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Refrigeration & Air Conditioning

Mechanic

2020 Practice Manual

www.rsecertified.ca
Canadian Refrigeration & AC Mechanic: Red Seal Practice Exam. Copyright © 2020 by rse_certified

All rights reserved. Written in Canada. No part of this book may be used or reproduced or distributed
in any manner whatsoever without written permission except in the case of brief quotations embodied
in critical articles or reviews.
This book is a practice guide. Diagrams, tables, questions, and examples are to be used for practice
purposes only. For other information and assistance about the certification exam, candidates must
contact their local or assigned apprenticeship office. If any errors or omissions are noted, please
contact the author via email redseallearn@gmail.com

For information, please visit our website: www.rsecertified.ca


First Edition: June 2020

This practice exam book will help you to familiarize yourself with the Canadian Refrigeration & Air
Conditioning Interprovincial (Red Seal) Examination environment, mirroring the types of questions
and exam delivery settings that will be used in the real exam. It is a Comprehensive Guide to the
Interprovincial Exam, the only book thus far specifically developed for the Refrigeration & Air
Conditioning Mechanic Trade. It contains the information necessary to improve your scores on your
exam and help you pass the first attempt.
This practice manual is an excellent, thorough Canadian resource for HVAC & Refrigeration
journeyman, apprentices, and trade qualifiers preparing for the Red Seal examination. It features
extensive reviews in the most critical interprovincial exam areas, which include ladder diagrams,
graphs, and calculations, which usually slow candidates down when writing the exam.

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Table of Contents
Preface ................................................................................................................................................................. 2
Interpretation of Ladder Diagrams ................................................................................................................. 7
Methods of Troubleshooting ........................................................................................................................... 7
24-Volt Thermostat Terminal Designations ................................................................................................10
HVAC Equipment Nomenclature ................................................................................................................15
HVAC Rooftop Units .....................................................................................................................................17
Refrigeration Schematics.................................................................................................................................20
Gas-Fired Equipment Installation .................................................................................................................24
Furnace Venting ...............................................................................................................................................27
Furnace Controls .............................................................................................................................................30
Furnace Electrical & Controls .......................................................................................................................33
Furnace Troubleshooting ...............................................................................................................................36
Refrigerant Control Devices...........................................................................................................................39
Refrigeration Circuits ......................................................................................................................................42
Refrigeration Piping .........................................................................................................................................46
Lockout Relay ...................................................................................................................................................50
Electricity ..........................................................................................................................................................50
Duct System Pressures ....................................................................................................................................53
Psychrometric Processes .................................................................................................................................58
Cooling Towers ................................................................................................................................................60
Single Phase Compressors ..............................................................................................................................63
Canadian/US Electrical Symbols...................................................................................................................65
Basic Examination Information.....................................................................................................................67
References .........................................................................................................................................................69
ANSWERS .......................................................................................................................................................69

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Exam Components
COMMON OCCUPATIONAL SKILLS

ROUTINE TRADE ACTIVITIES

INSTALLATION PLANNING

INSTALLATION

COMMISSIONING

MAINTENANCE AND SERVICE

Source:

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NOA Task Competencies

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Ladder Diagram: Make-Up Air Unit

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The most crucial part of successfully taking the red seal exam is understanding the electrical wiring
diagram and understanding what physical components the various symbols represent. A legend is
usually used on the bottom of the circuit diagram to explain what the symbols or abbreviations mean.
Most ladder diagrams show the following basic components: where the power supply is, what path
the power takes, the load component, the switch component, and a legend for the symbols used in
the diagram.
The tricky part of reading ladder diagrams is understanding that even though the relay coil and relay
contacts are both parts of the same component, they are separated into their individual circuits in the
ladder diagram.
For example: In the diagram above (Ladder Diagram: Make-Up Air Unit), 1R, 1R1, 1R2, and 1R3 are
parts of one relay where 1R=contactor coil and 1R1, 1R2 &1R3=normally open contacts. See other
components in the table below.

Component Parts
Overload #1 1OL (3 normally closed contacts)
1OL1 (normally closed contact)
Overload #2 2OL (3 normally closed contacts)
2OL1 (normally closed contact)
Contactor #1 1R (contactor coil)
1R1, 1R2, 1R3 (normally open contacts)
Contactor #2 2R (contactor coil)
2R1, 2R2, 2R3 (normally open contacts)

Common troubleshooting techniques used in HVAC & refrigeration circuits include;

Note: Make sure to familiarize yourself with these troubleshooting methods.

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The Hop-Scotch Method

Legend: LPS-Low Pressure Switch, DTS-Discharge Temperature Switch, HPS-High Pressure


Switch, LAS-Low Ambient Switch, CC-Compressor Contactor Coil
A voltmeter only displays a value when there is a difference in pressure between one lead and
another. As
previously stated, the final destination of each side of line voltage is the load. The hop-scotch
method steps through
each circuit until you get to THE LOAD, which is the "the End of the Line."
If the load is not working and the voltage is correct, then you must assume the load is at fault. If
the voltage is not there, keep one lead of the meter on the neutral side and work back towards the
supply. At the point you see the voltage, stop. This is where something has made the circuit stop
operating. Remember, current must have a complete path in order to flow.

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Other Troubleshooting Rules

Electrical Troubleshooting Terms


Continuity Means a continuous or complete path
Resistance of a The designed resistance that a load normally has
load
An Open When a wire, switch, or load does not have a continuous or complete path for
current to flow
A Short The lack of resistance or no measurable resistance found, but the meter displays
continuity
Load Electrical component or part of a circuit that consumes electric power

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R 24V Power To Thermostat
G Indoor Blower Control Circuit
W Heating Control Circuit
Y Cooling Control Circuit
C 24V Common To Transformer

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Ladder Diagram

Legend-1R: Fan Relay, S1: Switch, M: Fan Motor

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HVAC Unit Nomenclature

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HVAC Rooftop Units

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Air Conditioner Schematics

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Furnace Vent Termination Clearances

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Maximum Allowable Length of Vent/Flue Pipe

Furnace Direct Vent (2-Pipe) & Non-Direct Vent(1-Pipe)(6)

Maximum Allowable Length Of Vent And Combustion Air Pipes(1)(2) (Ft)

Unit Input Pipe Size(4) Number Of Elbows(3)(5)


(BTU) (In.)
1 2 3 4 5 6 7 8
40000 2 or 2-1/2 120 115 110 105 100 95 90 85
60000 2 or 2-1/2 95 90 85 80 75 70 65 60
80000B 2 or 2-1/2 75 70 65 60 55 50 45 40
80000B 3 200 193 186 179 172 165 158 151
80000C 2 or 2-1/2 25 20 15 10 5 NA NA NA
80000C 3 200 193 186 179 172 165 158 151
100000 2 or 2-1/2 25 20 15 10 5 NA NA NA
100000 3 200 193 186 179 172 165 158 151
120000 2 or 2-1/2 45 40 35 30 25 20 15 10
120000 3 95 90 85 80 75 70 65 60

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Furnace DIP Switches
SWITCH PURPOSE FUNCTION DIP SWITCH
BANK 1 2 3 4
HEATING OFF 90 OFF OFF
DELAY 120 ON OFF
150 OFF ON
S1 180 ON ON
THERMOSTAT 2 Stage Stat ON ON
SETUP 2 Stage Stat ON OFF
1 Stg Stat 5 Min Delay OFF OFF
1 Stg Stat Auto Delay OFF ON
COOLING A OFF OFF
AIRFLOW B ON OFF
C OFF ON
S3 D ON ON
TRIM Add 5% OFF OFF
Minus 5% ON OFF
Add 10% OFF ON
Minus 10% ON ON
RAMPING A OFF OFF
PROFILE B ON OFF
C OFF ON
S4 D ON ON
HEATING A OFF OFF
AIRFLOW B ON OFF
C OFF ON
D ON ON
DEHUM Disabled OFF
Enabled ON
TRIM Disabled OFF
S5 Enabled ON
CONTINUOUS 25% OFF OFF
FAN 50% ON OFF
75% OFF ON
100% ON ON

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Bard® Unit Ladder Diagram

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Service Information Label
If status code recall is needed, do not remove power or blower door. Briefly remove and then reconnect one main limit
wire to display stored status code.
LED CODE STATUS
Continuous Off Check for 115VAC at L1 and L2, and 24VAC at SEC1 and SEC2
Continuous On Control has 24VAC power
Rapid Flashing Line voltage (115VAC) polarity reversed. If twinned, refer to twining kit instructions
Each of the following status codes is a two-digit number with the first digit determined by the number of short flashes
and the second digit by the number of long flashes.
11 NO PREVIOUS CODE - Stored status codes are erased when power (115VAC or 24VAC) to control is
interrupted or 48 hours after each fault is cleared.
12 BLOWER ON AFTER POWER UP (115VAC or 24 VAC) - Blower runs for 90 seconds if the unit is powered
up during a call for heat (R-W closed).
13 LIMIT OR FLAME ROLL-OUT SWITCH LOCKOUT - Control will auto-reset after three hours. Reset switch
or replace the fuse link. Refer to #33
14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34
21 GAS HEATING LOCKOUT - Control will NOT auto-reset. Check for: - Mis-wired gas valve - Defective
control (valve relay)
22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while the gas valve is de-energized. Inducer will
run until the fault is cleared. Check for: - Leaky gas valve - Stuck-open gas valve
23 PRESSURE SWITCH DID NOT OPEN. Check for:- Obstructed pressure tubing - Pressure switch stuck closed.
24 SECONDARY VOLTAGE FUSE IS OPEN. Check for: Short-circuit in secondary voltage (24VAC) wiring
31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED. Check for: - Control
relay may be defective - Refer to #32
32 LOW HEAT PRESSURE, DRAFT SAFEGUARD, AUX-LIMIT (when used*) SWITCH DID NOT CLOSE
OR REOPENED (DOWN-FLOW ONLY*) If open longer than five minutes, inducer shuts off for 15 minutes
before retry. Check for: - Proper vent sizing - Low inducer voltage (115VAC) - Defective Blower motor or
capacitor - Defective inducer motor - Defective pressure switch - Restricted vent - Inadequate combustion air
supply - Excessive wind - Disconnected or obstructed pressure tubing. If it opens after trial for ignition period,
the blower will come on for a 90 second recycle delay.
33 LIMIT OR FLAME ROLL-OUT SWITCH IS OPEN - If open longer than three minutes, code changes to #13.
Flame roll-out switch requires a manual reset. Check for: - Dirty filter or restricted duct system. - Loose blower
wheel. - Defective blower motor or capacitor. - Defective switch or connections. - Inadequate combustion air
supply (Flame Roll-out Switch or fuse link open). - Open Flame Roll-out switch, or fuse link. Manual reset or
replace.
34 IGNITION PROVING FAILURE - Control will try three more times before lockout #14 occurs. If the flame
signal is lost after trial for the ignition period, the blower will come on for a 90 second recycle delay. Check for:
- Gas valve defective or gas valve turned off. - Oxide buildup on the flame sensor (clean with fine steel wool). -
Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal in HIGH HEAT). - Green wire MUST
be connected to furnace sheet metal. - The flame sensor must be ungrounded. Manual valve shut-off. - Defective
Hot Surface Ignitor - Control ground continuity.- Inadequate flame carryover or rough ignition. - Low inlet gas
pressure
43 LOW-HEAT PRESSURE, DRAFT SAFEGUARD, OR AUXILIARY LIMIT (when used*) SWITCH OPEN
WHILE HIGH HEAT PRESSURE SWITCH IS CLOSED. Check for: - Disconnected or obstructed pressure
tubing - Pressure switch stuck open - Refer to #32 and #33
45 REPLACE CONTROL
COMPONENT TEST

To initiate the component test sequence, shut "OFF" the room thermostat or disconnect the "R" thermostat lead.
Briefly short TWIN/TEST terminal to "Com 24 V" Terminal. Status LED will turn off, control will turn "ON" the
inducer motor low speed, inducer motor-high speed, hot surface ignitor, blower motor-low gas heat speed, blower
motor-high gas heat speed and blower motor-high cool speed for 7-15 seconds each. The gas valve and the humidifier
will not be turned on.

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Metering Device

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Vapor Compression Refrigeration

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Pressure Loss in HVACR Elbows Expressed as Equivalent Length of Tube in Feet
Line Size in Inches (OD) 90º Short Radius Elbow (FT) 90º Long Radius Elbow (FT)
¼ 0.7 0.6
5/16 0.8 0.7
3/8 0.9 0.8
½ 1.2 1.0
5/8 1.5 1.3
¾ 1.6 1.4
7/8 1.8 1.6
1-1/8 2.4 2.0
1-3/8 3.2 2.2
1-5/8 3.8 2.6
2-1/8 5.2 3.4
2-5/8 6.5 4.2

Copper Tubing Specifications


(as per ASTM B-SS Standard)
Nominal Diameter Type Diameter OD Diameter ID Flow Area Weight
(OD) (Inches) (Inches) (Sq.In) (Lb/Ft Length)
3/8 K 0.375 0.305 O.073 0.145
L 0.375 0.315 0.078 0.126
½ K 0.500 0.402 0.127 0.269
L 0.500 0.430 0.145 0,198
5/8 K 0.625 0.527 0.218 0,344
L 0.625 0.545 0.233 0.285
¾ K 0.750 0.652 0.334 0.418
L 0.750 0.666 0.348 0.362
7/8 K 0.875 0.745 0.436 0.641
L 0.875 0.785 0.484 0.455
1-1/8 K 1.125 0.995 0.778 0.839
L 1.125 1.025 0.825 0.655
1-3/8 K 1.375 1.245 1.220 1.040
L 1.375 1.265 1.260 0.884
1-5/8 K 1.625 1.481 1.720 1.360
L 1.625 1.505 1.780 1.140
2-1/8 K 2.123 1.959 3.010 2.060
L 2.125 1.985 3.100 1.750
2-5/8 K 2.625 2.435 4.660 2.930
L 2.625 2.465 4.770 2.480
3-1/8 K 3.125 2.907 6.640 4.000
L 3.125 2.945 6.810 3.330
3-5/8 K 3.625 3.385 9.000 5.120
L 3.625 3.425 9.210 4.290
4-1/8 K 4.125 3.557 11.70 6.510
L 4.125 3.905 12.00 5.380

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R410 PRESSURE-TEMPERATURE CHART
PSIG 0F PSIG 0F PSIG 0F PSIG 0F PSIG 0F PSIG 0F PSIG 0F PSIG 0F

12 -37.7 88 25.4 164 57.7 240 81.1 316 99.7 392 115.5 468 129 548 141.6
14 -34.7 90 26.4 166 58.4 242 81.6 318 100.2 394 115.8 470 129.3 552 142.1
16 -32.0 92 27.4 168 59 244 82.2 320 100.7 396 116.2 472 129.7 556 142.7
18 -29.4 94 28.5 170 59.8 246 82.7 322 101.1 398 116.6 474 130 560 143.3
20 -36.9 96 29.5 172 60.5 248 83.3 324 101.6 400 117 476 130.3 564 143.9
22 -24.5 98 30.5 174 61.1 250 83.8 326 102 402 117.3 478 130.7 568 144.5
24 -22.2 100 31.2 176 61.8 252 84.3 328 102.4 404 117.7 480 131 572 145
26 -20.0 102 32.2 178 62.5 254 84.8 330 102.9 406 118.1 482 131.3 576 145.6
28 -17.9 104 33.2 180 63.1 256 85.4 332 103.3 408 118.5 484 131.6 580 146.2
30 -15.8 106 34.1 182 63.8 258 85.9 334 103.7 410 118.8 486 132 584 146.7
32 -13.8 108 35.1 184 64.5 260 86.4 336 104.2 412 119.2 488 132.3 588 147.3
34 -11.9 110 35.5 186 65.1 262 86.9 338 104.6 414 119.6 490 132.6 592 147.9
36 -10.1 112 36.9 188 65.8 264 87.4 340 105.1 416 119.9 492 132.9 596 148.4
38 -8.3 114 37.8 190 66.4 266 87.9 342 105.4 418 120.3 494 133.3 600 149
40 -6.5 116 38.7 192 67 268 88.4 344 105.8 420 120.7 496 133.6 604 149.5
42 -4.5 118 39.5 194 67.7 270 88.9 346 106.3 422 121 498 133.9 608 150.1
44 -3.2 120 40.5 196 68.3 272 89.4 348 106.6 424 121.4 500 134 612 150.6
46 -1.6 122 41.3 198 68.9 274 89.9 350 107.1 426 121.7 502 134.5 616 151.2
48 0 124 42.2 200 69.5 276 90.4 352 107.5 428 122.1 504 134.8 620 151.7
50 1.5 126 43 202 70.1 278 90.9 354 107.9 430 122.5 506 135.2 624 152.3
52 3 128 43.8 204 70.7 280 91.4 356 108.3 432 122.8 508 135.5 628 152.8
54 4.5 130 44.7 206 71.4 282 91.9 358 108.8 434 123.2 510 135.8 632 153.4
56 5.9 132 45.5 208 72 284 92.4 360 109.2 436 123.5 512 136.1 636 153.9
58 7.3 134 46.3 210 72.6 286 92.8 362 109.6 438 123.9 514 136.4 640 154.5
60 8.6 136 47.1 212 73.2 288 93.3 364 110 440 124.2 516 136.7 644 155
62 10 138 47.9 214 73.8 290 93.8 366 110.4 442 124.6 518 137 648 155.5
64 11.3 140 48.7 216 74.3 292 94.3 368 110.8 444 124.9 520 137.3 652 156.1
66 12.6 142 49.5 218 74.9 294 94.8 370 111.2 446 125.3 522 137.6 656 156.6
68 13.8 144 50.3 220 75.5 296 95.2 372 111.6 448 125.6 524 137.9 660 157.1
70 15.1 146 51.1 222 76.1 298 95.7 374 112 450 126 526 138.3 664 157.7
72 16.3 148 51.8 224 76.7 300 96.2 376 112.4 452 126.3 528 138.6 668 158.2
74 17.5 150 52.5 226 77.2 302 96.6 378 112.6 454 126.6 530 138.9 672 158.7
76 18.7 152 53.3 228 77.8 304 97.1 380 113.1 456 127 532 139.2 676 159.2
78 19.8 154 54 230 78.4 306 97.5 382 113.5 458 127.3 534 139.5 680 159.8
80 21 156 54.8 232 78.9 308 98 384 113.9 460 127.7 536 139.8 684 160.3
82 22.1 158 55.5 234 79.5 310 98.4 386 114.3 462 128 538 140.1 688 160.8
84 23.2 160 56.2 236 80 312 98.9 388 114.7 464 128.3 540 140.4 692 161.3
86 24.3 162 57 238 80.6 314 99.3 390 115 466 128.7 544 141 696 161.8

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AC Lockout Relay

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Duct Pressure Measurements

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Psychrometric Chart & Air-Conditioning Processes

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Choose answers from psychrometric processes listed below

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Cooling Tower

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Single Phase Compressors

Potential Relay

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Capacitor Coil N.C Contacts N.O Contacts

N.C., Time Closed N.C., Timed Open N.O., Timed Open Non-Fused Disconnect

Fused Disconnect Fuse Ground 1PH Induction Motor

Three Phase Overload Relay Overload Relay Illuminated Push


Induction Motor (Thermal Relay) (Magnetic Element) Button

(N.C.) Momentary (N.O.) Momentary (N.C.) Push Button, (N.O.) Push Button,
Push Button Push Button Mushroom Head Mushroom Head

Resistor (N.C.) Float Switch (N.O.) Float Switch (N.C.) Flow Switch

(N.O.) Flow Switch (N.C.) Foot Switch (N.O.) Foot Switch (N.C.) Limit Switch

(N.0.) Limit Switch (N.C.) Pressure (N.O.) Pressure Switch (N.C.) Temperature
Switch Switch

(N.0.) Temperature Current Voltage Transformer Standard Lights,


Switch Transformer Indicating

Heater

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What to bring to the exam?

What to expect during the test?

Exam Design

Source: http://www.red-seal.ca/docms/getready-eng.pdf

Breakdown of Examination Questions


Component Number of Questions (Marks)
Occupational Skills 18
Installation Planning 20
Installation 29
Commissioning 22
Maintenance and Service 36
Total 125

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Examination Preparation Resources

It is important for candidates to leave time for a thorough final review before the exam. In the last
three or four weeks before the exam, candidates should use practice exams to simulate the exam
experience as closely as possible, while keeping in mind that they need to be able to pass any set of
exam questions which has been drawn from the syllabus.
If you have moved to Canada from other parts of the world, you will need to familiarize yourself with
Canadian/US electrical standards and measurement units. It is important that you recognize and
understand common wiring diagram symbols as well.

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1. B
2. D
3. C
4. C
5. B
6. B
7. B
8. A
9. D
10. A
11. C
12. B
13. D
14. D
15. D
16. D
17. C
18. C
19. C
20. D
21. C
22. B
23. B
24. A
25. C
26. A
27. B
28. C
29. B
30. C
31. B
32. D
33. D
34. C
35. D
36. C
37. D
38. A
39. B
40. A
41. D
42. C
43. A
44. C
45. A
46. C
47. B
48. A
49. C
***

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50. D
51. B
52. B
53. B
54. D
55. B
56. B
57. B 2.5*24
58. C
59. C
60. A
61. B
62. B
63. C
64. B
65. D
66. C
67. D
68. C
69. A
70. A
71. D
72. D
73. C
74. B
75. D
76. B
77. B
78. C
79. A
80. A
81. D
82. D
83. D
84. B
85. C
86. C
87. C
88. A
89. D
90. C
91. B
92. * a-compression, b-de-superheating, c-condensation, d- subcooling, e-expansion, f-evaporation,
g-superheating
93. A
94. D
95. D
96. D
97. A
***

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98. B
99. B 75 + (3.4*5)
100. A
101. D
102. D
103. B P/V
104. A V2 / R
105. C
106. D (r1*r2)/(r1+r2)
107. C
108. C
109. C
110. D
111. A SP + VP = TP
112. D
113. C
114. B V=4005√VP
115. C
116. C
117. C
118. D
119. C
120. * a-humidification, b-humidification and heating, c-sensible heating, d-chemical
dehumidification, e-dehumidification, f-cooling and dehumidification, g-sensible cooling, h-
evaporative cooling
121. C
122. D
123. C
124. C
125. A
126. B
127. B
128. D
129. A temperature difference between the water leaving a cooling tower & the wet bulb (WB)
temperature of the air entering the tower.
130. C difference between hot water inlet temperature and cold-water outlet temperature
131. B
132. A
133. A Open path reads OL or infinite
134. C n = f (2 / p) 60
135. B
136. B
137. B
***

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72
Practice exams are a great way to prepare for your official Canadian Interprovincial (Red Seal)
Refrigeration and Air Conditioning certification test. This practice manual is an excellent tool for you
to improve your chances of passing the Red Seal exam. The book features 125 sample questions and
covers each block, task and sub-task in the Red Seal Occupational Analysis for the Refrigeration and
Air Conditioning Mechanic.

---Good Luck---

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73

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