Competency-Based Learning Materials: Heating, Ventilating Air Conditioning and Refrigeration (Hvac/R)

COMPETENCY-BASED
LEARNING MATERIALS
Sector
HEATING, VENTILATING AIR CONDITIONING AND
REFRIGERATION (HVAC/R)
Qualification Title
RAC SERVICING (DOMESTIC REFRIGERATION AND AIR
CONDITIONING) NC II
Unit of Competency
SERVICE AND MAINTAIN WINDOW-TYPE AIR-CONDITIONING/
DOMESTIC REFRIGERATION UNITS
Module Title
SERVICING AND MAINTAINING WINDOW-TYPE AIR-
CONDITIONING/ DOMESTIC REFRIGERATION UNITS
VALENZUELA CITY POLYTECHNIC COLLEGE

Kamagong St., Fortune Village 6 Parada Valenzuela City
COLLEGE OF TECHNICAL EDUCATION
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module, “Servicing and maintaining window-type
air-conditioning/ domesticrefrigeration units,” this was one of the
competencies in RAC Servicing (Domestic Refrigeration and Air
Conditioning) NC II Qualification. This qualification is a course which
includes knowledge, skills, and attitude required to possess by a TVET
Trainer.
This unit of Competency, “Service and maintain window-type air-
conditioning/ domestic refrigeration units,”comprises the knowledge,
skills and attitude that Trainees must become skilled at as required in the
said qualification.
To complete each of the Learning outcomes (L.O) of the module, you

are required to undergo a series of learning activities. In each learning
outcome there are Information Sheets, Tasks Sheets, Operation Sheets,
and Activity Sheets. Follow these activities on your own and answer the
Self-Check at the end of each learning activity. Queries in mind must be
asked to the trainer/facilitator to clarify the information you are learning.
The goal of this course is the development of practical skills in

supervising work-based training. Tools in planning, monitoring and
evaluation of work-based training shall be prepared during the workshop to
support in the implementation of the training program.
This module is prepared to help you achieve the required

competency, in “RAC SERVICING (DOMESTIC REFRIGERATION AND AIR
CONDITIONING) NCII”.
Recognition of Prior Learning (RPL)
You may already have some of the knowledge and skills covered in
this module because you have:
 been working for some time.
 already have completed training in this area.
If you can demonstrate to your trainer that you are competent in a

particular skill or skills, talk to him/her about having them formally
recognized so you don’t have to do the same training again. If you have a
qualification or Certificate of Competency from previous trainings show it to
your trainer. If the skills you acquired are still current and relevant to this
module, they may become part of the evidence you can present for RPL. If
you are not sure about the currency of your skills, discuss it with your
trainer.
Remember to:
 Work through all the information and complete the activities in

each section.
 Read information sheets and complete the self-check. Suggested
references are included to supplement the materials provided in
this module.
 Most probably your trainer will also be your supervisor or
manager. He/she is there to support you and show you the
correct way to do things.
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RAC SERVICING (DOMESTIC Date Developed:
REFRIGERATION AND AIR Issued by:
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SERVICING AND Developed by:

Revision # 00 Page 2 of 33
MAINTAINING WINDOW- GROUP 2 HVACR- 3A
TYPE AIR-CONDITIONING/
DOMESTIC
REFRIGERATION UNITS
QA System
 You will be given plenty of opportunity to ask questions and
practice on the job. Make sure you practice your new skills
during regular work shift. This way you will improve both your
speed and memory and also your confidence.
 Use the Self-checks, Operation Sheets or Job Sheets at the end
of each section to test your own progress. Use the Performance
Criteria Check list or Procedural Checklist located after the
sheet to check your own perormance.
 When you feel confident that you had sufficient practice, ask
your Trainer to evaluate you. The results of your assessment
will be recorded in your Progress Chart and Accomplishment
Chart.
 Inside this module you will find the activities for you to complete
followed by relevant information sheets for each learning
outcome. Each learning outcome may have more than one
learning activity.
You need to complete this module before you can perform the
next module,“Troubleshooting Window-type Air-conditioning /
Domestic Refrigeration systems.”
SUMMARY OF COMPETENCY-BASED LEARNING MATERIALS
Qualification Title: RAC SERVICING (DOMESTIC 480 hours

REFRIGERATION AND AIR
CONDITIONING)NC II
No. Unit of Competency Module Title Code

Installing Window
1. HVC723337
Install Domestic type Air-conditioning/
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Refrigeration and
Domestic
Airconditioning (DomRAC)
Refrigeration units
Units
Servicing and
Service and Maintain Maintaining Window-
Window-type Air- Type Air-
2. HVC723338
conditioning/ Domestic conditioning/
Refrigeration units Domestic
Refrigeration units
Troubleshooting
Troubleshoot and Repair
Window-type Air-
Domestic Refrigeration and
3. conditioning / HVC723339
Air-conditioning (DomRAC)
Domestic
systems
Refrigeration systems
LIST OF CORE COMPETENCIES
TABLE OF CONTENTS
HOW TO USE THIS COMPETENCY-BASED --------------------------------------------2
LIST OF CORE COMPETENCIES-------------------------------------------------------------4
TABLE OF CONTENTS---------------------------------------------------------------------------5
MODULE CONTENT-------------------------------------------------------------------------------6
DEFINITION OD TERMS------------------------------------------------------------------------8
LEARNING OUTCOME SUMMARY #1-------------------------------------------------------9
LEARNING EXPERIENCES--------------------------------------------------------------------10
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INFORMATION SHEET2.1-1
Types and classification of air filter used in WAC. ------------------------12
SELF CHECK- 2.1-1-----------------------------------------------------------------------------15
ANSWER KEY -------------------------------------------------------------------------------------16
Effects of restricted air flow in WAC-------------------------------------------17
SELF CHECK- 2.1-2-----------------------------------------------------------------------------23
ANSWER KEY-------------------------------------------------------------------------------------24
Cleaning and replacing air filters-------------------------------------------------25
SELF CHECK- 2.1-3 -----------------------------------------------------------------------------26
ANSWER KEY -------------------------------------------------------------------------------------27
TASK SHEET 2.1-3-------------------------------------------------------------------------------28
PERFORMANCE CRITERIA CHECKLIST 2.1-3-----------------------------------------29

MODULE CONTENT
RAC SERVICING (DOMESTIC
QUALIFICATION REFRIGERATION AND AIR CONDITIONING)
NC II
SERVICE AND MAINTAIN WINDOW-TYPE
UNIT OF COMPETENCY AIR-CONDITIONING/ DOMESTIC
REFRIGERATION UNITS
Servicing And Maintaining Window-Type Air-
MODULE TITLE
Conditioning/ Domestic Refrigeration Units
INTRODUCTION:
This module deals with the knowledge, skills, and application towards
servicing and maintaining window-type air-conditioning/ domestic
refrigeration units. It details the requirements for this competency in
accordance with standard specifications and enterprise practice such as
cleaning and replacing air filters, assembling and
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disassemblingevaporator/condenser in WAC, assembling and
disassembling fan motor assembly in WAC, proper servicing and
maintenance procedures in fan motor assembly, proper servicing and
maintenance procedures in electrical power and control circuits, and
reprocessing of refrigeration system.
This module covers materials to use such as CBLM, information

sheets, self-check, task sheet and performance checklist.
NOMINAL DURATION: 10 HOURS
LEARNING OUTCOMES:
At the end of this module, you MUST be able to:

1. CLEAN AND REPLACE AIR FILTER
2. Service evaporator and condenser
3. Maintain fan motor assembly
4. Service electrical power and control circuit
5. Maintain refrigeration system
ASSESSMENT CRITERIA:
1. Air filter is identified and removed following standard procedures.
2. Filter is checked for damage and replaced if required in line with
SOPs.
3. Air filter is cleaned using the correct tools and cleaning procedures.
4. Filter is replaced in accordance with filter specifications.
5. Tools are selected in dismantling the evaporator/ condensing unit as
per standard operating procedures (SOPs)
6. High pressure washer is used in cleaning evaporator/ condensing coil
based on established procedures.
7. Evaporator/condenser coil fins are repaired for damage and replaced
in accordance with service procedures.
8. Cleaning agent or non-corrosive chemical is used in cleaning and
maintaining evaporator/ condensing coil, fins and other body
accessories as per standard operating procedures (SOPs).
9. Fan motor is maintained in line with manufacturer’s instructions.
10. Fan blades and blower are serviced and maintained in line
withmanufacturer’s instructions.
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11. Fan motor terminals are checked and serviced in line with
manufacturer’s instructions.
12. Fan motor mounting is checked and serviced in line with
manufacturer’s instructions.
13. Correct instrument is used in checking power supply and diagnosing
electrical control.
14. Defective electrical control is replaced in line with service and repair
procedures.
15. All controls/wirings are checked/inspected as per schematic diagram
in line with SOPs.
16. Loose connections/wirings and defects are accurately diagnosed and
repaired/reported in line with SOPs.
17. Grounding is checked in line with SOPs.
18. All parts of the refrigerant circuit are checked/ inspected as per
manufacturer’s manual/specifications.
19. Refrigerant circuit condition accurately diagnosed, repaired and
reported in line with service and repair procedures.
20. Refrigerant system accessories are repaired in line with service and
repair procedures.
21. Operating parameters are measured and analyzed based on standard
specifications.
22. Refrigeration system is reprocessed in line with manufacturer’s
standard operation procedures.
Pre-requisite: A trainee should be competent in the basic and common

competency before proceeding to the module.
LEARNING OUTCOME #2 SERVICE EVAPORATOR AND CONDENSER
CONTENTS:
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 Effects of heavily dented, corroded coil fins in unit operation
 Preventive and corrective maintenance of WAC
 Safety practices
ASSESSMENT CRITERIA:
1. Tools are selected in dismantling the evaporator/ condensing unit

as per standard operating procedures (SOPs)
2. High pressure washer is used in cleaning evaporator/ condensing
coil based on established procedures
3. Evaporator/condenser coil fins are repaired for damage and
replaced in accordance with service procedures
4. Cleaning agent or non-corrosive chemical is used in cleaning and
accessories as per standard operating procedures (SOPs)
CONDITION:
Trainees must be provided with the following:
 Equipment
- Air-Conditioning Unit
- Pressurized washer
 Materials
- Cleaning Agent
 Soap powder
 Liquid
- Rags
 Tools
- Screwdriver
- Adjustable wrench
- Allen wrench
- Nut driver/Socket wrench
- Pliers
- Fin comb
- Steel brush
- Pallet
 Courseware
 Service Manual
 LEs
1.
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EVALUATION METHOD:
 Interview
 Demonstration with questioninG
LEARNING OUTCOME SUMMARY
LEARNING EXPERIENCES
Learning Outcome 2 : SERVICE EVAPORATOR AND CONDENSER
Learning Activities Special Instructions
1.Read information sheet 2.2-5 Read information sheet 2.2-5 on your

“Effects of heavily dented, CBLM about Effects of heavily dented,
corroded coil fins in unit corroded coil fins in unit operation. If you
operation" have some problem about the content of
the information sheet, do not hesitate to
1. approach your facilitator.
2. Answer self-check 2.2-5 Refer your answers to the answer key for
and compare your answers the self check. You are required to get all
to answer key. answers correct. If not, read the
information sheet again to answer all
questions correctly.
3. Read information sheet 2.2- You are free to ask questions if you have
6 encountered problems or if you have
“Preventive and corrective queries in your mind regarding the
maintenance of WAC” content of the information sheet.
If you feel that you are knowledgeable on

the content of the information sheet, you
can now answer self-check provided in the
module.
4. Answer self-check 2.2-6 Refer your answers to the answer key for
and compare your answers the self-check. You are required to get all
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to answer key. answers correct. If not, read the
5. Read information sheet 2.2- You are free to ask questions if you have
7 " Safety Practices” encountered problems or if you have
queries in your mind regarding the
content of the information sheet.
If you feel that you are knowledgeable on

the content of the information sheet, you
can now answer self-check provided in the
module.
6. Answer self-check 2.2-7and Refer your answers to the answer key for
compare your answers to the self-check. You are required to get all
answer key. answers correct. If not, read the
7. Observe Demonstration on Observe your trainer as he demonstrates

“Cleaning and replacing air how to clean and replace air filters. Take
filters”. note of the techniques used and
movements being performed.
After observing, you can now perform task

sheet 3.-1.
8. Perform Task Sheet 2.1-3 Compare to performance criteria checklist

on “Cleaning and replacing 2.1-3 on “Cleaning and replacing air
air filters.” filters.”
9. Evaluate your performance Compare your work to the Performance

using Performance Criteria Checklist2.1-3. If you got 100% correct
Checklist 2.1-3 answer in this task, you can now move to
the next activity. If not, review the
information sheet and go over the task
again.
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Congratulations for a job well done! You have now completed the
learning Outcome #2 – Service Evaporator and Condenser. You are
now ready to take the next Learning Outcome #3. God Bless!
Information Sheet 2.2-5

EFFECTS OF HEAVILY DENTED, CORRODED COIL FINS IN UNIT OPERATION
Learning Objectives:
After reading this information sheet, you must be able to:
1. Identify the effects of heavily dented, corroded coil fins in unit
operation.
2. Accurately use of heavily dented, corroded coil fins in unit
operation.
Introduction
Over the past several years the HVAC industry has experienced a large
increase in instances of leaks in the central portion of aluminum-finned,
copper tube heat exchange coils. These leaks are characterized as being very
small in size and very high in numbers within a single coil. There are many
chemical species that can cause these coil leaks, including chlorides from
pool chemicals and clothes washing, sulfur from tap water, lubricants and
nearby industries, and ammonia compounds from cleaners or nearby
industries.
CORROSION DETAILS
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Most corroding agents produce relatively straight tunnels through a
copper tube wall. This is the more common experience with outdoor heat
exchange coils and is usually attributed to galvanic corrosion. This occurs
whenever there are dissimilar metals in the presence of water containing an
electrolyte. Dissolved salts of chloride are the most common electrolytes.
Although, any soluble salt can lead to galvanic corrosion, such as those
containing fluoride, bromide, iodide, sulfate, nitrate, borate, etc. When
galvanic corrosion occurs, the more sacrificial metal ( aluminum in our coils)
will preferentially corrode, and by doing so, protect the more noble metal
(copper in our coils). Figure 1 shows an outdoor condensing coil that was
exposed to a severely contaminated environment. Note the copper tubes are
intact but the aluminum fins are gone. This is the image and mechanism
that most people think of when considering coil corrosion.
Leaks caused by organic acids typically appear as a single initiation

hole that branch into several tunnels of which only one or a few actually
penetrate the entire tube wall. As these tunnels appear similar to those in
an ant colony, they are often referred to as ‘formicary’ corrosion. Figure 3
shows microscopic images of the cross section of two copper tubes showing
this phenomenon – one starting from the inside and one from the outside .
CORROSION ANALYSIS PROCEDURES

Knowing all of this, how does one determine the cause of leak
formation in these coils? There are probably as many different approaches to
this as there are people doing them. Presented here is a collection of
procedures used in the industry. The order of the procedures is such that if
one elected to use them all, performance of one test would not interfere with
that for subsequent steps.
1) Confirm that the coil actually has leaks and pinpoint leak locations.
2) Remove fins to reveal bare tubes at leak locations.
3) Examine tubes under microscope.
4) Rinse coil with distilled/de-ionized water and analyze for anions.
5) Perform elemental analyses on leak sites.
6) Try to put two-and-two together.
Below is a closer look at each of these procedures and what can be learned
from the results.
1) Leak Confirmation There is nothing more frustrating than trying to find

leak causes on a coil that never had a leak or had one caused by a
manufacturing defect. Defects in tube welding, and in tube processing can
produce leaks at any position in the coil. These kinds of failures are
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suspected when only one leak is found in the coil, or found in only one U-
bend. The general appearance of the coil can reveal candidate causes. For
instance, a coil with black copper tubing and clean shiny aluminum has
likely been attacked by sulfur. The next steps would be confirmation of
sulfur. Figure 4 shows copper tubes with typical black sooty appearance of
sulfur attack. Pinpointing the leak location(s) is important for later analyses.
Leak location can provide evidence of the corroding agent source. Figure 5
shows internal tube corrosion in a coil. The corrosion was only present in
the first tube in each circuit. This indicated that the corroding agent was not
from the coil itself, but from somewhere upstream. Leaks that occur in only
the bottom row of the coil are likely to be caused by some corroding agent in
the condensate water, if not by some physical defect. High chlorine was
found in the bottom row of one coil returned from a home. A little diplomatic
questioning revealed that the homeowner had been pouring chlorine bleach
in the drain pan to kill ‘bugs’ growing in there!
2) Fin Removal This is a laborious exercise that requires a lot of

persistence. The intent is to reveal the leak location in the copper tube for
further analysis. The Japanese copper tubing manufacturers seem to have
perfected a technique for an entire coil as shown in Figure 6. It works
relatively well on 1-row and 2-row coils, but poorly on deeper coils. The
steps are slitting the fins along the tubes, twisting/tearing the fins, and
finally pulling the fins out. The picture on the right shows the typical purple
to black color of formicary. corrosion on the upper rows and little corrosion
on the bottom rows. This followed the airflow pattern for this coil, indicating
the corroding agent was likely from the application environment.
3) Microscopic Examination With the fins off and the tube surface
exposed, microscopic examination is possible. If the tube in the area of the
leak is clean and no pitting is observed, it may indicate that the leak
initiated from the inside. Slitting the tube and spreading it open would
reveal darkened inside surfaces and pitting in these cases. Most often
though, the exterior will resemble a lunar landscape – pockmarked with
pits. Often times these areas also show salt deposits. Analyses of these
deposits can sometimes reveal the corrosion cause. Figure 7 shows
microscope images of several pitted tubes. The vertical stripes are caused by
the contact of the aluminum fins. The light-color copper bands are where
the fin collars touched the copper tube. The darker gray or black bands are
the spaces between the fins. It is in these bands between the fins that
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pitting is predominant. The edge of the fin collar creates a miniature crevice
in which corroding agents can concentrate during drying cycles and thus
focus their strength in one spot creating a pit, rather than general surface
corrosion.
4) Coil Rinsing and Anion Analysis This step is most difficult, as the coils
are large and the water must be very pure for any real benefit. In addition,
few labs have Ion Chromatography capability and many of those are not
calibrated for this kind of analysis. The intent is to collect and identify the
negative ions (anions) that are on the coil. These anions include many of the
active species that directly attack copper, such as chloride, fluoride,
bromide, iodide, sulfate, nitrate, acetate, formate, and other soluble low
molecular weight organic anions. It should be noted that a coil that has
been submerged in tap water to confirm leaks, will not be suitable for this
test, as this water submersion will remove some of the anions of interest as
well as add others (chloride, fluoride, sulfate) that are commonly present in
tap water. The very best way to obtain a representative water sample for Ion
Chromatography is to collect the condensed water from the coil while in
operation. If this cannot be done, coil rinsing is the second choice. One
problem with analysis of condensate or rinse water is in the case where
there was a single contamination event in which leaks developed but were
not discovered for a long time. The long time after the event may be
sufficient for the corroding anion to be completely rinsed from the coil –
erasing the evidence. An example of this is domestic canning. Canning
pickles in the summer will release high concentrations of acetic acid in the
air that condense on the air conditioner coil. This can lead to formicary
corrosion in the coil which will likely not to be diagnosed until the following
year, at which time evidence of the acetic acid is long gone. Figure 8 shows
two ion chromatograms for air conditioner condensate samples from two
homes. In Sample A the condensate contained high levels of sulfate, and the
condensate in sample 3 contained both acetate and formate indicating
formicary corrosion.
5.Elemental Analyses of Leak Sites The Scanning Electron Microscope

(SEM) has proven to be a very valuable tool for analyzing leak sites from
HVAC coils. First, detailed photographs can be made at very high
magnification that show the topography around the leak site. Figure 3,
mentioned above, shows SEM photos of tubing cross sections at 200X
magnification. Then using the Energy Dispersive X-ray (EDX) feature on the
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machine, the elemental content of the feature can be obtained. Figure 9
shows an SEM image of a contaminated tube surface and the EDX analysis
of the salt on the surface. With careful sample preparation, the elemental
composition in the bottom of a pit can also be determined. Analysis of these
pit contents can be very valuable in sorting out the responsible corroding
agent when there are multiple contaminants on the tube surface. Figure 10
is an image of a typical corrosion pit with the associated EDX elemental
analysis of the bottom of that pit. Note the increase in silicon in the pit as
compared with the surface analysis in Figure 9. Silicic acid has been
implicated in some coil leak instances. One problem with SEM and EDX
analyses is that they are conducted on samples under vacuum. If the
corroding agent is volatile – as is the case with formicary corrosion caused
by acetic or formic acid – then the vacuum will remove most, if not all, of the
critical evidence. Figure 11 is an EDX analysis of a typical formicary
corrosion pit. One would expect to see the elements from the acid – carbon,
oxygen and hydrogen. Only oxygen is found in the analysis. The hydrogen
cannot be detected by EDX anyway, and the carbon is gone. Oxygen is
present as oxides of copper. The current theory on formicary corrosion
includes formation of copper oxide as a necessary step.
6) Putting it together The first step is “Round up the usual suspects!”,

and the next step is to sort the guilty from the innocent. It is in this last step
where all of this can be useful. As mentioned before, it is not likely that all of
these procedures will be necessary. If the copper tubing looks like it has
been in a sooty fire, just skip to SEM/EDX to confirm sulfur as shown in
Figure 12, or use a wet chemical procedure for copper sulfide. If a likely
cause of corrosion cannot be surmised from the visual appearance of the
coil, then start going through the steps one at a time until some condemning
evidence is obtained. The costs for the first few steps are lower than those
for the last steps. In-house visual examinations, coil tear-down, and
microscopic examinations can be performed with little expense prior to
obtaining the more costly outside analyses by Ion Chromatography or
Scanning Electron Microscopy. It does happen in some cases that the cause
cannot be determined, but in every case many potential causes can be
eliminated.
INDUSTRY STATUS
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There are a couple conflicting theories in the industry concerning the
mechanism for formicary corrosion. There have been many papers written
on the subject with most of these from the copper producers in Japan. The
Air Conditioning, Refrigeration Technology Institute has initiated a project
under its 21-CR program to determine the actual mechanism involved, and
from this develop a bench test that produces formicary corrosion in copper
tubes when subjected to the necessary corroding agents and environmental
conditions. Success in this project will give the industry the ability to assess
potential corroding agents and their sources as well as develop remedies
against this form of attack.
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SELF CHECK 2.2-5
DIRECTION: Identify the following tools or materials referred in the
statement below. Write your answer on the space provided.
After answering this Self-check 2.2-5, compare your answers

on the answer key.
_______________ 1. This are a couple conflicting theories in the industry

concerning the mechanism for formicary corrosion.
_______________ 2. This is the more common experience with outdoor heat

exchange coils and is usually attributed to galvanic
corrosion.
_______________ 3. What quote is the first step in putting together?
_______________ 4. It has proven to be a very valuable tool for analyzing leak

sites from HVAC coils.
_______________ 5. This step is most difficult, as the coils are large and the
water must be very pure for any real benefit.
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ANSWER KEY
1. INDUSTRY STATUS
2. Corrosion Details
3. “Round up the usual suspects!”
4. Elemental Analyses of Leak Sites The Scanning Electron Microscope
(SEM)
5. Coil Rinsing and Anion Analysis
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Information Sheet 2.2-6
PREVENTIVE AND CORRECTIVE MAINTENANCE OF WAC
After reading this information sheet, you must be able to:
Introduction
If you’ve got an aging air conditioner, you’re probably not looking
forward to the hot and humid summer days ahead. If you sweated your way
through last summer and shelled out a lot of cash for repairs, you may be
wondering what you can do to prevent breakdowns this summer.
The truth is, there is a simple and relatively inexpensive way to prevent
many repair issues: have AC preventative maintenance done before you
start up your system this spring.
8 ways AC preventative maintenance prevents breakdowns
These are some of the problems that a skilled AC service technician can
prevent with a thorough inspection and AC preventative maintenance. One
service call in the spring can save you from those dreaded breakdowns on
the hottest days of the season.
1. Electrical issues
Your technician will inspect all wiring and electrical connections, and find
and fix loose connections and worn wires before they cause a power loss
that takes out your air conditioner.
2. Worn parts
When a worn belt or pulley suddenly snaps, you’ll find yourself without
cooling in a hurry. But your service technician can see that the belt is worn
and replace it before it causes your system to shut down.
3. Dirty coils
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Your air conditioner has evaporator coils that remove the heat from the air
in your space, and condenser coils that release the heat outside the
building. When the coil gets coated with dirt and grime, it can’t effectively
transfer heat. That makes your system work harder and run longer to cool
the space. The increased load on the fan motor and compressor can cause
them to fail.
Cleaning the coils as part of AC preventative maintenance before the start of

the season, and sometimes more often depending on the air quality where
your air conditioner is located, takes care of this issue and prevents system
failure.
4. Faulty or improperly set controls
Those new electronic controls are handy and save money on your energy
bills, but if the battery dies you’ll find yourself with an air conditioner that
won’t turn on (or won’t turn off!). Your service technician will test
thermostats and other controls to ensure that the correct temperatures are
maintained, timer functions are set properly, and batteries are changed.
5. Low refrigerant charge
Refrigerant is the substance running through your AC’s coils that removes
the heat and humidity from the air. Sometimes small holes or cracks in the
refrigerant lines can develop, causing the system to leak refrigerant. When
that happens, your system gradually loses cooling power until it can’t cool
your space at all. As part of your AC preventative maintenance, your service
technician will test the refrigerant charge. If he finds a reduced level of
refrigerant, he can find and fix the leak before you even realize you have a
problem.
6. Filthy fan blades

The New York City air can be rough on air conditioning equipment,
especially the fan in your outdoor unit that is continuously exposed to smog
and pollution. When the blades get coated with grime, the fan speed can
slow down, putting a strain on the motor and eventually causing it to fail.
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Cleaning the blades during AC preventative maintenance easily prevents
this problem.
7. Air flow problems

Faulty fan motors, blocked ducts, clogged filters and other air flow issues
can cause your system to cool ineffectively, and can lead to frozen coils and
even a burned out compressor. When that happens, you might need to start
shopping for a new air conditioner. Finding and fixing airflow issues can
prevent a much more expensive problem.
8. Clogged drain lines and drain pan

Accumulating debris in drains and condensate lines can cause them to clog
and overflow. When that happens, not only will your system go down, but
you’ll have water damage to deal with. If it’s a slow water leak that’s been
going on for some time before you notice it, you could end up with
dangerous mold growth. Clearing the lines and drains is a simple process
that prevents a big mess.
Corrective Maintenance
The unexpected happens and when it comes to Air Conditioning and
Heating Systems, things can get real expensive, real fast, specially if you
don't have a long term care provider for your system. If you have are having
trouble with your A/C System, it needs to be addressed soon, and we are
here for you.
We can't stress enough how important it is for you to do two things:

1. Have long term care for your Air Conditioning System. (Schedule
Maintenance &/or Service Plan)
2. Be careful with who you let into your system.
Affordable A/C Systems is a Licensed and Insured company, so you can be

confident that we will back you up, and protect your investment. Also, the
technicians at Affordable A/C Systems are experienced and knowledgeable
in the field, we offer flat rate pricing instead of hourly rates, and if you
choose us as your Preventive Maintenance provider emergency service will
also be available to you.
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Stop worrying about out of budget expenses, and who will take care of
your system. Affordable A/C Systems is here to think about your AC, so
you don't have to.
Saving is important, so here's a couple things you can check yourself

before giving us a call.
Check your AIR FILTER

Check your Circuit Breakers
Check your Thermostat Settings
Check your Outdoor Unit for Ice.
1. Blown Fuses. Found in the evaporator coil, fuses protect the unit against
overheating of the motors and or compressor. Once a motor starts going
bad, a popped breaker is normally the first thing the technician will check.
2. Worn Contactor. There are three contactors in a unit: one for the
compressor, one for the condenser fan motor, and one for the blower motor.
When a call for cooling or heating is placed, the contactors engage, making
an electrical connection starting the compressor and motors. Arcing and
pitting will form on the contactor making it hard for the electrical current to
pass and start the particular motor.
3. Capacitors. The run capacitor is used to help the motors of the unit run
at a consistent speed, rated in microfarads. Start capacitors give the
compressor a brief increase in starting torque. If either capacitor burns out,
it will need to be replaced for your HVAC to work properly.
4. Gas valve. The gas valve meters the gas to flow from your gas line to your
unit. They are only used during the heating season. If the gas valve gets
corroded, it will need to be replaced.
5. Filters. Filters will always get dirty and clogged from air particles. Once
this happens, the filter will need to be changed. One way to tell if the filter
needs to be changed is to hold it up to the light see if you can see light pass
through it. If you cannot, the filter needs to be changed. If a dirty filter is left
in, it will reduce the air flow to the unit causing the unit to freeze.
6. Thermostat. This is the device that controls the system, telling it what to

do and when to do it. Before calling an HVAC company, make sure the
thermostat is on. Many times the thermostat is accidentally turned off.
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7. Drain lines. The drain line commonly becomes clogged with dirt or algae.
With the unit clogged, the drain pan will fill up and cause water to leak over
and create some water damage to the ceiling tiles or ceiling.
8. Refrigerant leak. Refrigerant leaks normally happen due to vibration of

the unit when it is operating. The only refrigerant leaks that cannot be
repaired are the ones in the condenser or evaporator coils. If the leak is
found in another place the technician will remove what is left and charge the
unit levels back to their correct amount.
9. Compressor. This is the heart of the A/C unit. The compressor is always

located with the condenser coil. If the unit is undercharged the compressor
it will run hot and will eventually seize. If the unit is overcharged, your
liquid refrigerant will get back to the compressor and cause liquid slugging.
If is important that the A/C unit has the proper amount of refrigerant.
10. Condenser Coil. These are always located outside with the compressor.
They are exposed to the outdoor elements, so they often get dirty and should
be cleaned yearly. This can be done with a water hose when the unit is not
operating. If the dirt and grime get bad enough a HVAC technician will have
to clean the coil with chemical cleaner.
11. Evaporator Coil. On split systems the evaporator coil is located in the
attic, but on a package unit it is located outside with rest of the unit. If the
coil is located inside, cleaning will only be necessary if suggested and should
only be about every three years or so. If the evaporator coil cracks, an HVAC
professional will need to fix the break.
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SELF CHECK 2.2.6


on the answer key.
_______________ 1. This are a couple conflicting theories in the industry

concerning the mechanism for formicary corrosion.
_______________ 2. This is the more common experience with outdoor heat

exchange coils and is usually attributed to galvanic
corrosion.
_______________ 3. When a worn belt or pulley suddenly snaps, you’ll find

yourself without cooling in a hurry.
_______________ 4. It has proven to be a very valuable tool for analyzing leak

sites from HVAC coils.
_______________ 5. This step is most difficult, as the coils are large and the
water must be very pure for any real benefit.
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ANSWER KEY
1. INDUSTRY STATUS
2. Corrosion Details
3. Worn parts
4. Elemental Analyses of Leak Sites The Scanning Electron Microscope
(SEM)
5. Coil Rinsing and Anion Analysis
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TASK SHEET 2.2-6
Title: PREVENTIVE AND CORRECTIVE MAINTENANCE OF WAC
Performance Objective: Given the appropriate tools and materials, you are
required to do the maintenance of WAC by following the
procedures. You are given 1 ½ hours to perform the task.
Supplies, Tools & Equipment:
 Window type air-conditioner
 Refrigerator Unit
 Vacuum pump
 Nitrogen cylinder and regulator
 Oxy-acetylene/Mopp gas
 Recovery/recycling machine
Steps/ Procedure:
The trainees will work in the Practical work area and they will be
given one and a half hour to perform the preventive and corrective
maintenance of wac. The trainer will go around and give comment/s
and suggestion/s. At the end of one hour, trainees will present their
output.
Perform:
 Tools are selected in dismantling the evaporator/ condensing unit as per
standard operating procedures (SOPs)
 High pressure washer is used in cleaning evaporator/ condensing coil
based on established procedures
 Evaporator/condenser coil fins are repaired for damage and replaced in
accordance with service procedures
 Cleaning agent or non-corrosive chemical is used in cleaning and
accessories as per standard operating procedures (SOPs)
Assessment Method:
Return Demonstration using Performance Criteria checklist
PERFORMANCE CRITERIA CHECKLIST 2.2-6

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Name of Trainee:
Date:
Performance Criteria YES NO

Did you….
1. Tools are selected in dismantling the evaporator/
condensing unit as per standard operating
procedures (SOPs)
2. High pressure washer is used in cleaning

evaporator/ condensing coil based on established
procedures
3. Evaporator/condenser coil fins are straightened in

accordance with service procedure
4. Cleaning agent or non-corrosive chemical is used in

cleaning and maintaining evaporator/ condensing
coil, fins and other body accessories as per standard
operating procedures (SOPs)
Comments/ Suggestions:
Trainer: Date: ________________
Document No.
Information
REFRIGERATION AND AIR Sheet 2.2-7
MAY 2021
Issued by:
CONDITIONING) NC II SAFETY PRACTICES
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Introduction:
5 Important Safety Guidelines for New HVAC Technicians
Being new to the HVAC system industry, you should know and understand
crucial safety guidelines for new technicians for your own protection
Choosing the heating, ventilation, and air conditioning (HVAC) industry is a

smart career move because it is thriving across the U.S. But while working
as a new HVAC technician might be a great career choice, remember that it
isn’t free from safety risks. For this reason, technicians must be aware of
the safety guidelines that only experienced heating and cooling
companies keep, and always bear them in mind. Here are the most
important ones.
Assess the Situation

Working in the heating and air
conditioning industry, new HVAC
technicians must learn how to
assess the situation before
jumping into the task in order to
identify any hazards or safety
threats. The Centers for Disease
Control and Prevention
recommends professionals
working around and with
electrical currents to take up
additional electrical safety
training.
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Alternatively, one must consider taking up a short electrician-training
program if electrical safety and precautions training is not a part of the on-
the-job training.
Spend some time in getting the job done, but also make sure not to rush
things. Assess the situation first to prevent winding up injured.
Know what you’re working up against with when new to the

profession. For example, identify any hazards so that you can take essential
safety precautions before work begins. Spend some time in getting the job
done, but also make sure not to rush things. Assess the situation first to
prevent winding up injured.
This OSHA guide is another useful resource on controlling electrical
hazards.
Double-check Your Equipment

On a typical day, HVAC technicians may have to work in multiple job sites.
For this reason, double-check your equipment and know the required tools
for every job order. A few of those necessary tools include wire strippers,
wrenches and a vacuum gauge. Make sure they’re functional for safety and
efficiency. With properly working HVAC equipment, you can also reduce the
chance of an injury when performing repairs, maintenance or installations.
Gas Cylinders in Trucks

HVAC technician trucks can have a temperature reaching to at least 100
degrees in the summer. And when combined with the heat generated by the
R-410A gas cylinder, pressure can reach up to 366 psig.
For example, a large, 1500-sq.in. gas cylinder can generate pressure of up to
549,000 psig. With such hot temperatures, the cylinder can take off and
explode like a rocket if it’s damaged or it fails.
Always watch out for extremely high summer temperatures and be extra
careful when working with or around gas cylinders in HVAC trucks.
Always watch out for extremely high summer temperatures and be extra
careful when working with or around gas cylinders in HVAC trucks.
Put Your Safety First

Just like in other professions, there are risks involved when working with air
conditioning equipment and tools. New air conditioning technicians should
always put safety first.
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Before working, you should always wear protective gears – something you
might have been taught of if you’ve attended a welding school. A few gears
HVAC technicians need are,
● Face shields for protection from dangerous HVAC liquids and chemicals
● Respiration gears when unsafe air contaminants exist
● Hard hats when working in an area where some falling objects and low
lying beams might pose hazards
● Work shoes and boots for protecting your feet from falling or heavy objects
● Proper clothing for protecting the hands, skin and body from harsh
temperatures
● Earplugs for protecting against hearing loss especially when working in
areas where there is at least 90 decibels
● Safety glasses for stopping flying objects and debris from getting into your
eyes.
Additional Safety Tips

Once again, check that your HVAC equipment is clean, updated and doesn’t
need replacement. Otherwise, you might suffer from an injury from working
with worn out or broken equipment. Make sure that those needing
replacement are replaced, to keep yourself safe.
(NOTE TO EMPLOYING CONTRACTORS: making sure equipment is in good
working condition can keep your technicians safe. Also, you should always
remind them to wear protective gears to prevent accidents and injuries,
such as hearing or eyesight lost or broken limbs).
Wear protective and safety gear to avoid health issues as well, because you
might always be exposed to harmful contaminants, gases and dusts in this
job.
For tasks in which you’ll be exposed to these elements, make sure to wear a
face shield or goggles to protect your eyes from any chemicals as well as a
respirator to avoid inhaling chemicals.
Chemical Safety
Take note of chemicals because you’re more likely than not be exposed to
them. Cleaning liquids, detergents, solvents and refrigerants, to name a few,
can pose serious health risks if mishandled.
There are also cases when some chemicals can explode, causing injury.
So again, wear protective gear – and gloves when handling liquids that can
burn your skin. You should also remember safety procedures and proper
handling when storing as well as transporting chemicals.
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Extra precaution is also needed if you’re a new HVAC technician who lacks
in-depth knowledge on the most common HVAC system chemicals.
It is better to be aware of what you’re going up against than regretting later,
so you should ask an expert HVAC technician if you’re unsure about a
particular chemical before handling/transporting/storing it. (Ed. note: New
technicians, in fact all technicians working for an HVACR contractor, will
ideally be made aware of all safety hazards during orientation and/or on-
the-job training or classroom training.)
Being new to the HVAC system industry, you should know and understand
crucial safety guidelines for new technicians for your own protection.
Safety Always FIRST

Always put safety first when working with and around heating and cooling
systems and tools. Wear protective gear, assess the situation, take note of
summer temperatures, and have adequate knowledge on chemicals.
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SELF CHECK 2.2-7

on the answer key.
_______________ 1. Always put safety first when working with and around
heating and cooling systems and tools
_______________ 2. Just like in other professions, there are risks involved

when working with air conditioning equipment and
tools.
_______________ 3. Your air conditioner has evaporator coils that remove the
heat from the air in your space, and condenser coils that
release the heat outside the building.
_______________ 4. Working in the heating and air conditioning industry,

new HVAC technicians must learn how to assess the
situation before jumping into the task in order to
identify any hazards or safety threats.
_______________ 5. Cleaning liquids, detergents, solvents and refrigerants, to

name a few, can pose serious health risks if mishandled.
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ANSWER KEY
1. Safety Always FIRST

2. Put Your Safety First
3. Dirty coils
4. Assess the Situation
5. Chemical Safety
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COMPETENCY-BASED

VALENZUELA CITY POLYTECHNIC COLLEGE

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

To complete each of the Learning outcomes (L.O) of the module, you

The goal of this course is the development of practical skills in

This module is prepared to help you achieve the required

Recognition of Prior Learning (RPL)

If you can demonstrate to your trainer that you are competent in a

 Work through all the information and complete the activities in

SERVICING AND Developed by:

SUMMARY OF COMPETENCY-BASED LEARNING MATERIALS

Qualification Title: RAC SERVICING (DOMESTIC 480 hours

No. Unit of Competency Module Title Code

SERVICING AND Developed by:

LIST OF CORE COMPETENCIES

HOW TO USE THIS COMPETENCY-BASED --------------------------------------------2

LIST OF CORE COMPETENCIES-------------------------------------------------------------4

LEARNING OUTCOME SUMMARY #1-------------------------------------------------------9

SERVICING AND Developed by:

SELF CHECK- 2.1-1-----------------------------------------------------------------------------15

ANSWER KEY -------------------------------------------------------------------------------------16

SELF CHECK- 2.1-2-----------------------------------------------------------------------------23

SELF CHECK- 2.1-3 -----------------------------------------------------------------------------26

ANSWER KEY -------------------------------------------------------------------------------------27

TASK SHEET 2.1-3-------------------------------------------------------------------------------28

PERFORMANCE CRITERIA CHECKLIST 2.1-3-----------------------------------------29

SERVICING AND Developed by:

This module covers materials to use such as CBLM, information

NOMINAL DURATION: 10 HOURS

At the end of this module, you MUST be able to:

SERVICING AND Developed by:

Pre-requisite: A trainee should be competent in the basic and common

LEARNING OUTCOME #2 SERVICE EVAPORATOR AND CONDENSER

SERVICING AND Developed by:

1. Tools are selected in dismantling the evaporator/ condensing unit

SERVICING AND Developed by:

LEARNING OUTCOME SUMMARY

Learning Activities Special Instructions

1.Read information sheet 2.2-5 Read information sheet 2.2-5 on your

If you feel that you are knowledgeable on

SERVICING AND Developed by:

If you feel that you are knowledgeable on

7. Observe Demonstration on Observe your trainer as he demonstrates

After observing, you can now perform task

8. Perform Task Sheet 2.1-3 Compare to performance criteria checklist

9. Evaluate your performance Compare your work to the Performance

SERVICING AND Developed by:

Information Sheet 2.2-5

SERVICING AND Developed by:

Leaks caused by organic acids typically appear as a single initiation

CORROSION ANALYSIS PROCEDURES

1) Leak Confirmation There is nothing more frustrating than trying to find

SERVICING AND Developed by:

2) Fin Removal This is a laborious exercise that requires a lot of

SERVICING AND Developed by:

5.Elemental Analyses of Leak Sites The Scanning Electron Microscope

SERVICING AND Developed by:

6) Putting it together The first step is “Round up the usual suspects!”,

SERVICING AND Developed by:

SERVICING AND Developed by:

After answering this Self-check 2.2-5, compare your answers

_______________ 1. This are a couple conflicting theories in the industry