WHAT IS 5S?
SEISO ( Sweep)
• 5S is a systematized approach to organize work
areas, keep rules and standards, and maintain
discipline needed to do a good job.
• It utilizes workplace organization and work
simplification techniques to make work easier,
faster, cheaper, safer and more effective.
• The practice of 5S develops positive attitude
among workers and cultivates an environment
of efficiency, effectiveness and economy.
SEIRI (SORT)
Remove unnecessary items and dispose them
properly
• Make work easy by eliminating obstacles
• Provide no chance of being disturbed with
unnecessary items
• Eliminate the need to take care of unnecessary
items
• Prevent accumulation of unnecessary items
SOME SEIRI PRACTICES
• Sorting and evaluation criteria
• Disposal Tags
• Designated storage area
• Material List
SEITON (Systematize)
Arrange necessary items in good order so that
they can be easily picked up for use
• Prevent loss and waste of time
• Easy to find and pick up necessary items
• Ensure first come – first – served basis
• Make work flow smooth and easy
SOME SEITON PRACTICES
Do things spontaneously without being told or ordered
• Place goods in wider frontage along passages
• Store goods for first-in first-out retrieval
• Have a fixed location for everything
• Label items and their locations systematically,
mark everything
• Separate special tools from common ones
• Put frequently-used items nearer to the user
• Make things visible to reduce searching time,
organize by color
• Don’t pile items without separator
• Put everything at right angles to the passage
line
• Fix unstable articles for safety
• Provide signs for abnormal condition or when
help is needed
• Keep space for safety equipment and
evacuation passage clear
Clean your workplace completely
• Easy to check abnormality
• Prevent machinery and equipment from
deterioration
• Keep workplace safe and easy to work
SOME SEISO PRACTICES
• Big Seiso ( clean-Up) Day
• 3-5 minutes cleaning daily
• Assign owner to each machine or area
• Combine cleaning with inspection
• Make daily maintenance points clear by
providing visible instructions
• Provide necessary tools for critical points of
cleaning
• Prevent causes of dust and dirt
SEIKETSU ( Standardize )
Maintain high standards or housekeeping and
workplace organization at all times
• Maintain cleanliness and orderliness
• Prevent mis-operation
• Make it easy to find out abnormality
• Standardize good practices
SOME SEIKETSU PRACTICES
• Visual control signs
• Color coding
• Responsibility labels
• Inspection marks
• Maintenance labels
• Prevention of dust, dirt, noise and vibration
• I can do it blindfolded
• One-point lessons
SHITSUKE ( Self-discipline )
• Maintain cleanliness and orderliness
• Prevent mis-operation
• Make it easy to find out abnormality
• Standardize good practices
SOME SHITSUKE PRACTICES
• Wash hands after going to the toilet
• Wash hands before and after meals
• Eat and smoke at designated areas
• Keep workplace always clean and tidy
• Wear clean uniform and shoes
• Observe proper office decorum
• Follow safety rules
• Put things back in their proper place after use
• Work according to standards
 Principles of 5S data in make work special
good order more activities
SEIRI - Waste Elimination Stratification Management with visual efficient Re-arrange
Dealing with Causes indices and procedures
Lay-out effective to make
SEITON - Functional Storage A place for Everything office to them more
economize efficient
SEISO - Cleaning as a Way of Purifying the Spirit movement manning
Cleaning as Inspection of allocation
personnel
SEIKETSU - Visual Management Standardization
SEISO Clean Polish up Upgrade
SHITSUKE - Habit Formation Disciplined Workplace (Sweep) office office manual
environme activities processing
WHY 5S?
nt Clarify with
• Workplace becomes clean and better organized Repair checkpoint appropriate
interiors, for process office
• Work becomes easier and safer
machines and result automation
• Results are visible to everyone and and
• Visible results trigger generation of more and equipment information
new ideas technologies
• People are automatically disciplined
SEIKETSU Centralize Standardiz Standardize
• People become proud of well-organized (Standardiz necessary e work
workplace e) files, data functional process and
• Resultant good image of the organization and check procedures
generates more business and positive materials Make
for information
impression to the public
common visible
BENEFITS OF 5S? use
Standardiz
• A clean and well-organized workplace is high in e
PRODUCTIVITY maintenan
ce
• A clean and well-organized workplace produces procedures
QUALITY products and services and
• A clean and well-organized workplace reduces provide
COST to a minimum visual
control
• A clean and well-organized workplace ensures
DELIVERY on time SHITSUKE Do things Enhance Upgrade
• A clean and well-organized workplace is SAFE (Self- spontaneo cross- productivity
for people to work in Discipline) usly functional consciousne
• A clean and well-organized workplace makes Keep rules coordinatio ss and
and n for working
employee MORALE high
standards activities skills
OTHER BENEFITS OF 5S Develop
multiple
• 5S improves CREATIVITY of people skills
• 5S improves COMMUNICATION among people Observe
office
• 5S improves HUMAN RELATIONS among people procedures
• 5S enhances COMRADESHIP among people
• 5S gives VITALITY to people KEY POINTS IN THE IMPLEMENTATION OF 5S

CONTENTS OF OFFICE 5S 1. Start small and easy, proceed slowly but steadily.

ITEM PHYSICAL ORGANIZ PROCESSIN • IF YOU MAKE HASTE, IT IS EASY TO FAIL.

ATIONAL G • For big organizations, start with pilot area.
• Trial practice at model area and model machine.
SEIRI Remove Eliminate Eliminate
(Sort) unnecessar input/outp unnecessary 2. Start with the most suitable “S”.
y private ut which work
and has no procedures • For messy workplace, start from 1st S-SEIRI
organizatio value • For troublesome machine, first conduct SEISO
nal items added then do SEISO-inspection.
SEITON Arrange Restructur Systematize 3. Only 1 or 2S’s are enough for the initial practice,
(Systematiz facilities, e office routine not all 5S’s.
e) materials activities to work and
 • First 3S’s (SEIRI, SEITON, SEISO) are action
words.
• 4th S-SEIKETSU is a CONDITION
• 5th S-SHITSUKE is accordingly CULTURE
4. Set simple, easily achievable and step-by-step
targets.
Themes are helpful to concentrate efforts and achieve
greater results. Practice 5S together with other
movements.
5. Everyone’s participation is IMPORTANT.
• Two heads are better than one.
• Four eyes see more than two.
• Encourage participation first by EDUCATION,
then by
• DEMONSTRATION, later through ACTUAL
practice, and of course RECOGNITION.
• Set aside a day for launching (e.g., Big Cleanup
Day)
 6. Management should take leadership of 5S
movement
• Lead by example
• Manage by walking around
• Let people know top management is interested
and watching though he may not always be
present
• Personally make official announcement
• Make periodic factory/company tour.
7. Record improvements for comparison.
• Situation appraisal
• Record starting points/benchmarks
• Spotshooting/Fixed Photography Method
• Action VS Documentation
QUALITY IS DOING THE RIGHT THINGS RIGHT, THE
FIRST TIME, EVERYTIME.
“PRODUCTIVITY means the efficiency with which
resources are used to produce government service
or product at specified levels of quality and
timeliness”.
ONE-IS-BEST-CAMPAIGN
• One-location
• One-day processing
• One-file projects
• One-hour meetings
• One-page memos
• One-copy filing
• One-minute telephone calls
• One-tool work
OFFICE 5S ACTIVITIES
1. Reduce the number of ledgers, forms, etc.
2. Arrange items in order to get anything needed within
30 seconds.
3. Keep things in just one place.
4. Have just one form for things.
5. Eliminate the idea that everyone has to have his own
copy of everything.
6. Shift from individual-based to group-based work.
7. Standardize and create manuals detailing office
procedure.
8. Provide mechanisms to evaluate what is happening
at any time.
9. Maintain cleanliness and orderliness.
KEY AREAS FOR OFFICE 5S
1. Physical and Psychological Aspect
• Communication
• Material Handling (document, equipment,
stationery)
• Movement of Personnel
• Good Impression for Customers and
Workers
2. Organizational Aspect
• Effectiveness of organizational units based on
input/output
• Restructuring of organization by means of
combination,
• elimination, etc.
• Vitalizing organizational units especially for
cross-functional activities
3. Information Processing Aspect
• Upgrading Quality, Response Time, Cost
Effectiveness
• Efficient Q/A System
• Upgrading Productivity Consciousness and
working skills
INSTALL DOMRAC UNITS
SELECTING AN AREA FOR INSTALLATION
• In selecting an area for installation, the
following should be avoided to prevent damage
or harmful effect to the unit.
• Greasy areas (e.g. areas near a machine)
• Salty areas (e.g. places/areas near the coast)
• Areas where sulfuric gas is present (such as hot
spring areas)
• Areas near flammable gas (e.g. LPG)
The following are general rules which need to be
considered in installing window-type air
conditioning unit.
a. It is important that the selected location where the
unit is to be placed suits the customer’s need.
b. Install the unit in an area with good ventilation. Any
obstacles affecting the airflow near the air inlet and the
air outlet will cause blockage to the airflow.
c. Install the unit away from heat or vapor.
d. Install the unit in an area away from television and
audio units, cordless phones, fluorescent lighting
fixtures and other electrical appliances (at least 1 meter
clearance). This is to eliminate or reduce interference to
other units generated by the motors running from the
air conditioning units.
e. Install the unit in an area that provides easy drainage
for condensed water.
PLUMB BOB
Plumb-bob or a plummet is a weight, usually with a
pointed tip on the bottom, that is suspended from a
string and used as a vertical reference line. This
instrument has been used since the time of the ancient
Egyptians by bricklayers, masons, carpenters and
electricians to ensure that their constructions are
"plumb", or perfectly upright.
A SPIRIT LEVEL is an instrument consisting of a
telescope and a tube level
like that used by carpenters, rigidly connected. When
the bubble in the
tube level is in the middle, the telescope's optical axis
(collimation axis)
will point exactly in the direction of the local horizontal.

f. Install the unit in an area not exposed to rain or direct Screw Driver-Use for driving and tightening a screw in
sunlight. (Install a separate sunblind if expose to direct fixing electrical appliances and insulators
sunlight)
Multi Meter –Reading
g. Fix the unit firmly if it is mounted in a high place.
See to it that the area would be able to endure the
vibration from the unit.

h. Install the unit where it will not cause neighbors to

experience hot wind and noise generated by the unit.

i. Install the unit where power source conforms to the

unit’s power requirements.

Refrigeration and Air Conditioning Schematic Symbols

Sample tools, materials and equipment

MEASURING TOOLS

STEEL TAPE-Bending and straightening are possible,

when straightening this is used as a straight measure.

WATER LEVELING TOOLS

Hose Leveling tool is a technique for determining

differences in height between points on the Earth's
surface.
FUNDAMENTALS OF ELECTRICITY INFORMATION SHEET
I. TERMS AND CONDITIONS
A. Anode – Positive terminal of an electronic device.
B. Branch – that portion of a total circuit which is
independent of other portions with each receiving full
supply voltage.
C. Capacitance – Factor in an electrical circuit that
allows for the storage of electrical charges and opposes
any change in existing voltage
D. Cathode – Negative terminal of an electronic device
E. Conductor – Any material with the ability to permit
passage of electrical current
F. Counter EMF – Voltage induced in a conductor which
is moving through a magnetic field in opposition to the
source voltage.
(NOTE: This is a generator action developed within
every motor.)
G. Current – Flow of electron through a conductor
measured in amperes.
H. Diode – Simplest kind of semiconductor having two
electrodes
(NOTE: The most important function of a diode Is to act
as a one-way valve for the passes of electrons;
therefore, a diode is basically a switching device rather
than regulating device.)
I. Electrons – Negatively charged particles
J. Hertz (cycle) – One complete reversal of an
Alternating Current from positive to negative and back
to the starting point in one second.
K. Impedance – Total opposition in an electrical circuit
to the flow of alternating current
L. Inductance – Property in an electrical circuit that
opposes any change in the existing current
M. Insulator – Material with an extremely high
resistance to current flow
N. LED – Light-Emitting Diodes which produce an
infrared light to which most semiconductor light sensors
are sensitive.
(NOTE: Visible light emitting diodes are widely used as
display lights on calculators, instruments, and readout
panels.)
O. Load – power consuming device
P. Low line voltage – Decrease in voltage available to a
power consuming device
Q. Parallel circuit – has more than one path it can take
R. Photovoltaic – a photo diode capable of converting
light energy into electrical energy
S. Power factor – Ratio of true power to apparent
power required
T. Rectification – function of the diode where there is
current flow in the positive half of a cycle
U. Resistance – Opposition to current flow measured in
Ohms.
V. SCR (Silicon Controlled Rectifier) – A thyristor that
can be triggered into conduction only in one direction.
W. Semiconductor – Conductor which has a resistance
value in between a good conductor and an insulator
X. Series circuit – Current has only one path it can take
Y. Series-Parallel circuit – Electrical circuit consisting of
both series and parallel components
Z. Solid state – Electrical circuits containing
semiconductors
AA. Thermistor – Thermal sensitive resistor whose
primary function is to exhibit a change in electrical
resistance with a change in temperature.
BB. Transistor – Semiconductor device which will
conduct, throttle, or block current flow.
CC. Thyristor – A semiconductor device used primary in
high power devices.
DD. Voltage (EMF) – Potential difference which causes
current to flow.
EE. Watt – Unit of power measurement.
FF. Zener diode – Diode used in delay or voltage
regulating circuit.
ELECTRICITY
-is a branch of physics concerning a natural
phenomenom.
-is one of the most important form of energy and it
cannot even be seen, heard or smell. It is much easier to
use than any other types of energy. Electricity can
caused to flow from other energy forms these include
heat energy, friction, mechanical energy, light,
chemistry and magnetism.
-is known only by its effect, electric charge, electric
current, electric field, and electromagnetism.
TYPES OF ELECTRICITY
STATIC ELECTRICITY
• Is often defined as electricity at rest. Static
electricity is often produced by friction.
• NOTE: lighting is created through the discharge
of static electricity.
CURRENT ELECTRICITY
• Is electricity flowing through conductors (wire).
 • Is the movement of electrons along electrical (NOTE: Air will conduct electricity under certain
conductor. Commonly used in homes and humidity conditions, and water will conduct electricity
industries. It is used to drive motors, weld, start when it contain trace minerals)
engines, etc..
IV. INSULATORS OF ELECTRICITY
II. DIRECT AND ALTERNATING CURRENT
A. Glass
A. DIRECT CURRENT
B. Rubber
1. Supplied by
C. Plastic
a. Generator
D. Wood
b. Battery
E. Ceramic
1.) Dry cell
F. Mica
2.) Wet cell
V. OHM’S LAW
2. Flows in one direction only
A. Establishes mathematical relationship between
3. Abbreviated as DC
1. Potential (voltage)
B. Alternating current
(NOTE: This is electromotive force (EMF), also called
1. Supplied by an Alternating Current Generator electrical pressure)
(Alternator)
2. Current flow (amperage)
2. Flows in one direction then reverses and flows in the
3. Resistance (ohms)
opposite direction
B. Equation symbol
3. Abbreviated as AC
1. E = Potential measured in volts
III. CONDUCTORS OF ELECTRICITY
2. I = Current flow measured in amperes
A. Silver
3. R = Resistance measured in ohms
(NOTE: Silver has the least resistance to current flows.)
C. Equations (Transparency 1)
B. Copper
1. E=IxR
C. Gold
2. I=E/R
D. Aluminum
3. R=E/I
E. Tungsten
VI. WATTS LAW FOR DC POWER
F. Zinc
(NOTE: This law also works for AC resistive circuits such
G. Brass
as electric heaters.)
H. Platinum
A. Establishes a mathematical basis for the amount of
I. Iron work done

J. Nickel (NOTE: The amount of wattage is the basis of the

electric bill.)
K. Tin
B. Equations for obtaining wattage
L. Steel
(NOTE: P is the letter symbol for power measured in
M. Lead
watts.)
N. Mercury
1. P = E x I
O. Nichrome
2. P = I2 x R
(NOTE: Nichrome has the highest resistance to current
3. P = E2 / R
flow)
VII. COMMON CONVERSIONS OF WATTAGE
P. Air
A. 1,000 watts = 1 kilowatt (kw)
Q. Water
B. 1,000,000 watts = 1 megawatt
C. 746 watts = 1 horsepower (hp) MEMORY AID FOR OHM’S LAW AND POWER
FORMULAS
D. 1 watt-hour = 3.413 b.t.u.’s

XI. RULES OF SERIES CIRCUITS

A. The current is the same through the circuit

B. The sum of the voltage drops around the series

circuit will equal the supply voltage

C. The largest voltage drop occurs in the component

with the highest resistance

D. The sum of the resistance of the components equal

to the total resistance.

XII. RULES FOR PARALLEL CIRCUITS

A. Total current equals to the sum of the current in all

branches

B. Voltage is the same across all branches

C. Total resistance is always less than the smallest

branch resistance

XIII. AMPERAGE LOADS AND WIRE SIZES

GENERAL PURPOSE

SERIES CIRCUIT

(NOTE: AWG stands for American Wire Gauge.)

MEMORY AID FOR OHM’S LAW

SERIES-PARALLEL CIRCUIT

FORMULAE:
 Basic Refrigeration
History Of Refrigeration
• Refrigeration relates to the cooling of air or
liquids, thus providing lower temperature to
preserve food, cool beverages, make ice and for
many other .
• Most evidence indicate that the Chinese were
the first to store natural ice and snow to cool
wine and other delicacies.
• Ancient people of India and Egypt cooled liquids
in porous earthen jars.
• In 1823, Michael Faraday discovered that
certain gases under constant pressure will
condense when they cool.
• In 1834, Jacob Perkins, an American, developed
a closed refrigeration system using liquid
expansion and then compression to produce
cooling. He used Ether as refrigerant, in a hand-
operated compressor, a water-cooled
condenser and an evaporator in liquid cooler.
• In 1842, Florida physician John Gorrie placed a
vessel of ammonia atop a stepladder, letting the
ammonia drip, which vaporized and produced
cooling. This basic principle is used in
airconditioning and refrigeration today.
• In 1856, Australian inventor James Harrison, an
emigrant from Scotland, used an ether
compressor. He used ammonia on an
experimental basis but used ether in equipment
that was previously constructed.
• In 1902, Willis Carrier, the “father of air
conditioning,” designed a humidity control to
accompany a new air-cooling system. He
pioneered modern air conditioning. In 1915, he,
along with other engineers, founded Carrier
Engineering, now known as Carrier Corporation.
• 1930 - In 1902, Willis Carrier, the “father of air
conditioning,” designed a humidity control to
accompany a new air-cooling system. He
pioneered modern air conditioning. In 1915, he,
along with other engineers, founded Carrier
Engineering, now known as Carrier Corporation.
• Many different refrigerants have been
developed over the years. The refrigerant R-12,
a chlorofluorocarbon (CFC), was developed in
1931 by Thomas Midgley of Ethyl Corporation
and C. F. Kettering of General Motors. It was
produced by DuPont. By the 1930s refrigeration
was well on its way to being used extensively in
American homes and commercial
establishments.
• In 1939, the Copeland Company introduced the
first successful semi-hermetic (Copelametic)
field-serviceable compressor.
• In 1974, two professors from the University of
California,Sherwood Rowland and Mario
Molina, presented the “ozone theory.” This
hypothesis stated that released CFC refrigerants
were depleting the earth’s protective ozone
layer. Scientists conducted high-altitude studies
and concluded that CFCs were linked to ozone
depletion.
what IS REFRIGERATION?
• Process that involves removal of heat from
the area which is desired to be kept cool
and the rejection of that heat to an area
whose temperature remains practically
constant.
What is Air Conditioning?
• It is the method of controlling the
temperature humidity, air movement and
cleaning of air in a confined space.
What is Ventilation?
• It is the circulation and refreshing of air in a
space without necessary change of
temperature.
what is TEMPERATURE?
• TEMPERATURE is the measurement of heat
level in a substance. It is the hotness or
coldness of the body. The movement of
molecules is the starting point of the
temperature. The instrument used to
measure the temperature of the substance
is called THERMOMETER.
what is MATTER?
• MATTER-is anything that occupies space
and it has mass and weight, matter is
compose of MOLECULES.
• THE 3 STATES OF MATTER ARE; SOLID,
LIQUID AND GAS
TEMPERATURE unit conversion
To change a Celsius reading to Fahrenheit, use the
formula
̊ F= 9/5 ̊ C + 32
To change a Fahrenheit reading to Celsius, use the
formula
̊ C= 5/9 ( ̊ F-32 )
To change to Absolute temperature
̊ K= ̊ C + 273
̊ R= ̊ F + 460
Major Components in Refrigeration Cycle
• COMPRESSOR-used to compress the low
pressure gas to high pressure thereby raising its
boiling point, used to circulate the refrigerant
within the system, used to maintain low
pressure at the evaporator to maintain low
temperature.
• CONDENSER-it act as heat exchanger between
hot gas refrigerant and cooling medium, used to
remove the heat of compression and latent
heat of condensation.
• EVAPORATOR-it is used to conduct the heat
from the provisions to the refrigerant. Allows
evaporation of liquid refrigerant to gaseous
state.
• EXPANSION VALVE/METERING DEVICE-it is
used to expand the high pressure warm liquid
refrigerant into a mixture of cold liquid
refrigerant from flooding back to condenser.
PRINCIPLES OF OPERATION
• The refrigerant in the form of low pressure gas
is suck by the compressor and compress to
change its state to high pressure high
temperature gas it is discharged from the
compressor at this state.
• The refrigerant in the form of hot gases enters
the condenser where it is made to pass around
the coil tubes of the condenser, due to the
cooling effect its latent heat of vaporization is
remove turning its state to a high pressure
warm liquid. It leaves the condenser in this
state and it is sorted in the receiver where the
liquid refrigerant is made to settle down at the
bottom of the receiver and the uncondensed
gas floats to the top of the liquid.
• Only liquid is allowed to leave the receiver and
flows to the liquid line to the expansion valve.
At the expansion valve the refrigerant
undergoes the expansion process wherein, its
pressure is reduced and its temperature is also
reduced to the freezing temperature. The cold
liquid refrigerant now flows to the evaporator.
• At the evaporator, the refrigerant absorbs the
heat conducted by the evaporator from the
provision. because of the heat absorb it boils
and vaporizes into low pressure, low
temperature gas. The refrigerant in this state is
again suck by the compressor and has
completed one cycle operation the cycle is now
then repeated.
1. The refrigerant in the form of low-pressure gas
is suck by the compressor and compress to
change its state to high pressure high
temperature gas it is discharged from the
compressor at this state.
2. The refrigerant in the form of hot gases enters
the condenser where it is made to pass around
the coil tubes of the condenser, due to the
cooling effect its latent heat of vaporization is
remove turning its state to a high pressure
warm liquid. It leaves the condenser in this
state and it is sorted in the receiver where the
liquid refrigerant is made to settle down at the
bottom of the receiver and the uncondensed
gas floats to the top of the liquid.
3. Only liquid is allowed to leave the receiver and
flows to the liquid line to the expansion valve.
At the expansion valve the refrigerant
undergoes the expansion process wherein, its
pressure is reduced and its temperature is also
reduced to the freezing temperature. The cold
liquid refrigerant now flows to the evaporator.
4. At the evaporator, the refrigerant absorb the
heat conducted by the evaporator from the
provision. because of the heat absorb it boils
and vaporizes into low pressure, low
temperature gas. The refrigerant in this state is
again suck by the compressor and has
completed one cycle operation the cycle is now
then repeated.
COMPRESSOR
• The compressor is the “heart” of the system.
The compressor compresses the low pressure
refrigerant vapor from the evaporator and
compresses it into a high pressure vapor.
• Types of Hermetically Sealed Compressor
1.Reciprocating
2.Rotary
3.Scroll
The Reciprocating Compressor
• Piston type compressor. Usually applied for long
pipe run application due to its durability
because of its mechanical design (linear
compression).
The Rotary Compressor
• Often used for WRAC and refrigerators due to
its quiet operation.
• Since this type of compressor is not as durable
as the reciprocating compressor, it is usually
comes with an accumulator to separate liquid
refrigerant from entering the compression
chamber.
The Scroll Compressor
• The most efficient type of compressor.
Combined durability (compliant scroll) of a
 reciprocating compressor with a quiet
performance like that of a rotary
The Condenser
• The “Discharge Line” leaves the compressor and
runs to the inlet of the condenser.
• Because the refrigerant was compressed, it is a
hot high pressure vapor (as pressure goes up –
temperature goes up).
• The hot vapor enters the condenser and starts
to flow through the tubes.
• Cool air is blown across the outside of the
finned tubes of the condenser (usually by a fan
or water with a pump).
• Since the air is cooler than the refrigerant, heat
jumps from the tubing to the cooler air (energy
goes from hot to cold – “latent heat”).
• As the heat is removed from the refrigerant, it
reaches it’s “saturated temperature” and starts
to “flash” (change states), into a high pressure
liquid.
• The high pressure liquid leaves the condenser
through the “liquid line” and travels to the
• “metering device”. Sometimes running through
a filter dryer first, to remove any dirt or foreign
particles.
Metering device/expansion valve
• Metering devices regulate how much liquid
refrigerant enters the evaporator .
• Common used metering devices are, small thin
copper tubes referred to as “cap tubes”,
thermally controller diaphragm valves called
“TXV’s” (thermal expansion valves) and single
opening “orifices”.
• The metering device tries to maintain a preset
temperature difference or “super heat”,
between the inlet and outlet openings of the
evaporator.
• As the metering devices regulates the amount
of refrigerant going into the evaporator, the
device lets small amounts of refrigerant out into
the line and looses the high pressure it has
behind it.
• Now we have a low pressure, cooler liquid
refrigerant entering the evaporative coil
(pressure went down – so temperature goes
down).
Metering device/expansion valve
• Common Types of Metering Devise
• Thermostatic Expansion Valve
• Capillary Tube
• Accurator
Evaporator
• The evaporator is where the heat is removed
from your house , business or refrigeration box.
• Low pressure liquid leaves the metering device
and enters the evaporator.
• Usually, a fan will move warm air from the
conditioned space across the evaporator finned
coils.
• The cooler refrigerant in the evaporator tubes,
absorb the warm room air. The change of
temperature causes the refrigerant to “flash” or
“boil”, and changes from a low pressure liquid
to a low pressure vapor.
• The low pressure vapor is pulled into the
compressor and the cycle starts over.
• The amount of heat added to the liquid to
make it saturated and change states is called
“Super Heat”.
• One way to charge a system with refrigerant is
by super heat.
What is a REFRIGERANT?
• If the compressor is the heart of the system, the
refrigerant is the blood of the system. A
refrigerant is a fluid that easily boils at a lower
temperature. It absorbs heat in the evaporator
and discharges heat into the condenser.
• The principle behind mechanical refrigeration is
that when a compressed air expands, it absorbs
heat from the environment. Similarly when a
solid is liquefied, it absorbs heat as well.
• The refrigerants that were used in mechanical
refrigeration in the early days were sulphur
dioxide, carbon dioxide, ammonia and methyl
chloride.
• The use of these refrigerants caused health
hazards to the users when they leaked. This
calls for new development of refrigerants that
were safe and non-toxic.
• DuPont led the industry in the invention of safer
fluorocarbon refrigerants with the introduction
of FREON 12 in 1931. The word "Freon" hence
become a trade name for HCFCs and CFCs
refrigerants that are sold by this company. This
range of products have been used extensively in
air conditioning and refrigeration industry.
BASIS ON IDENTIFYING REFRIGERANT
1. Identify refrigerant by using digital refrigerant
identifier
2. By pressure
REFRIGERANT STANDARD PRESSURE
R-12 70 PSIG
R-134A 90 PSIG (REF)
R-22 150 PSIG (ACU)
R-410A 200 PSIG (INVERTER)
3. By Nameplate specification
4. By color coding
• R-40A ROSE
• R-407B CREAM POLYOALKALENE GLYCOL (PAG)
• R-407C BROWN
• Designed for HFC compatibility
• R-11 ORANGE
• Not considered suitable with CFCF/HCFC
• R-12 WHITE
• R-22 GREEN HFC OILS
• R-113 PURPLE
• Polyolester (POE) and Poly Alkalene Glycol
• R-134A LIGHT BLUE
(PAG)
• R-114 DARK BLUE
• PAG Oils are developed for Mobile air
• R-500 YELLOW
conditioning (MAC)
• R-502 ORCHID
• These oils are extremely sensitive to humidity
• R-717 SILVER
and will absorb moisture from air if exposed to
• R-49A TAN ambient.
• R-123 LIGHT GRAY • Should always be kept in a well sealed can.
• R-401A CORAL RED • PAG Oil in cans that have opened and not
• R-401B MUSTARD YELLOW protected with dry nitrogen should not be used
• R-401C AQUA in system.
• R-404A ORANGE • Humidity will drastically reduce stability and
Oils for Alternative Refrigerants reduce lifetime of system.
• Careful evacuation and used of nitrogen are
1. An important consideration in the development essential for long term reliability.
of Hydro Chlorofluorocarbon (HCFCs) and Hydro
Fluorocarbons (HFCs) as alternative refrigerants POE Oils are developed for stationary refrigeration
in the testing of oils for solubility., stability, and air conditioning (RAC) systems but are also
lubricity with the refrigerant, and compatibility used by some auto manufacturers for retrofit as
with materials of construction. Testing will they are more tolerant to contaminations than
determine which lubricants can be used in PAG.
current systems and what changes are required. • POE oils are sensitive to humidity and will
2. In general the ternary blends and HCFCs can be absorb moisture from ambient air if exposed.
used with oils that are commercially available;
• Humidity will drastically reduce stability and
however, some development work may be
reduce lifetime of system.
required to optimize performance. Applications
• Careful evacuation and use of nitrogen are
with HFCs require the development of new oils.
essential for long term reliability
The desirable properties for development use
• Low viscosity Alkylene Benzane (AB) are used in
are:
rotaries for R407C and R410A.
Acceptable solubility with the refrigerant (ideally,
APPLICATION
single phase over a broad temperature range);
-Food processing, preservation and distribution
• Acceptable lubricity;
• Good thermal stability for the • The fundamental reason for having a
refrigerant/lubricant combination; refrigerator is to keep food cold. Cold
• Acceptable compatibility with system temperatures help food stay fresh longer. The
materials (elastomers, metals and plastics); basic idea behind refrigeration is to slow down
• Low toxicity; and the activity of bacteria (which all food contains)
• Commercial availability at a reasonable so that it takes longer for the bacteria to spoil
cost. the food.
3. Listed below are the refrigeration lubricating
-Comfort Air Conditioning
oils and their characteristics:
MINERAL OIL (MO) • Most important applications of refrigeration is
• Designed for and miscible in CFC/HCFC in cooling and dehumidification as required for
• Very soluble in HC (higher viscosity/superheat summer air conditioning.
can be required)
ALKYLBENZENE (AB)
• Designed for and miscible in CFC/HCFC
• Soluble in CFC/HCFC/HFC/HC
• High solubility in CFC/HCFC/HC must be
considered
 REFRIGIRATION
Refrigeration is the process of removing heat from
an enclosed space or from a substance, maintaining
it at desired low temperature and moving the heat
to a place where it is unobjectionable.
The application of refrigeration can be grouped into
following four major equally important areas:
• Food processing, preservation and
distribution
• Chemical and process industries (to liquefy
gases – oxygen, nitrogen, propane and
methane)
• Comfort air conditioning
• Special applications (surgery, storage of
drugs, storage of blood and tissues)
I. Classification of Refrigeration Cycle
1. Cyclic refrigeration (close cycle) The heat is
removed by a working medium from a low
temperature space or source and rejected to a high
temperature sink with the help of external work
(compressors, pumps, etc.)
2. Non-cyclic refrigeration (open cycle) Is
accomplished by ice or dry ice (frozen Carbon
Dioxide) used to absorb the heat from a substance
to be cooled. These methods are used for small scale
refrigeration such in laboratories and workshops,
portable coolers, fish preservation (in a market), etc.
No electricity is used in the process of cooling.
Refrigeration used in airplane air conditioning is also
non-cyclic.
II. Methods of Refrigeration
1. Vapor compression refrigeration (most
common)
2. Ice refrigeration
3. Dry ice refrigeration
4. Evaporative refrigeration
5. Gas throttling refrigeration
6. Steam jet refrigeration
7. Liquid gas refrigeration
8. Air expansion refrigeration
9. Vapor absorption refrigeration
10. Adsorption refrigeration
11. Thermoelectric cooling
III. Vapor-compression refrigeration
The vapor-compression uses a circulating liquid
refrigerant as the medium which absorbs and
removes heat from the space to be cooled and
subsequently rejects that heat elsewhere.
A. Schematic Design
B. Pressure-Enthalpy Diagram (P-h Diagram)
The diagram is a way of describing the liquid and gas
phase of the substance. Pressure is indicated on the
y-axis and enthalpy is indicated on the x-axis.
• Saturation curve defines the boundery of
pure liquid and pure gas/vapor.
• Liquid region – the substance is pure liquid.
Vapor region – the substance is pure vapor.
The saturated liquid line and saturated line
meets at the critical point.
• Mixture region (underneath the curve) is a
mixture of liquid and vapor.
C. Main components vapor compression system
1. Evaporator is a heat exchanger which allows
transfer of heat from the substance/body being
cooled. The main purpose of an evaporator is to
absorb the heat coming from the air, water or some
other substance through the use of refrigerant.
2. Compressor is the heart of the vapor compression
system. The compressor raises the pressure of the
refrigerant vapor at the desired temperature to
reject the heat.
3. Condenser is a heat exchanger which rejects heat
to atmosphere from substance being cooled,
compressor and other components. It receives
superheated refrigerant and liquefying it.
4. Expansion valve is used mainly to reduce the Analogue Multi-tester - Use by Electrician to measure
pressure of liquid refrigerant by allowing refrigerant Current, Voltage and Resistance
to expand coming from the condenser. It also Digital Multi Meter - Use by Electrician to measure
regulates the amount of refrigerant going inside the Current, Voltage and Resistance
evaporator.
Digital Clamp Tester- A clamp meter (clamp-on
ammeter) is a type of ammeter which measures
COMMON TOOLS & EQUIPMENTS
electrical current without the need to disconnect the
(Refrigeration Tools and Equipment)
wiring through which the current is flowing.
Phillips / Flat Screwdrivers - Use for driving and
Tool Holster - Use to organized hand tools, it is best to
tightening a screw in fixing electrical appliances and
use when working above 5 feet high
insulators
Tool Box - A toolbox, also known as a tool chest, varies
Stubby Screw Driver - Perfect to use in close confined
with the craft of the owner. The purpose of the toolbox
spaces it is less than 4 ½” long.
is to organize, carry, and protect the owner's tools used
Insulated Screw Driver set - Use for driving and for trade.
fastening live electrical parts
Wire Gauge- Use to Measure the diameter of conductor
Steel Tape (push/pull roll) - Bending and straightening
Metal Hacksaw - A hand tool with a blade that is put
are possible, when straightening this is used as a
under tension use to cut metal sheets and pipes. There
straight measure.
are 18,24, & 32 Teeth per Inches.
Spirit Leveling Tool - A spirit level is an instrument
Hole Saw - Use to cut work piece in circular form
consisting of a telescope and a tube level like that used
by carpenters, rigidly connected. When the bubble in Puller - Anything that pulls, use especially when
the tube level is in the middle, the telescope's optical replacing a bearing of an electric motors.
axis (collimation axis) will point exactly in the direction
Machinist Vise - This vise is designed to be fixed on a
of the local horizontal.
working table and use to hold works for hand finishing
Long Nose Plier - Use for wiring inside the switchboard or installing.
and other similar boxes or Fixing wires to terminal of
Swivel Table Vise- Swivel base turns 360 degrees,
electrical appliances.
adjustable jaws, use to hold works in different side.
Combination Plier - Use for cutting, splicing electrical
Scaffoldings - A temporary modular system of metal
wires and conductor and sometimes reaming the edge
tubes forming a framework used to support people and
of conduits.
material in the construction or repair of buildings and
Side Cutter Plier - Use for cutting excess parts of wires other large structures. The framework may also be
made of bamboo or wood.
End Cutting Pliers - Ideal for cutting solid wires 8.0 sq.
mm and above Oil Can - A container with a long spout, for containing
oil and delivering it in drops or small quantities for
Wire Stripper (Manual) - A wire stripper is a small,
lubricating machineries and tools
hand-held device used to strip the insulation from
electric wires. Hexagonal Key (Allen Wrench)- A hex key, also known
as an Allen, Alum, hex-head, or zeta key or wrench, is a
Wire Stripper/crimping tool - A tool use for squeezing
tool used to drive screws and bolts that have a
wires together
hexagonal socket in the head.
Ball Peen Hammer - Ball peen hammer of the proper
Combination Wrench - A Combination wrench or
size is designed for striking Chisels and punches. They
spanner is a tool used to provide a mechanical
also may be used for riveting, shaping and straightening
advantage in applying torque to turn bolts, nuts or
unhardened metals.
other hard-to-turn items.
Claw Hammer - Can be used to mount electrical boxes
Adjustable Wrench - Adjustable wrench is a tool which
and drive nails. Can also be used to determine height of
can be used to loosen or tighten a nut or bolt. It has a
receptacle box since most hammers are 12” long from
"jaw" (the part into which the nut or bolt goes) which is
head to handle.
of adjustable size, which allows for different size nuts
Rubber Face Hammer - They are typically used to form and bolts to be handled by the same spanner.
sheet metal, since they don't leave marks, as well as for
forcing tight-fitting parts together.