INTRODUCTION

TO INDUSTRIAL REFRIGERATION AND AIR-
ARTS 2  CONDITIONING
LESSON 1- INTRODUCTION
TO COOLING
TECHNOLOGIES-
REFRIGERATION

Learning outcomes: 
•At the end of the lesson, the
learners must have:
a. Identify  what is refrigeration
b. Acquired the cooling
technologies refrigeration 
c. Learned the basic elements of
a refrigeration system 
Refrigeration may be defined as the
process of reducing and maintaining a
temperature of a space or material
below that of the surroundings. This is
accomplished by removing heat from
body being refrigerated and transferred
it to another body whose temperature is
higher than that of the refrigerated body
or space. It is evident that refrigerating
and heating are actually opposite ends
of the same process. Often, it is the
desired result that distinguishes one
from the other.
Refrigeration is basic to the
heating, ventilation and air conditioning
industry. One of the most important
applications of refrigeration has been the
preservation of perishable food products,
food processing, packaging, storing
and transportation by storing them at low
temperatures. Refrigeration systems are also
used extensively for providing thermal
comfort to human beings by means of air
conditioning. Refrigeration essentially means
continued abstraction of heat from a
substance (perishable foods, drinks and
medicines etc.) at low temperature level and
then transfers this heat to another system at
high potential of temperature​.
The basic elements of a refrigeration system are as follows:
1.Compressor The refrigerant begins as a cool vapor
and heads to the first component:
the compressor. The compressor is
widely considered the engine of the
refrigeration cycle; it consumes the
most power out of the HVAC system's
components and forces the
refrigerant through the system. In the
process of being compressed the
cool, gaseous refrigerant is turned to
a very hot and high-pressure vapor.
 2. Condenser
After compression, the refrigerant moves to the next component m
the refrigeration cycle: the condenser.
The condenser's job is to cool the refrigerant so
that it turns from a gas into a liquid, or
condenses. This happens when warm outdoor
air is blown across the condenser coil that is
filled with hot, gaseous refrigerant. This allows
heat to transfer from the refrigerant to the
cooler outdoor air, where the excess heat is
rejected to the atmosphere. The condenser coils
wind through the condenser to maximize the
surface area of the piping, and effectively, the
heat transfers to the air. The refrigerant turns
from a vapor into a hot liquid due to the high
pressure and reduction in temperature.
3. Expansion Device
The refrigerant is now approaching the
expansion device as a hot, highpressure
liquid. The expansion device is responsible
for quickly driving the pressure of the
refrigerant down so it can boil (evaporate)
more easily in the evaporator - and that's it!
The expansion device has one sole purpose:
to reduce refrigerant pressure. Because the
pressure drops so rapidly at the expansion
device, the refrigerant turns into a
combination of a cold liquid and vapor.
 7 TYPES OF EXPANSION DEVICE
Thermal expansion valves (TEVs) Manual valves. Capillary tubes. Automatic valves

Electronic expansion valves. High-pressure float valves.

Low-pressure float valves
4. Evaporator Now that the refrigerant is a cold mix of liquid and
gas (vapor), it begins to move through the
evaporator. The evaporator is responsible for cooling
the air going to the space by boiling (evaporating)
the refrigerant flowing through it. This happens
when warm air is blown across the evaporator as
cold refrigerant moves through the evaporator coil.
Heat transfers from the air to the refrigerant, which
cools the air directly before it is vented to the space.
Like the condenser coil, the evaporator coil also
winds through the evaporator to maximize heat
transfer from the refrigerant to the air. The low-
pressure liquid refrigerant is easily boiled by the
warm air blown across the evaporator and heads
back to the compressor as a cool gas/vapor.
Hot Gas Bypass Hot gas bypass (also called discharge bypass) is a
feature in a refrigeration system uses to satisfy the
(HGBP) and the mechanical needs of the system during low load
conditions. Low load conditions can lead

Pressure Enthalpy to frosting or freezing the evaporator, refrigerant

flood back to the compressor, system
shutdown, oil return problems, and several other
Diagram undesirable conditions.​
The hot gas bypass utilizes a line from the
discharge of the compressor to deliver
high temperature, high pressure refrigerant either
to the evaporator distributor (preferred) or
the suction line to the compressor (which may
overheat the compressor).​
The components usually are a solenoid valve and a
pressure/flow control. Larger systems will likely
only have an automatic valve, but no solenoid
valve. Below, is a system sketch of a
basic discharge bypass line on a simple air-cooled
system.​
​
LESSON 2 INTRODUCTION
TO COOLING
TECHNOLOGIES-
AIRCONDITIONING
Learning outcomes: 
•At the end of the lesson, the
learners must have:
a. Identify  what is air
conditioning 
b. Acquired the cooling
technologies-air conditioning 
Air conditioner
An air conditioner is a system that is used to
cool down a space by removing heat from
the space and moving it to some outside
area. The cool air can then be moved
throughout a building through ventilation.
Air conditioners require some input of work
to operate, otherwise entropy would
decrease naturally which is forbidden by the
Second law of thermodynamics. Air
conditioners act similarly to a heat pump,
but instead follow a cooling cycle. This
cooling cycle can be seen in a figure shown
below.
To cool, a substance known as a refrigerant is processed in
the following steps:
• A cold liquid refrigerant absorbs heat from the hotter
room in the evaporator, cooling the room down.
• The refrigerant then changes phase to a gas and is put
through a compressor to increase its temperature.
• Refrigerant then passes through the condenser coils,
transferring heat from the refrigerant to the outside air.
• Refrigerant expands in order to decrease its pressure and
cool down to below the room's temperature to repeat the
cycle again.
The air conditioner is a key component of the HVAC system, which focuses on
home temperature control in order to maximize comfort and livability in a
space.

Air conditioners are called "split-systems" because there is an outdoor unit

(the condenser) and an indoor unit (the evaporator). These two systems work
together to accomplish the task of cooling an interior space while also
dehumidifying it. This dehumidification happens as warm air from inside
passes over the cold evaporator, where the warm air condenses and loses
moisture, just like warm air does on a cold glass of lemonade.

The split-system describes an air conditioner with separate indoor and outdoor
components. There is also another type of air conditioner which combines these
components into one outdoor system, known as a "packaged" system.
LESSON 3 - REFRIGERATION AND
AIRCONDITIONING TOOLS AND
EQUIPMENT

Learning outcomes: 
•At the end of the lesson,
the learners must have:
a. Identify the tools and
equipment used in
refrigeration and  air
conditioning 
Refrigeration tools are used in performing preventive maintenance and
repair on air conditioners, refrigerators, freezers, and automotive air
conditioner. They are as follows:

Tube Cutter - is a refrigeration tool use

to cut copper tubing from sizes 1/8" to
1/2" outside diameter. A larger tube
cutter is also available for large tube
diameters. Tubes are mark first before
cutting. Slight pressure is applied to
the copper tube during cutting. The
burr inside the tube is cleaned with
blade reamer.
Flaring Tool - is a refrigeration tool use to spread
the copper end outward until a flare is formed.
File and ream the copper tube before flaring. The
copper tube is inserted into the flaring block with
30% of its diameter protruding. Turn the flaring
yoke slowly until the flare is completed. Remove
copper tube and inspect for defects.
Swagging Tool - is a refrigeration tool use to
expand the inside diameter of a copper tube so
that the resulting diameter is the same as the
outside diameter. It is used to join two copper
tubes of the same diameter. Clamp the copper tube
by the flaring block so that an 'equal to the outside
diameter' of the copper tube length is to be
swagged.
Brazing Torch - is a refrigeration tool use in soldering
the joints of two copper tubes together. 800 degrees
Fahrenheit is required to solder copper tubing. Map
gas is generally used in this application, although
oxygen-acetylene is also popular except they are bulky
and heavy. It can reach a temperature of 3600 degrees
Fahrenheit. When brazing copper tube joints, do it in a
well-ventilated area. Prolong inhalation can cause
cancer.
Copper Tube Bender - is a copper tube bending
refrigeration tool. It has a three-size molded half-
round wheels. The most common sizes are from
1/4 of an inch diameter, to 5/16, then 3/8. Copper
tubes are bent beautifully using this professional
bending tool.
Adjustable wrench - is a wrench with an
adjustable jaw. A six-inch adjustable
wrench is very useful in the field of
refrigeration repair. It can accommodate
nuts and bolts' sizes from 1/8 of an inch to
1 inch. It can fit into the tool box easily.

Flat Screw Driver- is a screw driver with

a flat driving end. An 8-inch screw driver
with a blade width of 1/4" is the most
useful size. It is always a good idea to
have a 1/8" blade and a 3/16" blade
around with you.
Philip Screw Driver - is a screw driver
with a cross driving end. It is a good idea
to have three sizes of this type also. Buy
only good quality Philip screw driver
because the teeth easily become blunt
very slippery.

Allen Wrench - is an angle hexagonal driving

wrench. They are made of hardened steel.
You will need Allen key when removing the
squirrel caged fan of a window type air
conditioner. The circular fan of an indoor
unit is fastened with an Allen screw.
Long Nose Plier - is a plier with a long-pointed
nose. A 7-inch-long nose plier is very useful and
is a good addition to your tool box. You will find
the many uses of a long nose plier; from hard
to-reach areas like removing a clip from a fan
or holding the copper tube when brazing alone. 

Slip Joint Plier - is a mechanical plier with a

slip joint in order to adjust the size. Either
for fastening a 1/2" pipe to loosening a 1"
water pipe, it is a very handy tool to have. I
have with me a 10" slip joint plier all the
time.
Electrical Plier - Insulated plier use by
electrician. An 8-inch electrical plier is a
must have in your tool box. There is a
time when it is necessary to remove a
live fuse from a fuse box. Or arranging
the stranded wires.

Pipe Wrench - is a wrench for fastening

tubes and pipes. A 12 in pipe wrench must
be in your tool box as well. Sometimes we
have to remove a rounded hex nut.
Socket Wrench set - wrench with driving socket.
We have the 1/2" drive and the 3/8" drive and the
1/4" drive. I carry all of them when I am on the
field. You will need a socket wrench to remove a
remote hex nut or bolt where you have to add
extension just to remove it. The set come with a
ratchet which is also a very handy tool.

Nut Drivers - Hand held driver to drive or

remove hex nuts or bolts. Mostly applicable to
deep down places where our hand is not able to
reach. Straight hand grip type and the T-type
drivers are available for you to choose.
Box Wrench - Hand held box type wrenches.
They came in from 1/4 of an inch to 1-1/4-inch
size. Usually they are in combination as far as
the size is concern. A practical tool for
assembling and disassembling home air
conditioner and automotive air conditioner
compressors.

Open Wrench - Open-end hand-held wrench.

Their sizes are from 1/8 of an inch to 1-1/4 of an
inch. It is most useful when you are removing a
machine bolt where access is only 50 to 75
percent, or the area is restricted that the
wrench can make only one-half turn.
Flat File - flat hardened steel with cutting
ridges. Used for filing a newly cut copper tube
ends to square it. Or to remove burrs from
steel brackets. File surface joints so that they
can fit squarely.

Round File - round long hardened steel with

cutting ridges. Round file is very useful in
enlarging a hole by filing. Cleaning a rusty steel
tube, removing a clogged from a drain hole.
Enlarging a flat washer hole to fit the larger bolt.
Or to shape a certain part through filing. Making
prototype spare parts for hard-to-find spare.
Half Round Files - Half round shaped long
hardened steel with cutting ridges. When it is
necessary to make a hole larger where the
application of a round file is not practical. The
half round side can finish a curve surface, and
the flat side for the flat surface.

Carpenter's Saw - a hand tool with tooth blade

used to cut wood. Fabricating wooden frame for
a window type air conditioner, cutting wooden
sticks to be used to elevate an air conditioner
unit. Fabricating elevated stand for a split type
stand-alone indoor unit.
Tape measure - steel tape measuring device. Put
one in your pocket whenever you are going out
into the field. Either you are going to make
measurement for the length of the copper tubing
you will need for a certain project, or measuring
the volume of a room.

Hack Saw - a hand tool with tooth blade used to cut

iron pipes or iron bars, maybe you need to shorten
the length of a certain PVC pipe, or fabricating a
bracket for a new air conditioner. Making a new
home air conditioner installation. Cutting the
window frame so that the new air conditioner will
fit.
Electric Drill Gun - is also a good refrigeration
tool a refrigeration mechanic should have. We
measure the size of a drill gun by the size of the
chuck. I have with me a 1/2-inch chuck, and it is
all I need in doing different things, like installing
a new compressor and I need to make new holes
for the anchor bolts.

Bench Vise - a refrigeration tool with two jaws

for holding works. Most of the time we need a
vise to hold the copper tube so that we can braze
the joints correctly. Or we must clamp the
machine bolt so that we can remove the hex nut.
Or simply clamp a piece of steel bar so that we
can cut it into the size we need.
Yoke Vise - a pipe vise. It is good to have a yoke
vise in your working bench. Yoke vise is a common
refrigeration tool a mechanic should have. Either
you are lengthening your water pipes or removing
electrical conduit pipes, a yoke vise clamps the
tubing without deforming them.

Gauge Manifold-refrigeration tool pressure

gauges. Whenever you are reprocessing a
refrigerator, or replacing a new compressor for a
freezer, or charging refrigerant to your
automotive air conditioner, you need a gauge
manifold to tell you if you are doing it right.
PREPARED BY:
GLEAH ELOISA TALDE 
WELLA ALDEA
RHYNZ JOY MALAYAS
MARVIN ESMAYA
ROY SENTINO
JOHN LLOYD NONAILLADA
THANK YOU!!!