: Check that the shorting wire should not touch the body of the dual pressure
cutout.
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3. Check pressure at low side of the system.
a. Run the compressor for some time and note the readings in the compound gauge
which should be 28”—30’ Hg.
b. Stop the unit and keep an eye on the compound gauge.
c. If the reading remains constant it is sure that there are no leaks in the compressor.
d. The vacuum should stand constant for 24 hrs.
e. Check seal for any leakage of oil.
4. Check pressure at high side of the system

a. If the suction side is O.K. then slowly front seat the discharge service valve stem.
b. Allow dry air to suck through the suction service valve or place a clean cloth
soaked with compressor oil in the suction gauge port opening.
c. Built up a pressure of about 250 P.S.I.G. in the high side of the compressor.
d. Test leaks by applying soap sud to all joints in the high side of the compressor.
e. See that the pressure remains constant in the high side of the compressor.
f. If the discharge pressure decreases and the Suction pressure increases as
recorded in the gauge, it indicates that the reeds are leaky.
5. Test efficiency
a. Release the high side pressure till it is 150 P.S.I.G.
b. in the compressor and check the amount of vacuum the compressor will draw and
the time it takes.
c. Determine the vacuum the compressor can produce against a 150 P.S.I.G. head
pressure. It should not be less than 20” Hg.
d. Check leaks at all joints including seal.
e. Remove gauge manifold set and charging lines.
f. Plug the gauge port openings.
g. Connect the dual pressure cutout properly.
QUESTIONS:
1. Why is it necessary to test the efficiency of a compressor?

2. Why is it advisable to test leak of the low side of the compressor by compressor oil?
3. What would happen when the discharge reed of a compressor is leaky?
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Job Sheet 2
Charge oil in the Compressor
Tools, Materials and Equipment Needed:
Equipment: Tools:
 PACU/CRE  Ratchet wrench
 System analyzer  Adjustable wrench
Materials: PPE:
 Refrigeration oil of correct grade  gloves
 Clean cloth  goggles
 ¼ flared copper tube
Procedures:
1. Check oil level of the unit through the oil

level sight glass
Oil level
too low
2. Install gauge manifold set in the system

and purge the charging lines
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3. Frontseat the suction service valve.
4. Replace center charging line of the gauge manifold with flared copper tube.
5. Start the unit, when the low side gauge

manifold reached 25-28 inches of
mercury, stop the unit.
6. Place the tube into a container of

refrigeration oil. Open the low side hand
valve of the manifold and charge oil into
the compressor.
7. Close low side hand valve and check oil

in the compressor through the oil level
sight glass of the compressor.
Note: If oil level seems to be low,

charge the correct amount of oil
by repeating the procedures
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above.
8. Remove gauge manifold from the system and let the system run in normal operation.
Caution: Be careful not to spill oil from the system
9. Perform housekeeping.
10. Have your instructor check your work.
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Job Sheet 3
Evacuate the System
Definition:
Evacuation/Vacuuming is the removal of any gases not recommended for a system

or vessel.
Methods of Evacuation:
A. Deep Evacuation
It involves reducing the pressure in the system to about 50 to 250 microns.

It utilizes two stage vacuum pumps.
B. Triple Evacuation
It is accomplished by
evacuating a system to a low
vacuum, about 1 to 2 mm, and
the allowing a small amount of
refrigerant to bleed into the
system three (3) times. It utilizes
single stage vacuum pump.
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Objectives: At the end of this practice the learner/trainee will be able to:
o Evacuate the system
Tools, Materials and Equipment Needed
Equipment: Instrument:
 PACU/CRE  Vacuum gauge with adapter
 System analyzer
 Vacuum pump
Tools:
 Pliers
 Screw drivers
Procedures:
1. Remove discharge and suction

service valve cap.
2. Midseat discharge and suction service

valves.
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3. Remove service port cap of discharge
and suction service valve
4. Connect gauge manifold into the

system and center connection of the
manifold to the vacuum pump.
5. Turn on the vacuum pump. Open

both hand valves and evacuate the
system long enough or as required.
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6. If evacuation is completed, close both
hand valves of the gauge manifold
and turn off the vacuum pump.
7. Observe the pointer that it should not

deflect back to 0 psig. at the
compound gauge. (Note: If the pointer
deflects back to zero psig or less, it
indicates that a leak is present in the
system.)
8. Set-up the system for charging.

9. Perform housekeeping
10. Have your instructor check your
work.
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Job Sheet 4
Charge Refrigerant in the System (Vapor

Charging)
o Vapor charge a PACU/CRE system
I. Tools, Materials and Equipment Needed
Equipment: Tools:
 PACU/CRE  Adjustable wrench
 System analyzer  Ratchet wrench
  Screw driver
Instruments: PPE:
 Charging/Weighing scale  Goggles
 Thermometer  Gloves
 Clamp ammeter
II. Procedures
The correct amount of refrigerant must be charge in a PACU/CRE system to obtain a

maximum efficiency of the system. The desired temperature and proper functions of the
controls depends on the correct amount of refrigerant charge. This job sheet will guide you to
charge refrigerant in a PACU/CRE system.
1. Check system under vacuum, it

should be between 28 to 30 inches
of mercury.
2. Connect the service cylinder to the

center charging line of the manifold.
Note: Place the cylinder on upright position in

a weighing scale. Record the weight of the
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Job Sheet 4
refrigerant cylinder. Purge the refrigerant
hoses.
3. Turn the suction and discharge

service valve on a backseat position
and crack a bit to note down the
suction and discharge pressure.
4. Open the service cylinder valve and

charge refrigerant until the pressure
in the gauge shows above 50-55
psig.
5. Start the compressor and operate it
until enough refrigerant is charge in
system. Control the low side
pressure by opening and closing the
low side hand valve of the gauge
manifold.
Caution: Never allow the system to
run in vacuum.
6. Close refrigerant cylinder valve and

check both suction and discharge
pressure. When pressure seems to
be steady, note down the weight of
the refrigerant cylinder.
7. Check the cabinet temperature,

running current and operation of
pressure control.

work.
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Job Sheet 5
Test Leaks in the System
=
o Test leak the system
o Practice safety precaution and proper housekeeping
Materials, Tools and Equipment:
Materials:
o Match - ½m
o Clean cloth - 1 pc
o Compressor oil of the same specification
o Soap suds
Tools
o Adjustable wrench - 1 set
o Ratchet wrench - 1 set
o Double ended spanner - 1 set
o Small paint brush - 1 set
o Charging lines - 1 pc
Equipment
o Halide torch
o Service cylinder containing R12
o Service cylinder containing nitrogen - 1 cylinder
Instrument
o Gauge manifold - set
Personal Protective Equipment

o Goggles
o Mask
o Gloves
* - Item is optional
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Procedure:
Make sure that before you perform this activity, you are wearing appropriate personal
protective equipment.
1. Prepare the system
a. Install gauge manifold set into

the system.
b. Place high and low compressor

valve to cracked off to back seat
position.
c. Place high and low side manifold

shut off valve in closed position.
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d. Note down the pressure in the system to determine the refrigerant in the
system.
Caution: See that a minimum of 50-55 P. S. I. G. is needed for leak test.
If the system pressure is below than 50-55 P. S. I. G. or new piping system, it needs to be
charged first (follow steps e to i).
e. If there is no refrigerant in the

system then attach the center
line of the gauge manifold to a
refrigerator cylinder.
f. Open the refrigerant in the

system service cylinder valve,
and charge the refrigerant into
the system till the pressure reads
50-55 P. S. I. G. in the low side
and high side gauge.
See that the solenoid valve is energized is energized to pass refrigerant throughout the
system.
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g. Close the hand valve of the

gauge manifold.
h. Close the service valve of the

refrigerant cylinder.
2. Prepare the leak detector

a. Open valve and light gas torch.
b. Adjust for low flame which burns about 1/2 “ above the reactor plate.
c. Let it burn until the reactor plate, a copper element, turns to a cherry red color.
d. Lower flame or even with the reactor plate.
3. Check for leaks in the system by moving the search hose under all joints and
connections in the system including the compressor shaft seal. Be sure to check
below every joint because R12 and R22 refrigerants are heavier than air.
Caution:
a. A halide torch must only be used in a well ventilated area
b. It must never be used in places where explosive gases are present.
c. Never inhale the vapors or fumes from halide torch, they are poisonous.
4. Observe for the change in color of the flame of halide torch.

a. Yellow flame means there is no leak on the part where the search is pointing
b. Green flame means, there is a small amount of leak to where the search hose
is pointing
c. Dark blue or violet flame means there is a large amount of leak to where the
search hose is pointing
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5. If the location of the leak cannot be detected, use the soap suds method to pinpoint
the actual location of leak.
6. Let your instructor check your work
7. Perform house keeping
Evaluation:
While performing the activity it is important for you to assess your performance
following the criteria below:
 Joints are checked for leaks

 Actual location of leaks are pinpointed
 Safety practices and proper housekeeping are employed in the conduct of activity
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Job Sheet 6
Remove and Replace Filter Drier
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:
o Filter drier - 1 pc
o Refrigerant -
Tools
o Wrenches - 1 set
Instrument
o System analyzer - 1 set
o Thermometer - 1 set
o Ammeter -
o Leak detector -
Equipment
o Vacuum pump - 1 unit
o Recovery/recycling Machine - 1 unit
Personal Protective Equipment

o Goggles
o Globes
o Mask
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.
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Procedure:
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.
3. Remove defective filter drier.
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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.
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.
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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
are tightened.
10. Open all valves to its normal

operation
11. Run the unit and observe its

operation. Add refrigerant if needed.
12. Have your job checked by your

instructor
13. Perform proper housekeeping
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Evaluation:
 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.
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Job Sheet 7
Remove and Replace Oil Separator
Objective:
The trainees will be able to:

 Remove and replace oil separator.
General Instructions:
The purpose of an oil separator in the refrigerating unit is to separate oil from the refrigerant
vapor. The oil is highly miscible (soluble with refrigerant) at higher temperature and pressure.
It also serves as a muffler in reducing pulsations to prevent the condensation of the
refrigerant vapor in the oil separator, it should be insulated. This worksheet will guide the
trainees to remove and replace an oil separator in a Commercial Refrigeration system.
1. Gauge manifold set.

2. Charging lines.
3. Adjustable wrench.
4. Double ended spanner set.
5. Ratchet wrench.
6. Halide torch.
7. Match box.
8. Goggles.
9. Clean cloth.
10. Service cylinder containing F-12.
11. New oil separator of same capacity.
12. Thermometer.
Procedure:
1. Prepare the system
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a. Install gauge manifold set in the

system.
b. Purge the charging lines.
c. Check suction and discharge

pressure of the system.
2. Check the system

a. Run the Unit about 10-15
minutes.
b. Observe the cooling effect in the
evaporator.
c. Check the oil level of the
compressor. Oil at its
proper level
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3. Pump down the system

a. Close the receiver service shut off valve.
b. Energize the solenoid valve to open the liquid line passage.
c. Short the electrical terminals of the dual pressure cutout.
Caution: Check the shorting wire should not touch the body of the dual pressure
cutout.
d. Run the unit until the compound gauge shows about 2 P.S.l.G. and stop the unit.
e. Wait for some time and see that if the pressure in the compound gauge rises or
not.
f. If the pressure rises, start the unit again until the pressure in the suction side
comes to 2 P.S.I.G. and then stop the unit.
Caution: Do not run the unit below 0 P.S.I.G.
g. Repeat the process from 3(d) to 3(f) until a steady pressure one or two P.S.I.G. is
obtained in the suction side.
h. Close suction and discharge mainports.
i. Close the hand valve after the oil separator.
4. Remove oil separator
a. Open the discharge line flarenut connections of the oil separator.
Caution: If the pressure seems to be more, open the flarenut slowly.
b. Open the flare connection of the oil separator with the crank case.
Caution: Place a bucket underneath the oil separator to collect oil to be drained from
it.
c. Open both the flarenuts at the two ends of the oil separator and remove the oil
separator from the system.
Caution: Do not tilt the oil separator as the oil may come out from the oil separator.
d. Place the oil separator in a safe place.
5. Replace oil separator
a. Connect the oil separator to the flarenuts on the discharge line and tight them
properly.
b. Connect the bottom connection of the oil separator with the crank case and tight it
properly.
Caution: Check that the oil separator is properly insulated.
c. Place the oil separator in such a way that it does not produce strains on the
discharge
Caution: Check that the oil separator is vertically connected.
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d. Open the receiver service valve a bit and allow the refrigerant to flow.
e. Open suction and discharge mainports.
f. Purge from the outlet of the oil separator.
Caution: Wear goggles while purging.
g. Now open tile receiver service shut off valve and allow the liquid to flow in the
system
h. Open the hand valve after the oil separator in the discharge line.
i. Connect the dual pressure cutout properly.
j. Run the unit and cheek suction and. discharge pressures.
k. Charge refrigerant, if necessary.
l. Check oil level in the compressor.
m. Check the cabinet temperature after running at least for one hour.
1. Outlet connection
2. Inlet connection
3. Separator
4. Filter
5. Fastening strap
6. Ball float
7. Needle
8. Nozzle
9. Oil pipe connection
Figure 5.
n. Check the operation of the dual pressure cutout.

o. Check leaks by the halide torch after stopping the system.
p. Remove gauge manifold and charging lines and plug the gauge part openings.
q. Close the system covers.
QUESTIONS
1. Why is it necessary to insulate the oil separator properly?

2. What happens if the accumulation of oil in the oil separator is too much?
3. What happens when the float valve of the oil separator collapses?
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Job Sheet 8
Remove, Replace or Clean Thermostatic

Expansion Valve Strainer
1. Install system analysis
2. Pump down the unit
3. Recover refrigerant
4. Remove and reinstall expansion valve
5. Page and link list
6. Add refrigerant
7. Observe system operation
8. Observe safety and wear PPE
Materials:
o Expansion Valve
o Refrigerant
Tools
o Wrench
o Flaring tools
Instrument
o Multi-tester
o System analyzer
o Thermometer
o Ammeter
o Leak detector
Equipment
o PPE
o Vacuum pump
o Recovery/recycling Machine
Introduction:
Automatic expansion Valve - A refrigerant control valve that maintains a constant

pressure in an evaporation system. These valves are hermetic and cannot be
disassembled for inspection and cleaning. If found defective or inoperative. It is possible
sometimes to adjust the valve until the obstruction is dislodged. The usually work best
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when the system is running. If it leaks around the spring housing it will have to be
replaced. The bellows have been permanently damaged.
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Procedure:
1. Install system analyzer
2. Pump down the unit
3. Recover remaining refrigerant from

liquid line, evaporator and suction line.
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4. Remove expansion valve and replace it
with a new set (the same specification)
5. Purge the system and test for leak.
6. Run the unit and observe its operation.

Make some adjustment on the valves if
needed. Add refrigerant
7. Have your job check by your instructor
8. Perform proper housekeeping
Evaluation:
a. Install system analyzer on suction and discharge valves of the system.

b. Pump down the unit thru liquid receiver service valve.
c. Recover remaining refrigerant thru the use of recovery machine.
d. Remove expansion valve.
e. Reinstall new expansion valve.
f. Purge the system and leak test.
g. Observe system operation by taking data
h. Add refrigerant to the system
i. Perform house keeping.
j. Wear PPE
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Job Sheet 9
Service Commercial Refrigeration System
Objective:
The trainees will be able to:

 Service commercial refrigerating system.
General Instructions:
The inherent construction of a refrigerating system is such that any trouble in the
system will be accumulative, i.e., one trouble will cause another. It is, therefore, essential
that refrigerating system should be completely checked over periodically for efficient
working of the system. This worksheet will guide the trainees to service the commercial
systems in a systematic way.
1. Gauge manifold set

2. Charging lines
4. Double ended spanner set
5. Ratchet wrench
6. Halide torch
7. Match box
8. Clean cloth
9. Amprobe
10. Voltmeter
11. Spirit level
12. Thermometer
13. Wire brush
14. A small blower
15. One packet mild detergent.
Procedure:
1. Inspection
a. Check the proper installation.
b. Check that the cabinet is not exposed to direct sun light.
c. Check the proper ventilation.
d. Check that the machine is very close to an electrical outlet.
e. Check the proper level of the cabinet as well as the machine.
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CHECKLIST
2. Check and service YES NO
a. All electrical connections are checked according to

circuit diagram so that there should not be any chance
of leakage of electricity.
b. The compressor is checked for any noise.
c. The belt is taken out from the motor and compressor
pulley.
d. The condition of the belt is checked for dryness or
wearing out.
e. The end bearings of the motor are carefully checked.
f. The pulley alignment and the end play are carefully
checked.
g. Motor bearing is lubricated properly.
h. Unit is thoroughly cleaned.
i. The fan and motor pulley are checked for proper
tightness.
j. The line voltage is checked using voltmeter.
k. The current drawn by the motor is checked using an
amprobe.
l. The belt around the motor and compressor pulley is
fixed.
m. The belt is checked for alignment and proper tightness.
n. The oil level in the compressor is checked.
o. The seal of the compressor is checked for oil and
refrigerant leakage.
p. The leakage of the entire system is checked by halide
torch.
q. The condenser externally.
r. The suction pressure is checked.
s. The discharge pressure is checked.
t. The cabinet temperature is checked.
u. The operation of the dual pressure cutout is checked.
v. The door gasket is checked for proper tightness.
w. The door binges are lubricated and the latches aid are
adjusted if found necessary.
x. The condition of suction, discharge and liquid lines are
checked.
y. The noise and vibration of the unit is checked and
rectified by using a suitable method.
z. The cabinet is cleaned both internally and externally.
Caution: Refrigeration oil should never be used to lubricate motor bearings.
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QUESTIONS
1. What happens if the belt of the compressor and motor is misaligned?

2. What would happen if the seal is leaking of excessive oil?
3. What happens to the “hot gas” as it enters into the evaporator?
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Belt Inspection and Analysis
Tools:
1. Allen wrench
3. Steel rule
4. Spirit level
5. Screwdriver
Follow this procedure to inspect a belt:
1. Shut down the power switch and tag it: “Down for maintenance. Do not turn the power
on”. Lock the switch open.
2. Remove the guard and inspect it for wear or damage. Clean grease and debris from
the guard to ensure good ventilation.
3. Notice the temperature. A belt that is too hot to touch just after the drive is shut down
has problems. Find and correct the source of overheating before returning the drive to
service.
4. Inspect the belt. Mark a starting point and work your way around, looking for cracks,
nicks, frays, cuts, or unusual or uneven wear. Replace belts wit excessive wear, cuts,
or missing teeth.
5. Check alignment by removing the belt and laying a straight edge along the outside
edges of both pulleys (see below). Misalignment will increase the chances for
premature wear instability and turnover.
6. Inspect other parts of the drive: motor and pulley mounting, and housing.
ALIGNING A BELT
To prevent premature wear and failure, belt drives must be in proper alignment, with the
shafts parallel and the pulleys in the same plane. If your inspection reveals a misalignment,
corrective action is indicated. A heft can have either angular misalignment and/or parallel
misalignment. (Misalignment can also result from a pulley that is damaged or improperly
mounted.)
1. Angular misalignment can be detected by a long straight edge; a tape measure, string,
or straight board can be substituted on a long drive (see Figure 16). In general, pulley
alignment should be within 1/10 inch per foot (8.4 mm per meter) of the span between
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the pulleys. Correct a misalignment by loosening the mounting bolts and rotating one
piece of equipment until both shafts are aligned. Then tighten the mounting bolts and
check for parallel misalignment.
2. To check for parallel misalignment, use a square to show that each shaft is at 90º to
the straightedge. Correct by loosening pulley mounting screws and sliding the pulley
until both edges of both pulleys line up to the straightedge.
Figure 16. Belt alignment.
INSTALLING AND TENSIONING A BELT
Belts must be properly installed and tensioned for good performance. Overtight belts will
cause compressor seals to leak, and bearings and belts to wear prematurely. Loose belts will
slip, heat up, and fail. New belts will stretch slightly, so manufacturers recommend they be
installed somewhat tighter than normal. Always check and retension a new belt after 4 to 24
hours of operation.
After performing the inspections suggested above, use this procedure to replace and
tension a belt
1. Check the number on the belt to order a replacement. If the number is illegible,
measure the length (along the outside) before removing it from the drive. (Check the
belt section later or use a gauge on the sheave to find the section.)
2. Loosen the motor mount and slide the motor toward the compressor to slack off the
belt.
3. Remove the old belts without prying them.
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4. Install the proper size belt. All belts should be replaced on a multiple drive to ensure
that they pull equally.
5. Slide the motor back into position to tighten the belt.
6. Check and adjust alignment using the above procedure. Check tension by deflecting
the bell at the midpoint between the pulleys. (Rotate multiple-belt drives by hand to
seat them in the grooves and even out the tension before checking tension.) Although
belt tension gauges are available, most mechanics deflect the belt manually and
check that the belt moves a little without having excess slack. Use this rule of thumb:
a force of 10 pounds (4.5 kg) should deflect a belt about ½ inch (1.3cm).
7. Tighten motor mounting bolts to the proper torque.
8. After 4 to 24 hours of operation, recheck and readjust the tension.
Figure 17. Fan motor mounting.
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Job Sheet 10
ADUSTING THE FAN SPEED
The fan motor is usually equipped with

an adjustable pitch pulley, figure 18. This
pulley can be adjusted to vary the fan speed
to obtain a range of air quantities. To obtain
the desired fan speed, adjust the fan motor
pulley according to the following procedure.
1. Remove the belt from the fan motor

pulley after loosening the motor (as
outlined in the section Adjusting Fan
Belt Tension).
Figure 18. Adjustable speed motor pulley
2. Loosen the setscrew in the movable flange of the pulley. Screw the movable flange in
toward the fixed flange as far as possible. In this position, the pulley gives the
maximum fan speed.
3. Each half-turn of the adjustable flange away from the fixed flange reduces the fan
speed.
CAUTION: Under no circumstances should the flange be screwed more than six turns
from the fixed flange. Before tightening the setscrew, insure that the setscrew is over
the nearest flat surface of the pulley hub.
4. Replace the belt and adjust the belt tension as outlined in the following section. It is
not possible to measure the fan speed accurately while the front panel is removed
from the unit. Such fan speed measurement should not be necessary if the preceding
instructions have been followed.
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Job Sheet 11
Electric Motors
Introduction
Electric motor converts electrical energy to magnetic energy and then to kinetic energy.
The rotation is caused by repeated attractions and repulsions between electromagnets
located in the motor housing and induced magnets rotating on the armature (rotor).
Practically every motor used in a commercial cooling system operates on alternating

current because the wavelike magnetic field of alternating current (AC) induces a current in
conductors whether or not they are moving in relation to each other (see figure below).
Electric motors have basic parts: the stator (housing or field) and the rotor (armature)
which spins on a shaft inside the housing. When electricity passes through the stator
winding, they become an electromagnet whose field strength rises and falls with the AC
waves. This induces current in the rotor, causing it to become a magnet. The rotor would not
rotate if the opposite poles were positioned next to each other, so motors are designed so
the magnetic fields can never rest in this condition. Due to magnetic attraction and repulsion,
the rotor tends to spin, and as it does, the magnetic field shifts position to cause the
attraction or repulsion to continue.
As the AC waves increases in strength during the start of each half of its cycle, the
induction of magnetism in the rotor lags slightly. The time the rotor is fully magnetized, the
stator is already starting to change polarity due to the change in the AC wave, so the field
can never line up with north opposite south.
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Job Sheet 11
LUBRICATION AND CLEANING OF MOTOR
Tools: Equipment Supplies

1. Oile  Blower
 Rags/clo
r  Grease/o
2. Gre
ase gun
3. Scr
ew driver
4. Adj
ustable wrench
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Job Sheet 11
Procedure for Lubrication of Motor – Sleeve Bearing
Procedure for Cleaning of Motor – Sleeve Bearing
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Job Sheet 11
Procedure for Lubrication of Motor – Ball and Roller Bearing
Procedure for Cleaning of Motor – Ball and Roller Bearing
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Job Sheet 11
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Job Sheet 12
How to Service Motor Properly
Tools and Equipment
1. Screwdriver
2. Clamp ammeter
3. Megger
4. Feeler gauge
5. Speedometer/tachometer
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Job Sheet 13
Fitting and Removing Gauge Manifold to a System
o Fit gauge manifold to a system
o Remove gauge manifold to a system
III. Tools, Materials and Equipment Needed
Equipment:
o System analyzer
o PACU/CRE
Tools:
o Ratchet wrench
o Adjustable wrench
Screw driver
PPE:
o goggles
o gloves
Introduction
The purpose of fitting and removing gauge manifold to a system properly is to
minimize the frequent release of refrigerant from the system. Improper removing and
fitting of gauge manifold contribute a lot in venting refrigerant to the atmosphere and
contribute to the high costs in maintaining and servicing of refrigeration and air
conditioning system.
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Job Sheet 13
Procedure
A. Fitting Gauge Manifold
1. Prepare the gauge manifold. Inspect

the rubber of the hoses and be sure
to zero in the gauge manifold
2. Prepare the tools and PPE. Install

the flexible hose to the pressure
lines: blue hose to low pressure line,
red hose to thigh pressure line while
the yellow hose to common line
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Job Sheet 13
3. Remove valve cap of discharge and

suction service valves
4. Backseat discharge and suction

service valves
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5. Remove the service port valve caps
6. Connect the high pressure line to the

discharge service valve(DSV) port,
hand tight and should be leak free
Purge here!
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7. Connect the low pressure line to the

suction service valve (SSV) port
leaving the knurled nut loose
8. Ensure that the common manifold

service leg is blanked off or center
hose is connected to the center park
port of the gauge manifold
9. Crack open the DSV, open both

hand valves, and purge air from
gauge line thru the blue hose near
the suction service port. Tighten the
knurled nut after blowing out the air
inside the hose
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Job Sheet 13
10. Close both hand valves and crack

open the SSV. Ensure that the two
gauges will have a balance pressure
and check for manifold leaks
11. Run the unit and record the pressures
B. Removing Gauge Manifold
1. Backseat discharge service valve
2. Slowly open both hand valves of the

gauge manifold to bypass the
pressure from high side to low side
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Job Sheet 13
3. Allow the pressure of both gauges to

equalize at suction pressure gauge
then backseat the SSV
4. Remove the manifold lines Return the

cap and seal caps
5. Leak test all service valves
7. Have your instructor check your work
TESDA-GOTEVOT 79
Version 2007-1.0
Information Sheet 6
Charging a Refrigeration System
Introduction
Charging a system refers to the adding of refrigerant to a refrigeration system. The

correct charge must be added for a refrigeration system to operate as it was designed to,
and this is not always easy to do. Each component in the system must have the correct
amount of refrigerant. The refrigerant may be added to the system in the vapor or liquid
states by weighing, by measuring, or by using operating pressure charts.
The charge of the system is usually indicated in the nameplate of the unit. If
nameplate is unavailable, charging should be done carefully using the other method such as
superheat setting, amperage and temperature monitoring.
Vapor Refrigerant Charging
Vapor refrigerant charging of a system is accomplished by allowing vapor to move

out of the vapor space of a refrigerant cylinder and into the low-pressure side of the refrig-
erant system. When the system is not operating--for example, when a vacuum has just been
pulled, or when the system is out of refrigerant-you can add vapor to the low and high-
pressure sides of the system. When the system is running, refrigerant may normally be
added only to the low side of the system because the high side is under more pressure than
the refrigerant in the cylinder. For example, an R-12 system may have a head pressure of
169 psig on a 95°F day this is determined by taking the outside temperature of 95°F and
adding 30°F this gives a condensing temperature of 125°F or 169 psig for R-12). The
cylinder is setting in the same ambient temperature of 95°F but only has a pressure of 108
psig.
The low-side pressure in an operating system is much lower than the cylinder
pressure if the cylinder is warm. For example on a 95°F day the cylinder will have a pressure
of 108 psig, but the evaporator pressure may be only 20 psig. Refrigerant will easily move
into the system from the cylinder.
When vapor refrigerant is pulled out of a refrigerant cylinder, the liquid boils to replace
the vapor that is leaving. As more and more vapor is released from the cylinder, the liquid ill
the bottom of the cylinder continues to boil, and its temperature decreases. If enough
refrigerant is released, the cylinder pressure will decrease to the low-side pressure of the
system. Heat will have to be added to the liquid refrigerant to keep the pressure up. *But
never use concentrated heat from a torch. Gentle heat, such as from a tub or warm water, is
safer. The water temperature should not exceed 90°F. This will maintain a cylinder pressure
of 100 psig for R-12 if the refrigerant is kept the same as the water in the tub. Move the
refrigerant cylinder around to keep the liquid in the center of the cylinder in touch with the
warm outside of the cylinder.
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Information Sheet 6
A water temperature of 90°F is a good one to work with because it is the approximate
temperature of the human hand. If the water begins to feel warm to the hand, it is getting too
hot.
The larger the volume of liquid refrigerant in the bottom of the cylinder, the longer the
cylinder will maintain the pressure. When large amounts of refrigerant must be charged into a
system, use the largest cylinder available. For example, don't use a 25-lb cylinder to charge
20 lb of refrigerant into a system if a 125 lb cylinder is available.
90°F
Tub of warm water

(Water should
Water
NOT exceed 90°F)
Liquid Refrigerant Charging

Liquid refrigerant charging- of a system is normally accomplished in the liquid line.
If the system is in a vacuum, you can connect to the liquid valve of a cylinder of refrigerant
and liquid refrigerant may be allowed to enter the system until it has nearly stopped. The
liquid will enter the system and move toward the evaporator and the condenser. When the
system is started, the refrigerant is about equally divided between the evaporator and the
condenser, and there is no danger of liquid flooding into the compressor. When charging with
liquid refrigerant, the cylinder pressure is not reduced. When large amounts of refrigerant are
needed, the liquid method is preferable to other methods because it saves time.
Be careful not to over charge the system.
Cylinder must be inverted when

charging liquid refrigerant.
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Information Sheet 6
Weighing Refrigerant
When a measured amount of refrigerant must be charged into a system, it may be

weighed or measured by using a graduated charging cylinder. Package systems, such as air
conditioners and refrigerated cases will have the recommended charging refrigerant printed
on the nameplate.
Weighing refrigerant may be accomplished with various scales. Bathroom and other
inaccurate scales should not be used. The illustration below shows an accurate dial scale
graduated in pounds and ounces. Secure the scales (make sure they are portable) in the
truck to prevent the mechanism from shaking and changing the calibration. Dial scales can
be difficult to use, as the next example shows.
TO LOW-PRESSURE
SERVICE PORT
TO HIGH-
PRESSURE
24 lb 4 oz 24 lb 4 oz
24 lb 4 oz AFTER CHANGE WEIGHT
SCALES
Suppose a 28 oz of refrigerant is needed with a cylinder of refrigerant weighing 24 Ib 4

oz. As refrigerant runs into the system, cylinder weight decreases, hence the system charge
of 28 0z. is subtracted from the 24 lb 4 oz as follows:
The calculated final cylinder weight is 24 Ib 4 oz - 28 oz = 384 oz
To determine this, 24 Ib 4 oz should be converted to ounces
24 lb X 16 oz/lb = 384 oz + 4 oz = 388 oz, Now subtract 28 oz from the 388 oz:
388 oz - 28 oz = 360 oz – cylinder weight in ounces
Because the scales do not read in ounces, you must convert to pounds:
360 oz divided by 16 oz/lb = 22.5 lb= 22 lb 8 oz final cylinder weight
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Electronic scales are often used. These are very accurate but more expensive than
dial-type scales. These scales can be adjusted to zero with a full cylinder, so as refrigerant is
added to the system the scales read a positive value. For example: if 28 oz of refrigerant is
needed in a system, put the refrigerant cylinder on the scale and set the scale at O. As the
refrigerant leaves the cylinder, the scale counts upward. When 28 oz is reached, the
refrigerant flow can be stopped. This is a timesaving feature that avoids the cumbersome
calculations involved with the dial scale. The picture below shows an electronic scale that
can be programmed for the correct amount of charge. A solid-state microprocessor controls
a solenoid that stops the charging process when the programmed weight has been
dispensed.
Using Charging Devices
Graduated cylinders are often used to add refrigerant to systems. These cylinders
have a visible column of liquid refrigerant, so you can observe the liquid level in the cylinder.
Use the pressure gage at the top of the cylinder to determine the temperature of the
refrigerant. The liquid refrigerant has a different volume at different temperatures, so the
temperature of the refrigerant must be known. This temperature is dialed on the graduated
cylinder. The final liquid level inside the cylinder must be calculated much like the previous
example, but it is not as complicated.
Suppose a graduated cylinder has 4 lb 4 oz of R-12 in the cylinder at 100 psig. Turn
the dial to 100 psig and record the level of 4 Ib 4 oz. The system charge of 28 oz is sub -
tracted from the 4 lb 4 oz as follows:
4 lb X 16 oz/lb = 64 oz + the remaining 4 oz = 68 oz
Then, 68 oz - 28 oz = 40 oz
in the final cylinder level,
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Information Sheet 6
40 oz divided by 16 oz/lb = 2.5 lb = 2lb 8oz final cylinder weight
The advantage of the graduated cylinder is the refrigerant can be seen as the level drops, See illustration below for an example of this
setup.
Some graduated cylinders have heaters in the bottom to keep the refrigerant
temperature from dropping when vapor is pulled from the cylinder.
When selecting a graduated cylinder for charging purposes, be sure you select one
that is large enough for the systems that you will be working with. It is difficult to use a
cylinder twice for one accurate charge. When charging systems with more than one type of
refrigerant, you need a charging cylinder for each type of refrigerant. You will also not
overcharge the customer or use the wrong amount of refrigerant if you closely follow the
above-mentioned methods.
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Information Sheet 6
VALVE
CLEAR GLASS CYLINDER
REFRIGERANT REFRIGERANT
(LIQUID) (LIQUID)
LEVEL IN TUBE LEVEL IN
DRUM
VALVE
CROSS SECTION
Other available refrigerant charging devices may make it more convenient to charge
refrigerant into a system. This device can be set to charge a system using pressure or
weight. A predetermined amount of refrigerant can be charged in pounds and ounces in 1-oz
increments. This type of device also has many other features. Be sure to follow the
manufacturer's instructions.
Some system manuals give typical operating pressures that may be compared to the
gage readings for determining the correct charge. These are called charging charts. The
chart can be used while using the manufacturer's directions. A charging chart must be
developed by the manufacturer for each system manufactured so there are no general
charts. "
Charging by Amperage Monitoring
All compressors have specific full-load amperage. The current of the compressor can
be used as a guide in charging. Approximately full load amperage of the compressor means
a full charge unit. This method must always be used with other method of charging.
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Information Sheet 6
Approximate Full Load Current
(Full Rating of Hermetic Compressor Motor 220V)
Horse Power (HP) Full Load Ampere

1/10 H.P. 0.75 FLA
1/8 H.P. 0.9-1.0 FLA
1/6 H.P. 1.1-1.2 FLA
1/5 H.P. 1.3-1.4 FLA
¼ H.P. 1.5-1.6 FLA
1/3 H.P. 2.0-2.5 FLA
½ H.P. 3.0-3.5 FLA
¾ H.P. 4.0-5.0 FLA
1 H.P. 6.0-7.0 FLA
1 1/2 H.P. 8.0-9.0 FLA
2 H.P. 10.0-12 FLA
3 H.P. 15-18 FLA
5 H.P. 22-25 FLA
Charging by Temperature Monitoring
During charging process, the technician usually monitors the temperature of

evaporator and condenser. The freezing component of a refrigerator is typically operating at
–10˚F to 5˚F while condenser temperature can be 130˚F more or less.
The cold air coming out of an evaporator ranges from 40˚F to 55˚F while the air
coming out from the condenser is around +125˚F to 200˚F. This temperature usually
depends on the ambient temperature and the heat absorbed in a compartment.
COLD EVAPORATOR
FREEZER COIL
COMPARTMENT
FAN AND MOTOR
DAMPER
36 – 40˚F COLD AIR GOVERNED

FRESH-FOOD BY DAMPER
COMPARTMENT
36 – 40˚F
VEGETABLE STORAGE
(CRISPER)
COMPRESSOR
TESDA-GOTEVOT 86
Version 2007-1.0
Information Sheet 6
Charging by Superheat Monitoring
This is the least method use by refrigeration and air conditioning technicians in
charging.
Superheat is a sensible heat. Any heat added above boiling liquid is termed as
superheat. To arrive at the correct superheat, take the following steps.
For example, an air-conditioning system unit gives the following data;
a. A suction reading from a gauge manifold is 69 psig.

b. Convert the suction pressure reading to suction saturated temperature using the
pressure/temperature chart for R-22 (you can also use PT chart for R-12), which is
40˚F.
c. Use a suitable thermometer to record the actual temperature of the suction line
which is 50˚F.
d. Subtract the saturated suction temperature from the actual suction line
temperature 50˚F-40˚F=10˚F superheat.
TESDA-GOTEVOT 87
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Job Sheet 14
Charge Refrigerant in the System (Liquid

Charging)
o Liquid charge a PACU/CRE system
I. Tools, Materials and Equipment Needed
Equipment: Tools:
 PACU/CRE  Adjustable wrench
 System analyzer  Ratchet wrench
  Screw driver
Instruments: PPE:
 Charging/Weighing scale  Goggles
 Thermometer  Gloves
 Clamp ammeter
II. Procedures
The correct amount of refrigerant must be charge in a PACU/CRE system to obtain a

maximum efficiency of the system. The desired temperature and proper functions of the
controls depends on the correct amount of refrigerant charge. This job sheet will guide you to
charge refrigerant in a PACU/CRE system.
1. Check system under vacuum, it

should be between 28 to 30 inches of
mercury.
2. Connect the service cylinder to the

center charging line of the manifold.
Note: Place the cylinder on inverted

position in a weighing scale. Record
the weight of the refrigerant cylinder.
Purge the refrigerant hoses.
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Job Sheet 14
3. Backseat liquid receiver service valve

and connect the high side part of the
gauge manifold.
4. Open the refrigerant cylinder valve

and purge the charging hoses.
Midseat the liquid receiver service
valve.
Note: Extreme care must be
considered for liquid refrigerant
will escape of the cylinder.
5. Start the compressor and operate it

until enough refrigerant is charge in
system.
Caution: If the system needs
additional small amount of
refrigerant, you may add by
vapor charging.
6. Close refrigerant cylinder valve and

liquid receiver service valve. Remove
gauge manifold.
Note: Extreme care must be
considered for liquid refrigerant
will escape from the hoses.
7. Check the cabinet temperature,

running current and operation of
pressure control.
9. Have your instructor check your work.
TESDA-GOTEVOT 89
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Job Sheet 15
Deep Evacuation
DEEP EVACUATION normally ranges from 24 hours to 36 hours vacuum pumping the refrigeration
system. This is done in order to safely remove the moisture especially in bigger units ranging from 10
tons (42 kW) and above.
Procedure:
Procedure of evacuating the system (DEEP EVACUATION):
Note: Be sure that the compressor is not running when doing this exercise, and in no case to
operate the compressor while doing the procedures.
1. Fit the gauge manifold to the system, following the procedures previously mentioned.
2. Normally the system is pressurized prior to the evacuation process, remove the pressure
by opening the low pressure valve of the gauge manifold and discharge the pressure to
the atmosphere until the gauge registers zero.
3. Connect common line of the gauge manifold to the vacuum pump.
4. Operate the vacuum pump by connecting the plug to appropriate source.
CAUTION: NEVER ATTEMPT TO OPERATE THE VACUUM PUM IF THE SYSTEM TO

BE EVACUATED CONTAINS PRESSURE, THIS WILL DAMAGE THE VACUUM
PUMP.
NOTE: OPENING BOTH GAUGE MANIFOLD VALVE IS BETTER TO HAVE A GOOD

AND FAST EVACUATION.
4. Leave the vacuum pump operating for several hours as mentioned in the succeeding
paragraph.
5. When 29.9 in. of Hg. has beet achieved, open the gas ballast of the vacuum pump to
avoid condensation of moisture in the vacuum pump.
6. When enough time is already achieved, close the low pressure valve of the gauge manifold,
the system is ready for charging.
TESDA-GOTEVOT 90
Version 2007-1.0
Job Sheet 15
Equipment set-up for deep evacuation.
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Job Sheet 15
JOB SHEET
Equipment/Instrument:
1. Vacuum pump
2. Manifold gauge/system analyzer
3. Wrench
4. PACU/CRE unit
Procedure
Yes No N/A
1. Prepare equipment/instrument accordingly.
2. Install the equipment/instrument correctly.
3. Evacuate the system according to procedure.
4. Perform proper housekeeping.
5. Observe safety precaution.
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Job Sheet 16
Triple Evacuation
TRIPLE EVACUATION is normally utilized for smaller units as in domestic refrigeration. This is the
simplest and speedy form of evacuation. It is done by vacuum three times and breaking the vacuum at
10 psi (70 kPa) twice. The vacuum is being breaked twice in order to help the moisture to accelerate
the movement to the point where the gauge connection is located.
Procedure:
Procedure of Triple Evacuation
1. Fit gauge manifold following the procedures mentioned in the previous exercise.
2. Remove the end of the common line (yellow) hose from the blanks.
3. Open the low pressure valve of the gauge manifold, allow the pressure to bleed off to
the atmosphere.
4. Connect the common line to the vacuum pump, operate the pump for 30 minutes, the
compound gauge should register 28 in. of Hg. If the gauge does not register such
pressure the system has leak, find the leak by doing leak testing methods mentioned in
the previous exercise.
5. When the compound gauge register around 28 in of Hg. vacuum after 30 minute
evacuation, close the gauge manifold valve and stop the vacuum pump.
6. Remove the common line hose from the pump and connect it to the refrigerant cylinder,
open the cylinder valve, purge common hose, open the low pressure valve of the gauge
manifold to allow the pressure to enter the system to break the vacuum.
NOTE: The pressure to be charged to the system is only 10 psi, this is only used for the
purpose of breaking the vacuum.
WARNING: Do not use nay other gas except refrigerant similar to refrigerant used in the
system.
7. After breaking the vacuum, wait for 3 minutes to stabilize the gas charge, then purge it
to the atmosphere, re-vacuum again to 29 in. Hg. for around 15 minutes.
8. Repeat the process as in step number 6 and 7.

9. When 29.9 in of Hg. vacuum is achieved, charge refrigerant to around 40 psi, then operate
the unit by running the compressor. Continue charging until full charge is attained.
TESDA-GOTEVOT 93
Version 2007-1.0
Job Sheet 16
Equipment set-up for triple evacuation.
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Job Sheet 16
JOB SHEET
5. Vacuum pump (single-stage)

7. Wrench
8. PACU/CRE unit
Procedure
Yes No N/A
3. Evacuate the system according to procedure.
TESDA-GOTEVOT 95
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Job Sheet 17
Liquid Charging of Refrigeration
Charging liquid refrigerant is much faster than vapor charging, it takes only a few in minute to charge
liquid refrigerant than, say, 2 hours vapor charging. Because of this reason almost all large
refrigeration plant installed in the field utilize this method.
Liquid charging requires either a charging valve in the liquid line, a process fitting in the high pressure
side of the system, or a liquid receiver outlet valve with charging port.
Liquid charging should he carried out through a filter drier to prevent any contain mauls being
introduced into the system.
WARNING: NEVER CHARGE LIQUID INTO THE COMPRESSOR SUCTION OR DISCHARGE

SERVICE VALVE PORTS, SINCE THIS CAN DAMAGE THE COMPRESSOR VALVES.
Procedure in Liquid charging.
NOTE: In doing this exercise, be sure that the refrigeration unit is not operating.
1. Fit gauge manifold to refrigeration system, following the procedures given in the previous
exercise.
2. Connect a flexible hose to the liquid receiver service valve port hand tight and leak free, fit this
hose to a suitable refrigerant cylinder.
3. Open the refrigerant cylinder valve, purge the hose to blow off the air inside the hose, and hold
the cylinder up-side-down.
NOTE: The refrigerant drum should be placed on a scale so that the weight of the refrigerant can be
checked frequently.
4. Open the liquid receiver service valve (open the valve stem 3 complete turns clockwise) so that
liquid refrigerant would rush inside the liquid receiver.
5. Watch the weighing scale carefully, when correct amount had been charge close the liquid
receiver service valve (valve stein turned counter clockwise fully).
6. Close the refrigerant cylinder valve, remove the hose and place it in the right storage.
7. Operate the refrigeration system and check performance.
NOTE: If the charge is still low finish it using vapor charging method.
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Job Sheet 17
Equipment set-up for liquid charging method.
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Job Sheet 17
JOB SHEET #1

10. Wrench
11. PACU/CRE unit
12. Weighing scale
13. Ammeter
14. Thermometer
Materials:
1. Refrigerant
2. Rags
Procedure
Yes No N/A
3. Verify the characteristics of the unit.
4. Charge the system according to procedure.
7. Monitor system performance.
TESDA-GOTEVOT 98
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Job Sheet 19
Vapor Charging of Refrigeration
When there is a shortage of refrigerant due to leak, or loss through a service operation, it is necessary
to add refrigerant to bring the charge back to normal. In the vapor charging operation, refrigerant is
transferred to the low side of the system Irma the service cylinder.
The quality of the refrigerant added to the system can be ascertained by weighing the cylinder before
and after the charging operation.
Procedure:
1. Install gauge manifold to the system, follow the procedure given in previous exercises
2. Evacuate the system, follow the steps given in previous exercises.
3. After the desired vacuum had been obtained close both hand valve of the gauge manifold and
remove the common line (yellow flexible hose).
4. Fit a gauge manifold and a suitable cylinder of refrigerant to the system you are working on.
NOTE: Be sure to determine the type of refrigerant (in most cases walk-in freezer uses refrigerant 12),
and the correct amount (in kilograms) required/necessary to charge a refrigeration system. This could
be done by looking at the name plate data. All refrigeration units are equipped with name plate data
that register all necessary information.
5. Open the refrigerant cylinder valve then purge the gauge lines to remove air present in the
flexible hose.
NOTE: Refrigerant cylinder should be in a up-right position.
6. Crack open the low pressure hand valve of the gauge manifold, notice that refrigerant rushes
inside the system, continue charging until 60 psi registers in the gauge, after obtaining this
pressure close the gauge manifold valve.
NOTE: Weigh the refrigerant cylinder so that you can determine the amount you had charged.
7. Operate the system by running the compressor, when the compressor starts to operate the
pressure of the low side gauge will decrease, continue charging by cracking the low pressure
hand valve of the manifold until correct amount of refrigerant had been charged.
NOTE: When the compressor starts to operate do not allow the compressor to run under vacuum.
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Job Sheet 19
While doing this exercise you will notice that the pressure of the refrigerant cylinder will decrease
during continuous charging, to remedy this dip the refrigerant cylinder in a bucket filled with warm
water at a maximum temperature of 55ºC.
Equipment set-up for vapor charging method.
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Job Sheet 19
JOB SHEET #1

16. Wrench
17. PACU/CRE unit
18. Weighing scale
19. Ammeter
20. Thermometer
Materials:
3. Refrigerant
4. Rags
Procedure
Yes No N/A
3. Verify the characteristics of the unit.
4. Charge the system according to procedure.
7. Monitor system performance.
TESDA-GOTEVOT 101
Version 2007-1.0
Job Sheet 19
Pumping Down a System
o Pump down a system
IV. Tools, Materials and Equipment Needed
Equipment: Tools:
 PACU/CRE  Ratchet wrench
 System analyzer  Adjustable wrench
PPE:
 gloves
 goggles
V. Procedures
The purpose of pump down is to remove all the refrigerant from the system and
store it in the system’s receiver so maintenance or service can be performed.
1. Wear appropriate PPE.
2. Install gauge manifold in the system.
3. Frontseat the outlet liquid receiver

service valve.
Note: Some liquid receiver has inlet

and outlet service valve
4. Run the system until the system’s

low side pressure is reduced to 2
psig. The unit should then be shut
off.
TESDA-GOTEVOT 102
Version 2007-1.0
Job Sheet 19
5. Frontseat the compressor discharge

and suction service valve.
6. The unit now is ready for

maintenance or repair.

work.
TESDA-GOTEVOT 103
Version 2007-1.0

Servicing and Maintaining PACU and CRE

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TRAINING PROGRAM

FOR GOTEVOT TRAINERS

CLEANING THE FILTERS AND FRONT PANEL--------------------3

DISMANTLING, INSPECTING AND REASSEMBLING SERVICE

CHECKING THE CONDITION AND LUBRICATION OF THE

POOR CONDENSATION IN PACU/CRE------------------------------22

MAINTAIN SECONDARY HEAT TRANSFER EQUIPMENT----25

TEST THE EFFICIENCY OF A COMPRESSOR--------------------31

CHARGE OIL IN THE COMPRESSOR--------------------------------33

EVACUATE THE SYSTEM-----------------------------------------------36

CHARGE REFRIGERANT IN THE SYSTEM (VAPOR

TEST LEAKS IN THE SYSTEM-----------------------------------------43

REMOVE AND REPLACE FILTER DRIER---------------------------48

REMOVE AND REPLACE OIL SEPARATOR-----------------------53

REMOVE, REPLACE OR CLEAN THERMOSTATIC

SERVICE COMMERCIAL REFRIGERATION SYSTEM----------60

BELT INSPECTION AND ANALYSIS----------------------------------63

FITTING AND REMOVING GAUGE MANIFOLD TO A SYSTEM73

CHARGE REFRIGERANT IN THE SYSTEM (LIQUID

LIQUID CHARGING OF REFRIGERATION--------------------------96

VAPOR CHARGING OF REFRIGERATION-------------------------99

Pumping Down a System-------------------------------------------------102

 Filters Air filters

Life Time of Filters

Note: Additional information for air filter.

Cleaning the Filters and Front Panel

Cleaning the Filters and Front Panel

Refreshing the Optional Photo-catalyst filter

Cleaning the Main Unit

3. Clean the indoor and outdoor unit and wrap

Some compressors are

Before gauges and service Nomenclature of service valve assembly

1. Suction service valves

Back Seated - this is when the spindle is turned

Mid-seated - in this position the spindle can be

SAFETY PROCEDURES IN HANDLING SERVICE VALVE

a. Valve ratchet wrench

This is a special tool used mainly in

This tool is not new to us, this is a universal

CONSTRUCTION OF THE MANIFOLD

Basically the gauge manifold consists of compound amid

Gauge manifold set

The two types of gauges are incorporated into the

1. Low Pressure Gauge:

The compound gauge indicates pressures above and

This gauge is used on the high pressure or condenser

CARE IN HANDLING GAUGE MANIFOLD

4. Calibrate the gauge regularly before using.

Dismantling, Inspecting and Reassembling

TOOLS AND MATERIALS

Discharge line valve Ratchet wrench, 1/4 in.

A. Two-way Service Valve

B. One-Way Service Valve

C. Liquid Line Valve

These are the basics used by a refrigeration man in troubleshooting a system.

An example of operating data of a motor is shown below:

- Maker’s name or trade mark.

Check Head or Suction Pressures

2. Install the gauge manifold set, as shown.

Refer to L.E. “Gauge and Manifold Set”