HVACR Series Study Guide PDF

Heating, Ventilation, Air Conditioning, & Refrigeration Study Guide Assessments: 3401 HVACR Technician 3402 Process Piping Technician 3403 Refrigeration Technician 3404 Sheet Metal Technician Aligned to PAHRA Technical Program Requirements, Oklahoma Construction Industries Board,...

Heating, Ventilation, Air Conditioning, & Refrigeration Study Guide Assessments: 3401 HVACR Technician 3402 Process Piping Technician 3403 Refrigeration Technician 3404 Sheet Metal Technician Aligned to PAHRA Technical Program Requirements, Oklahoma Construction Industries Board, & NCCER National Standards Endorsed by the Air Conditioning, Heating, and Refrigeration Institute  Overview This study guide is designed to help students prepare for the HVACR assessments which include the following: HVACR Technician, Process Piping Technician, Refrigeration Technician, and Sheet Metal Technician. It not only includes information about each assessment in the series, but also the skill standards upon which the assessments are based, resources that can be used to prepare for the assessments, and test taking strategies. Each of the four sections in this guide provides useful information for students preparing for the HVACR assessments and the industry-level certifications through the Partnership for Air Conditioning, Heating, Refrigeration Accreditation (PAHRA) for 3401 HVAC Technician, Oklahoma Construction Industries Board (OCIB) (3402-3404) and the National Center for Construction Education and Research (NCCER) HVAC modules. _CareerTech and Competency-Based Education: A Winning Combination _HVACR assessments ▶ Assessment Information ▶ Standards and Test Content ▶ Sample Questions ▶ Textbook/Curriculum Crosswalk ▶ Additional Resources ▶ Abbreviations, Symbols, and Acronyms Strategies for Test Taking Success Notes The HVACR Technician (3401) was developed and aligned to the PAHRA Technical Program Requirements and to align to the ICE exam for Residential Air Conditioning and Heating. PAHRA is a third party organization that is a partnership between HVACR educators and the HVACR industry that will award accreditation to programs that have met and/or exceeded industry validated standards. The Process Piping Technician (3402), Refrigeration Technician (3403), and Sheet Metal Technician (3404) were developed and aligned with the OCIB industry-recognized licensure assessments. The OCIB regulates the licensing of plumbers, electricians and mechanical trades in the state of Oklahoma. All four assessments and associated standards are endorsed by the Air Conditioning, Heating, and Refrigeration Institute (AHRI). AHRI is a trade association representing manufacturers of HVACR and water heating equipment within the global industry. AHRI is viewed as a resource for industry shipment data, education, and workforce information and research. www.ahrinet.org All four assessments in the series have also been crosswalked to the NCCER HVAC modules for certification. NCCER develops standardized construction and maintenance curricula and assessments with portable credentials. The HVACR assessments measure a student’s ability to apply knowledge and skills in HVACR related careers. The HVACR assessments are designed to prepare a student for the industry-recognized credentialing assessments mentioned above. 2 Disclaimer The Oklahoma Department of Career and Technology Education cannot vouch for the accuracy of the information contained in any linked site. Our intent is to simply provide a list of sites that we feel may be useful to you. Some of the links presented here are commercial sites. We do not endorse these sites or their products, and we do not request or accept any fee for inclusion on this list. The Department makes no representations or warranties, express or implied, with respect to the document, or any part thereof, including any warrantees of title, noninfringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose. Equal Opportunity/Non Discrimination Statement The Oklahoma Department of Career and Technology Education does not discriminate on the basis of race, color, national origin, sex/gender, age, disability, or veteran status. Inquiries concerning application of this policy may be referred to the ODCTE Compliance Coordinator, 1500 W. 7th Ave. Stillwater, OK 74074-4364, or call 1-800 522-5810 or (405) 377-2000. 3  CareerTech and Competency-Based Education: A Winning Combination Competency-based education uses learning outcomes that emphasize both the application and creation of knowledge and the mastery of skills critical for success. In a competency-based education system, students advance upon mastery of competencies, which are measureable, transferable outcomes that empower students. Career and technology education uses industry professionals and certification standards to identify the knowledge and skills needed to master an occupation. This input provides the foundation for development of curriculum, assessments and other instructional materials needed to prepare students for wealth-generating occupations and produce comprehensively trained, highly skilled employees demanded by the work force. Tools for Success CareerTech education relies on three basic instructional components to deliver competency-based instruction: skills standards, curriculum materials, and competency assessments. Skills standards provide the foundation for competency-based instruction and outline the knowledge and skills that must be mastered in order to perform related jobs within an industry. Skills standards are aligned with national skills standards and/or industry certification requirements; therefore, a student trained to the skills standards is equally employable in local, state and national job markets. Curriculum materials and textbooks contain information and activities that teach students the knowledge and skills outlined in the skills standards. In addition to complementing classroom instruction, curriculum resources include supplemental activities that enhance learning by providing opportunities to apply knowledge and demonstrate skills. Certification Assessments test the student over material outlined in the skills standards and taught using the curriculum materials and textbooks. When used with classroom performance evaluations, certification assessments provide a means of measuring occupational readiness. Each of these components satisfies a unique purpose in competency-based education and reinforces the knowledge and skills students need to gain employment and succeed on the job. Measuring Success Evaluation is an important component of competency-based education. Pre-training assessments measure the student’s existing knowledge prior to receiving instruction and ensure the student’s training builds upon this knowledge base. Formative assessments administered throughout the training process provide a means of continuously monitoring the student’s progress towards mastery. Certification assessments provide a means of evaluating the student’s mastery of knowledge and skills. Coaching reports communicate assessment scores to students and provide a breakdown of assessment results by standard area. The coaching report also shows how well the student has mastered skills needed to perform major job functions and identifies areas of job responsibility that may require additional instruction and/or training. 4  HVACR Assessments Information What are the HVACR assessments? The HVACR assessments are end-of-program assessments for students in HVACR-related programs. The assessments provide an indication of student mastery of knowledge and skills necessary for success in careers in the HVACR industry. How were the assessments developed? The assessments were developed by the CareerTech Testing Center in alignment with PAHRA Technical Program Requirements, OCIB industry-recognized credentialing exams, and NCCER National Craft Assessment and Certification Program Specifications. A committee of industry representatives and educators validated the areas covered on the assessments. The content on each assessment was developed and reviewed by a committee of subject matter experts from the respective crafts. The committee assigned frequency and criticality ratings to each skill, which determines the significance of each task for test development: Frequency: represents how often the task is performed on the job. Frequency rating scales  vary for different occupations. The rating scale used in this publication is presented below: 1 = less than once a week 2 = at least once a week 3 = once or more a day Criticality: denotes the level of consequence associated with performing a task incorrectly. The rating scale used in this publication is presented below: 1 = slight 2 = moderate 3 = extreme What do the assessments cover? The assessments are aligned to the various credentialing requirements. The areas of emphasis are as follows for each assessment in the HVACR Series: 3401 – HVACR Technician (100 questions) HVACR Industry 2% Heating Systems 7% Thermodynamics & Heat Transfer Principles 6% Commercial Refrigeration 4% Safety Skills 4% Air Handling 6% Tools and Equipment 8% System Installation and Start-Up 4% Piping Principles and Practices 5% System Servicing and Troubleshooting 9% Electricity 7% Indoor Air Quality 1% Controls 6% Preventative Maintenance 2% Solid Sate Electronics 1% Refrigerant Recovery 4% Load Calculations 3% Refrigerant Retrofits 0% Refrigerant System Components 9% Refrigerants and Lubricants 2% Air-Conditioning Systems 1% Comply with Industry Regulations 5% Heat Pump Systems 3% Professional Service 1% 5 3402 – Process Piping Technician (55 questions) Safety and Environmental Skills 14% Piping Principles and Practices 29% DC Circuits 7% Natural Gas Piping 50% 3403 – Refrigeration Technician (60 questions) Safety and Environmental Skills 7% Refrigeration System Controls 3% DC Circuits 15% Piping Principles and Practices 13% AC Circuits 10% Refrigeration Cycle 12% Electric Motors 18% Refrigeration Systems 22% 3404 – Sheet Metal Technician (55 questions) Safety and Environmental Skills 16% Vents and Chimneys 13% Air Distribution Systems 71% What are the benefits of using these assessments? Students receive a certificate for each assessment that he/she passes. This certificate may be included in his/ her portfolio and used to communicate the student’s mastery of the subject matter to potential employers. When should the assessments be taken? The CareerTech Testing Center recommends that students take an assessment as soon as possible after receiving all standards-related instruction, rather than waiting until the end of the school year. Are the assessments timed? No. Although students may take as long as they need, most finish an assessment within one hour. What resources can students use on these assessments? Students are allowed to use calculators and scratch paper on CTTC assessments; however, these items must be provided by the testing proctor and returned to the proctor before the student’s exam is submitted for scoring. Calculator apps on cell phones and other devices may not be used on these assessments. Students taking these assessments may also use publisher-bound copies of the International Mechanical Code, the International Fuel Gas Code, and the International Plumbing code as long as they are free of markings and do not hold loose papers. Students may also access the following charts during testing: Pressure Temperature Chart & Formulas http://www.okcareertech.org/educators/assessments-and-testing/testing/ resources/PressureTemperatureFormulachart_05742015.pdf Static Pressure Chart http://www.okcareertech.org/educators/assessments-and-testing/testing/ resources/StaticPressureChart_05072015.pdf 6 What accommodations can be made for students with Individual- ized Education Plans (IEPs)? Accommodations are allowed for students with an Individualized Education Plan. Examples of allowable accommodations include: Extended time — This assessment is not timed, therefore students may take as much time as needed to finish. The assessment must be completed in one testing session. Readers — A reader may be used to read the assessment to a student who has been identified as needing this accommodation. Enlarged text — Students needing this accommodation can activate this feature by clicking the icon in the upper right corner of the screen. What can students expect on Test Day? All CTTC assessments are web-based and delivered exclusively by a proctor in the school’s assessment center. The proctor cannot be an instructor or anyone who was involved with the student during instruction. Assessments are delivered in a question-by-question format. When a question is presented, the student can select a response or leave the question unanswered and advance to the next question. Student may also flag questions to revisit before the test is scored. All questions must be answered before the test can be submitted for scoring. After the assessment is scored, the student will receive a score report that not only shows the student’s score on the assessment, but also how the student performed in each standard area. Can students retake the test? Students may retake the test unless their school or state testing policies prohibit retesting. Students who can retest must wait at least three days between test attempts. 7  Standards and Test Content HVACR Industry 1. Introduction to Refrigeration (1/1) E xplain the history of air conditioning and refrigeration Define air conditioning and refrigeration E xplain the differences between air conditioning and refrigeration D etermine career opportunities in the HVACR industry Describe the role of Trade Association 2. Introduction to Air Conditioning (1/1) U  nderstand the historical development of air conditioning D  efine "air conditioning" and relate to human comfort conditions D  iscuss the differences between air conditioning and heating Discuss the various systems of air conditioning ‣ mechanical compression cycle ‣ evaporative cooling ‣ desiccant dehumidification ‣ absorption cycle Explain why ventilation is often inadequate 3. Introduction to Heating (1/1) Define heating D  iscuss the differences between air conditioning and heating Explain the various heating systems ‣ gas ‣ electric resistance ‣ oil ‣ hydronics ‣ heat pump ‣ solar Thermodynamics and Heat Transfer Principles 1. Matter and Heat Behavior (3/3) Define matter and heat Explain the direction and rate of heat flow Describe the three methods of heat transfer Identify the reference points of temperature ‣ boiling point ‣ critical temperature ‣ freezing point ‣ absolute zero Explain the difference between heat and temperature Explain the difference between latent and sensible heat Explain the change of state of matter Explain heat/cool storage 8  Define specific heat Define sensible heat Define latent heat of fusion Define latent heat of vaporization Define enthalpy Define saturation temperature (dew point temperature) Define water vapor pressure Explain the direction and rate of moisture transfer C  alculate total heat (in BTU's) a pound of any substance contains 2. Fluids and Pressures (3/3) E xplain the relationship of pressures and fluids at saturation temperatures Identify the relationship between temperature and pressure using the P/T Chart Define pressure Explain atmospheric pressure Explain compound gauges Explain bourdon tubes Explain barometric pressure Explain absolute pressure Explain gauge pressure Explain inches of mercury absolute Explain micron 3. Refrigeration Cycle/Diagrams (3/3) Identify the four major components of the vapor compression refrigeration system Describe the state and conditions of the refrigerant during a cycle Explain the effects of: ‣ superheating the suction gases ‣ increasing the condensing pressure ‣ subcooling the liquid Explain the importance of superheat and subcooling Define refrigeration Explain the functions of the four major components of a refrigeration system ‣ compressor ‣ metering device ‣ condenser ‣ evaporator List the components which separate the high side from the low side of the system Describe the Temperature/Enthalpy (T-H) Diagram Calculate problems using Pressure/Enthalpy (P-H) Diagram L abel the line which represents each of the four basic components on a Pressure/Enthalpy (P-H) Diagram 9  4. Measurement Systems (2/2) Explain units of heat, power, velocity, mass and length Identify U.S. and S.I. units Convert from U.S. to metric units ‣ length ‣ pressure ‣ area ‣ temperature ‣ volume ‣ energy ‣ mass ‣ power ‣ force ‣ specific heat ‣ velocity ‣ volume flow rate ‣ density ‣ capacity Convert pounds to ounces Convert cooling capacity from tons of refrigeration to kW and BTUH to kW Safety Skills 1. Personal Safety and Work Practices (1/3) Explain clothing and safety equipment Review OSHA standards Explain the effects of substance abuse on safety Review safe driving practices Identify, handle, use, and dispose of hardware material Wear appropriate clothing Use safety equipment (e.g., footwear, hearing protection, hard hat, goggles, gloves) Demonstrate good housekeeping practices in the lab Demonstrate proper ladder safety ‣ wooden ‣ fiberglass ‣ aluminum ‣ scaffolding Demonstrate proper lifting procedures Pass safe driving course Use appropriate fire extinguishers Conduct routine safety inspections 2. Handling of Pressurized Fluids (2/3) List safety requirements Explain application of pressure relief devices Explain proper storage and handling of refrigerants Explain proper storage and handling of oxygen, nitrogen and acetylene bottles Explain the effects of mixing oxygen and oil Follow procedures specified on the Safety Data Sheet (SDS) Store and dispose of hazardous material according to EPA specifications Explain ASHRAE Refrigerant Safety Classification of Refrigerants for Toxicity and Flammability Properly fill and label a refrigerant cylinder Determine if a refrigerant cylinder needs retesting 10  3. Handling Hazardous Substances (2/3) Explain use of Safety Data Sheets (SDS) Define difference between hazardous materials, substances and wastes Explain use of hazardous material manifest Locate SDS and identify particular effect Demonstrate use of proper clothing and equipment Demonstrate basic first aid procedure 4. Electrical Safety (2/3) Explain importance of GFCI Explain the use of power tools and accessories Discuss work habits Explain environmental safety practices Explain proper procedures when working with hands on live equipment Fault a ground fault interrupter Demonstrate the use of lockout/tagout equipment Tools and Equipment 1. Hand Tools and Accessories (3/3) Identify basic tools ‣ adjustable wrenches ‣ pulley & gear pullers ‣ allen (hex) wrenches ‣ punches ‣ crimpers ‣ scratch awl ‣ diagonal cutting pliers (dikes) ‣ sheet metal snips ‣ flare nut wrenches ‣ socket wrenches ‣ general-use pliers ‣ torque wrenches ‣ hack saw ‣ various hammers ‣ hand saw ‣ various screwdrivers ‣ lineman pliers (sidecutters) ‣ wire strippers ‣ nutdrivers ‣ tape measure ‣ open & box end wrenches ‣ solder gun ‣ pipe wrenches ‣ Schrader valve Identify power tools ‣ general-purpose drills ‣ reciprocating saws ‣ hammer drill ‣ screwgun ‣ power screwdriver Identify fasteners ‣ bolts ‣ screws ‣ conduit, pipe & cable clamps ‣ various electrical connectors ‣ masonry anchors ‣ pop rivets ‣ nails 11  Identify pipe and tubing tools ‣ benders ‣ flaring tools ‣ pipe cutters, reamers and threaders ‣ pipe vises ‣ swaging tools ‣ tubing cutters and reamers Describe lubrication methods using different types of circuits ‣ grease guns ‣ oilers ‣ spray Show the proper use of a pipe cutter Show the proper use of a threader Demonstrate how to make a flared tubing join 2. Electrical Testing Devices/Meters (3/3) Define amps, volts, ohms and watts Demonstrate understanding of the basic types of electrical measurement Measure voltage with digital and analog voltmeters Measure AC current with a clamp-on ammeter Measure resistance with an ohmmeter Check winding insulation with megohmmeter Check voltage with a voltage tester Use a continuity tester to determine whether an open circuit or dead short exists Use a capacitance meter to measure capacitance of run and start capacitors Calculate capacitance Wire and measure resistance of different types of circuits ‣ series ‣ unequal ‣ parallel ‣ series – parallel 3. Refrigeration: Servicing and Testing Equipment (3/3) Measure pressures with the refrigeration gauge manifold Evacuate systems with a two-stage vacuum pump Measure vacuums with a thermistor vacuum gauge Measure temperatures with electronic thermometers Measure temperatures with bimetal, thermocouple or glass stem thermometer Charge a system with a charging cylinder Charge a system with an electronic charging scale Check for leaks with electronic leak detector and halide torch Use nitrogen with trace of R-22 for leak detection Compare readings to manufacturers' specifications Determine refrigerant amount and type Charge a system to manufacturers' specification 12  4. Heating: Servicing and Testing Equipment (2/3) Measure chimney draft with a gauge ‣ measure draft over fire ‣ measure draft at the chimney breaching Perform an efficiency test on an oil-gas burner ‣ smoke test ‣ check draft ‣ CO2 test ‣ series – check stack temperature ‣ O2 test Determine effectiveness of an oil pump using ‣ vacuum gauge ‣ pressure gauge Determine relative humidity using a sling psychrometer ‣ fi nd the relative humidity and dew point using psychrometric chart Measure gas pressure with the following equipment: ‣ u-tube manometer ‣ pressure gauge C  alculate proper size of chimney for both 80 and 90+ furnaces Determine what to do with an "orphaned" water heater Check wall thermostat and anticipator ‣ cooling system (fan on-automatic) Check electronic pilot system Check and adjust blower system Check and adjust fan control Check limit and safety controls 5. Air Flow: Measuring and Testing Equipment (2/2) Determine air velocity within a duct via: ‣ pitot tube ‣ electronic velometer ‣ inclined manometer ‣ u-tube manometer Determine air velocity at grilles and diffusers via: ‣ deflecting vane anemometer ‣ pitot tube ‣ velometer ‣ rotating vane anemometer ‣ hot wire anemometer Measure pressure drop with a magnahelic gauge Determine CFM Use manufacturers' airflow data sheets Solve problems using friction loss chart 13 Piping Principles and Practices 1. Piping Material and Fabrication (2/3) Identify types of pipe and tubing used in HVACR industry Identify various types of fittings or valves for specific applications Describe methods of insulating pipe and tubing Identify soldering and brazing alloys used in HVACR Explain applications of soldering and brazing alloys Describe heat sink methods Describe heat exchange techniques D  escribe the applications and installation of vibration eliminators Identify types of torches used for cutting and welding Flare copper tubing Swage copper tubing Bend copper tubing Solder and braze copper tubing Cut and thread steel/iron pipe Braze aluminum tubing Thread pipe used in pipe operations 2. Pipe Sizing and Troubleshooting (2/2) Explain capacities of refrigerant lines Explain effects of refrigerant velocity in lines Explain equivalent lengths of piping for fittings Explain use of traps in vapor risers Explain the effects of pressure drop in the refrigeration system Explain gas piping Calculate total effective length of pipe runs Calculate amount of refrigerant in lines Size piping using manufacturers' installation instructions Calculate pressure drop in liquid line risers Size liquid and vapor lines C  alculate gas piping sizes to multiple units, fed from a single meter 3. Sheetmetal (2/2) Explain use of bending tools Explain use of cutting tools Explain the types of ductwork and fittings Demonstrate use of tin snips left, right and straight Identify the different pressures of ductwork Identify the different types of connections 14 Natural Gas Piping 1. Demonstrate knowledge of/apply principles of natural gas piping systems (3/3) Pipe materials Installation Pipe size Pipe auxiliary accessories System design Code regulations 2. Design and install a natural gas piping system (2/3) 3. Identify/select specified natural gas piping, valves, connectors, and accessories (3/3) 4. Read and interpret piping layouts (3/3) Schematics Diagrams Trains Charts Blueprints Engineering specifications 5. Perform metallic tubing operations (3/3) Cleaning Soldering Pipe fitting Brazing Set up soldering/brazing system Bending Cutting Swaging Flaring Reaming Mechanical joints 6. Perform metallic pipe operations (3/3) Cutting Mechanical joints Reaming Welding Threading Fitting 7. Perform non-metallic pipe operations (3/3) Cutting Mechanical joints Fitting Fusion Cleaning Solvent cementing Reaming Bending Threading 8. Perform welding (2/2) Set up welding system TIG welder Arc welder Oxyfuel welder MIG welder Fusion equipment 9. Test for leaks (3/3) Electricity 1. Basic Electricity (3/3) Define watts, ohms, volts, and amps Define and compare single- and three-phase voltage and current Identify types of electrical loads (i.e., capacitive, inductive and resistive) Analyze applications of magnetism in electricity Apply magnetic principles to electrical theory 15  Compare conducting and insulating materials Identify principles of solid-state switching devices Demonstrate proper use of ammeter, ohmmeter, voltmeter and wattmeter Use Ohms Law to solve circuit problems and calculate circuit loads Use appropriate meters to check basic electrical components Determine the electrical characteristics of both series and parallel circuits Demonstrate algebra/math skills Determine the equivalent resistance in a parallel and series circuit Determine the equivalent capacitance in a parallel and series circuit Construct and analyze: ‣ series circuit ‣ parallel circuit ‣ series-parallel circuit 2. Electrical Generation and Distribution (2/2) Explain basic generator principle Explain how electricity is produced and distributed Define Wye (Y) and Delta ( ) distribution systems Draw and identify power transformer types U  se electrical meters appropriately to test and identify voltages in both single- and three-phase systems Size/test fuses/breakers and safely replace them U  se National Electrical Code (NEC) tables to check wire size and conduit size for connected equipment Determine correct wire size and voltage drops for electrical circuits Determine whether existing load centers are adequate to supply desired load addition 3. Electrical Components (3/3) Define magnetic theory Define and explain the use or function of: ‣ aquastats ‣ potentiometers ‣ capacitors ‣ pressure controls ‣ contactor/starters ‣ relays ‣ crankcase heaters ‣ rheostats ‣ current relays ‣ sail Switches ‣ damper actuators ‣ sequencers ‣ defrost timers ‣ solenoids ‣ fan/limit controls ‣ solid state time delays ‣ oil pressure safety ‣ thermostats ‣ overloads ‣ water valves ‣ positive temperature co-efficient (PTC) ‣ zone valves Demonstrate proper use of test equipment for testing the above items 4. Electrical Circuits and Controls (3/3) Interpret detailed instructions for wiring circuits D  raw electrical circuits that conform to standard industry logic and symbols using appropriate loads and controls 16  Wire actual electrical circuits from wiring diagrams Demonstrate use and understanding of basic electrical meters in actual wiring and testing of circuits Identify and draw all electrical symbols used by the HVACR industry in diagrams S ize an electric motor circuit, single and multiple, including overcurrent protection in accordance with National Electrical Code (NEC) Electric Motors 1. Explain electric motor theory (i.e., magnetism, electromotive force, etc.) (3/3) 2. Explain the operation, application, disassembly and reassembly of: (3/3) Capacitor start/induction run motor (CSIR) Permanent split capacitor (PSC) Capacitor start/capacitor run motor (CSCR) Shaded-pole Electronically controlled motor (ECM) Split-phase motor (RSIR) Modulating motor (economizers) Three-phase motor Multi-speed motor Variable-speed motor 3. Describe starting components associated with single-phase and three- phase motors (3/3) 4. Demonstrate knowledge of the operation/replacement of electric motor protection devices (3/3) 5. Explain the significance of power factor (3/3) 6. Determine characteristics and specifications of a motor – type, wattage, power, rpm, size, application (3/3) 7. Demonstrate proper use of testing equipment for motors (3/3) 8. Troubleshoot electric motors and motor circuits (3/3) 9. Determine physical conditions/alignment/replacement of motor bearings, rotors, belts, and pulleys (3/3) 10. Troubleshoot/replace starting components and relays for various types of motors (3/3) 11. Troubleshoot the resistance of windings in single-phase and three-phase motors (3/3) 12. Replace motor controls (3/3) Pressure Electric Temperature Pneumatic 13. Replace air-moving devices including fan blades and blower wheels (3/3) 14. Install/align shafts with motor-driven components (3/3) 15. Draw and explain the starting and run circuit for a single-phase CSIR compressor using a current type starting relay (3/3) 16. Draw and explain the starting and run circuit for a single-phase CSCR compressor using a potential type starting relay (3/3) 17. Draw and explain the circuit for a PSC compressor (3/3) 17 DC Circuits 1. Identify properties of a DC circuit (3/3) 2. Identify DC sources (3/3) 3. Define voltage, current, resistance, power, and energy (3/3) 4. Apply Ohm’s Law (3/3) 5. Measure DC circuits and components using VOA meter (3/3) 6. Troubleshoot circuits – series, parallel, and series-parallel (3/3) 7. Troubleshoot maximum power transfer theory (2/2) 8. Define magnetic properties of circuits and devices (2/2) 9. Describe physical and electrical characteristics of electronic components (3/3) 10. Set up and operate for DC circuits (3/3) VOA meter Specific equipment analyzers 11. Construct and interpret schematics and diagrams (3/3) Pictorial Ladder Line 12. Check anodes (electrolysis) (3/3) Millivolt meter AC Circuits 1. Identify properties of an AC circuit (3/3) 2. Identify AC sources (3/3) 3. Troubleshoot AC circuits (3/3) Capacitive Grounded Inductive Series Completed Parallel Open Complex Short Ampacity 4. Troubleshoot, analyze, and apply principles of transformers to AC circuits (3/3) Step up Step down 5. Troubleshoot circuits – series, parallel resonant, polyphase (2/3) 6. Demonstrate knowledge of basic electrical theory and operation of loads (3/3) 7. Set up and operate for AC circuits (3/3) VOA meters Specific equipment analyzers 8. Construct and interpret schematics and diagrams (3/3) Pictorial Ladder Line 18 Controls 1. Gas Valves (3/3) Identify types of gas valves ‣ low voltage ‣ two-stage ‣ line voltage ‣ modulating ‣ redundant Explain the operation of solenoid valves used to control gas flow Describe function and application of regulators Describe the methods of pilot/burner ignition: ‣ standing pilot thermocouple ‣ direct spark burner ignition ‣ glow coil pilot ignition ‣ hot surface burner ignition ‣ intermittent spark pilot ignition Describe methods of fan control for the three categories of gas furnaces: ‣ low-efficiency - 60-70% efficient ‣ mid-efficiency - 78-80% efficient ‣ high-efficiency - 90%+ efficient Describe the sequence of operation for 78-80% efficient gas furnaces Identify the components used in all types of gas furnaces: ‣ low-efficiency - 60-70% efficient ‣ mid-efficiency - 78-80% efficient ‣ high-efficiency - 90%+ efficient Explain the operation of a redundant gas valve Check gas valve operation Check flame sensing current of flame sensing device Check and adjust inlet and outlet pressure of a gas valve Perform conversion on gas valve from natural gas to liquified petroleum (LP) or reverse Check the operation of an induced draft blower by blocking flue outlet 2. Fuel Control (3/3) Explain the operation of ignition and pilot proving devices Explain operation of an oil delay valve Test and change a thermocouple flame sensor Test spark ignition modules Perform safety lockout procedures for burners Measure resistance of cad cell 3. Residential Control Systems—Heating/Cooling (3/3) Identify residential heating and cooling thermostats Identify controls for heating and cooling Explain heat and cooling anticipators Install and test a fan/limit control to identify set point of control Wire a complete heating system - line and low voltage Wire a humidistat into electrical circuit Wire an electronic air cleaner into an electrical circuit 19  P  rogram a programmable thermostat for heating, cooling and heat pump operation including set- up and set back Set heat anticipator on system thermostat Install residential heating and cooling thermostats 4. Heat Pump Controls (3/3) Explain the operation and function of a reversing valve Identify the main types of defrost controls Identify and explain the operation of each type of defrost control Identify and explain the operation of flow and safety control for geothermal system Describe the purpose and function of outdoor thermostats Describe the sequence and purpose of emergency heat controls Identify and explain the operation of check valves in heat pumps Describe the sequence between first stage and second stage heating thermostat Describe the auxiliary heat controls Select and install appropriate system thermostat Wire the control circuit of a heat pump system Install or replace a heat-sequencing relay Perform tests on reversing valve to determine if mechanical or electrical failure Solid State Electronics 1. Solid State Components (1/1) Explain the function and/or application in HVACR circuits and controls of: ‣ amplifiers ‣ semiconductors ‣ bilateral switches ‣ shielded wiring ‣ capacitors ‣ sensors ‣ diodes ‣ silicon controlled rectifiers (SCR) ‣ direct digital control/system (DDC/DDS) ‣ thermistors ‣ effects of heat and moisture ‣ transducers ‣ photoelectric Cell ‣ transistors ‣ rectifiers ‣ triacs ‣ resistors Explain the role computers are now playing in the HVACR industry Measure resistive value of various sensors Measure operability of various boards Test electronic air cleaners Refrigeration System Controls 1. Demonstrate knowledge of principles of safety and operating control devices (3/3) Pressure Pneumatic Temperature DDC Electric 20  2. Install/service/troubleshoot electro-mechanical control devices (3/3) Relays Sequencers Contactors Thermostats Magnetic starters Pressure switches Timers Solid state ignition modules 3. Install/service/troubleshoot pneumatic control devices (2/3) Thermostats Switches Actuators Relays 4. Troubleshoot DDC (2/3) Load Calculations 1. Refrigeration Loads (1/1) Define "U" value: (Btu/hr ft2 °F) Define "K" value: (Btu/hr ft2 °F) Define "R" value: (hr ft2 °F/Btu) Define "C" value: (Btu/hr ft2 °F) Interpret heat transfer tables ("U," "K," "C," "R") Explain the heat load sources: ‣ conduction ‣ infiltration (sensible and latent) ‣ product ‣ miscellaneous loads (people, motors, equipment, sensible and latent) ‣ radiation Explain the purpose of vapor barriers Interpret tables of specific heat values, latent heat, and heat of respiration Calculate total heating transfer value of any surface (R) - (U) 2. Psychrometrics (1/2) Identify the following on a psychrometric chart: ‣ dry bulb line (DB) ‣ enthalpy (h) ‣ wet bulb line (WB) ‣ apparatus dew point ‣ relative humidity (RH) ‣ dew point (DP) ‣ specific humidity (grains of moisture) or (lbw/lbda) Explain: ‣ specific humidity ‣ wet bulb ‣ apparatus dew point ‣ dew point ‣ contact factor ‣ enthalpy ‣ relative humidity ‣ specific volume ‣ dry bulb Calculate: ‣ refrigeration sensible heat ratio ‣ sensible heat ‣ latent heat ratio ‣ total heat ‣ contact factor ‣ water removal ‣ latent heat ‣ mixed air condition 21  On a psychrometric chart, plot the following: ‣ sensible heating ‣ humidifying ‣ sensible cooling ‣ dehumidifying ‣ heating and humidifying ‣ cooling cycle ‣ heating and dehumidifying ‣ mixed air process ‣ cooling and humidifying ‣ cooling and reheat ‣ cooling and dehumidifying 3. Heating Loads (1/2) Interpret structure design data Interpret building prints - size of rooms, etc Determine total resistance to heat flow ("R"), ("U") Calculate conduction loss: ‣ walls ‣ basement (walls, floor) ‣ roofs ‣ unconditioned space ‣ floors ‣ windows Calculate infiltration: ‣ doors ‣ windows Calculate ventilation load Calculate duct loss Calculate effects of bath and kitchen exhaust Calculate effects of power roof ventilators Calculate total heating load 4. Cooling Loads (1/2) Interpret structure design data Calculate "U" values for building material Calculate Cooling Load Temperature Difference (CLTD) Make corrections for CLTD Calculate conduction loads: ‣ walls ‣ doors ‣ roofs ‣ unconditioned space ‣ windows ‣ floors Calculate lighting load Calculate equipment load Calculate infiltration and ventilation load: ‣ heat load ‣ moisture loads Calculate duct gain Calculate refrigeration sensible heat ratio Calculate storage factor Calculate effects of bath and kitchen exhaust Calculate effects of power roof ventilators Calculate total cooling load: ‣ sensible loads ‣ latent loads 22 Refrigerant System Components 1. Metering Devices (2/3) Define types of metering devices: ‣ capillary tubes ‣ hand expansion valve ‣ thermal expansion valve ‣ restrictor orifices ‣ automatic expansion valve ‣ electronic expansion valve ‣ low side float ‣ solid state expansion valve ‣ high side float Evaluate system performance when using different types of flow control devices Explain how to size expansion valves Explain how to size a thermal expansion valve Explain how to size an automatic expansion valve Adjust and size metering devices when and where appropriate Check and adjust superheat and/or subcooling to manufacturers' specifications Install capillary tube 2. Evaporators (1/1) Identify types of evaporators: ‣ bare-tube ‣ unit coolers ‣ finned – internal and external ‣ chillers ‣ plate Determine the Mean Effective Temperature Difference (METD) Adjust for proper coil air flow Check coil performance Select and size evaporator based on compressor capacities 3. Compressors (2/2) Identify types of compressors: ‣ hermetic ‣ semi-hermetic ‣ open type Identify methods of compression: ‣ centrifugal ‣ scroll ‣ rotary ‣ reciprocating ‣ screw Explain the methods of compression Explain methods of capacity control: ‣ cylinder unloading ‣ hot gas bypass ‣ variable speed compressors ‣ multiple compressors Select the compressor based on cooling load Determine the system balance based on the selected components 23  4. Condensers (3/3) Define the types of condensers: ‣ air-cooled ‣ water-cooled ‣ evaporative-cooled Determine proper air and water flow Describe maintenance of a condenser Describe maintenance of a cooling tower Explain the operation and performance of a condenser Explain the terms "range" and "approach" related to cooling towers Explain purpose of heat reclaim Adjust the air flow for proper temperature difference Adjust water flow for proper gallons per minute (GPM) and temperature difference Size a cooling tower Select and size an air-cooled condenser 5. Accessories (3/3) Identify the proper location of all accessories: ‣ accumulators ‣ mufflers ‣ crankcase heaters ‣ oil separators ‣ crankcase pressure regulating valves ‣ receivers ‣ defrost timers ‣ solenoid valves ‣ driers/filters ‣ suction filters ‣ evaporator pressure regulating valves ‣ unloaders ‣ head pressure controls ‣ vibration eliminators ‣ heat exchangers ‣ check valves ‣ hot gas bypass ‣ water regulating valve ‣ low pressure controls ‣ liquid sight valve-refrigerant and oil ‣ low ambient controls ‣ relief valve Determine appropriate accessories for systems application Explain the operation of the above listed accessories Replace a drier/filter Adjust a crankcase pressure regulating valve 6. Access Valves (3/3) Identify front and back seat valves in the: ‣ operation and use of the suction and discharge service valves that service the compressor ‣ application and operation of the king valve at the outlet of the receiver ‣ application and operation of the queen valve where present, near the receiver ‣ small system high side and low side service ports ‣ front seating and Schrader valves, OEM and field installed Identify Schrader Type OEM and field installed in the: ‣ installation and use of clamp on valves ‣ installation and use of solder (in) or (on) stem valves ‣ use of A/C front seating/Schrader OEM service valves ‣ use of quick disconnects with Schrader-Based Valves 24 Refrigeration Cycle 1. Demonstrate knowledge of the theory of heat (3/3) Latent heat Sub-cooling Sensible heat Heat of compression Specific heat Heat of evaporation Superheat 2. Demonstrate knowledge of characteristics and identifications of refrigerants (3/3) Boiling points Maximum quantities Pressure temperature relations Color coding Dew points Name Hazards Chemical number 3. Read and interpret pressure-temperature curves and charts (3/3) Determine pressures and temperatures of a refrigeration system (3/3) Psychometrics 4. Demonstrate knowledge of principles and operation of the mechanical refrigeration cycle (3/3) Compressors Evaporators Condensers Other components Metering devices 5. Evacuate a refrigeration system (3/3) Measure vacuum Triple evacuate 6. Charge a refrigeration system (3/3) Superheat Manufacturers’ specifications Subcooling 7. Adjust head pressure controls (3/3) Air-Conditioning Systems 1. Unitary Cooling (3/3) D  escribe the sequence of the basic refrigeration cycle and operation of the various types of air- conditioning systems U  se and read various tools and instrumentation needed for checking, testing, and operating air- conditioning systems 2. Service and Problem Analysis (3/3) Explain the causes of electrical problems Explain the causes of mechanical problems Explain the causes of hydronic problems Analyze air conditioning systems and appropriately diagnose: ‣ electrical problems ‣ mechanical problems ‣ hydronic problems 25 Heat Pump Systems 1. Basic Principles and Components (3/3) Review the history of heat pumps Explain the basic theory of the air source heat pump system Explain the basic theory of the water source heat pump system Explain the basic theory of geothermal source heat pump system Identify and explain the function of the electrical and mechanical components of the heat pump systems Explain terms typically used for heat pumps: ‣ seasonal energy efficiency ratio (SEER) ‣ balance points ‣ coefficient of performance (COP) ‣ outdoor design temperature (ODT) ‣ heating seasonal performance factor (HSPF) ‣ optimizer A  nalyze and explain the refrigerant cycle in both cooling and heating — identifying the pressure and state of the refrigerant at any point in the refrigerant circuit Explain the different types of defrost methods Describe the operation of the time clock in a defrost control Identify which three components of a heat pump system are controlled directly during a defrost cycle Describe a heat pump thermostat function Check reversing valve for proper temperatures Calculate both economic and thermal balance points Calculate temperature settings for multiple outdoor thermostats Check refrigerant charge using charging chart C heck sequence of operation of an air-to-air split system heat pump for cooling, heating, and defrost modes 2. Applications (3/3) Identify and describe different types of heat pump systems: ‣ air-cooled ‣ water-source — open loop — water-to-water — closed loop — geothermal — air-to-water Analyze and compare the operation and performance of the different types of Heat Pump Systems: ‣ e xplain the integration and operation of the air-to- air heat pump with electric resistance heat ‣ explain the integration and operation of the water-to- air heat pump with electric resistance heat ‣ explain the integration and operation of the air-to- air heat pump with a fossil fuel unit ‣ explain applications for open vs. closed loop geothermal heat pump systems M  echanically and electrically connect and check out: ‣ air-to-air heat pump ‣ water-to-water heat pump 26 Heating Systems 1. Forced Warm Air Systems (3/3) Check the operation of the ignition system Derate or change over a gas burner Adjust burner flame for proper fuel/air ratio Check for proper temperature rise through the furnace Test all safety controls Remove, install and adjust blower motor and/or belt Clean pilot assembly Oil motor(s) and bearings Check and adjust heat anticipator of thermostat Use orifice sizing charts Test induced draft pressure switches Check all safety controls Check operation of sequence 2. Hydronic Systems (1/1) Identify types of hydronic piping systems Identify types of boilers Check circulator for alignment and lubrication Set aquastat Check water pressure regulating valve (PRV) Check the zone valve operation Remove air from system Check backflow preventer Check compression/expansion tank Check water temperature rise across the boiler Check and adjust water level in pressure tanks Check automatic air vent operation Wire multizone/multipump hydronic systems 3. Testing and Balancing Equipment (1/1) Perform pressure checks on air distribution system Perform pressure checks on fuel system Perform efficiency test and adjust to recommended rate: ‣ check draft ‣ check CO2 ‣ check smoke (if applicable) ‣ check O2 ‣ check stack temp ‣ check CO Perform balance method for an air distribution system Perform balance method for a hydronic system 4. Humidification (2/2) Explain importance of humidification Describe different types of humidifiers Explain factors affecting humidity in business and residence Select proper humidification equipment Check operation of humidification equipment 27  Perform maintenance on humidification equipment Determine relative humidity using a psychrometer Determine dew point using a psychrometer 5. Unitary Combination Heating and Cooling Equipment (3/3) Describe the sequence of operation of a heating system U  se and read various tools and instruments needed for checking and testing combination air- conditioning and heating systems 6. Oil Furnaces (1/1) Explain and check the sequence of operation of oil stack switches Explain and check the sequence of operation of Electronic Primary Controls Understand how to replace oil filters Understand how to purge water from oil storage tanks Understand how to oil motors Replace oil nozzle and adjust electrodes Perform combustion test and adjust to optimum efficiency Perform safety shutdown check Replace oil nozzles with proper size replacements Inspect and adjust electrodes replacing when necessary Test and adjust oil pumps and couplers 7. Electric Furnaces (3/3) Understand the use of sequencers in electric furnaces Understand the effects of air flow on temperature rise Inspect heating elements and insulators Test thermal fuses Inspect all electrical connections Check for proper temperature Oil motors Test sequence of operation of electric furnaces Refrigeration Systems 1. Demonstrate knowledge of principles of refrigeration applicants (3/3) High temperature Medium temperature Low temperature Ultra-low temperature 2. Calculate heating and cooling loads (2/3) Equipment sizing 3. Demonstrate knowledge of principles of refrigeration systems (3/3) Walk-in coolers Walk-in freezers Self-service cooler cases Self-service freezer cases Multiple evaporator systems 28  Packaged systems (unitary refrigeration) Water coolers 4. Demonstrate knowledge of principles of electric and hot gas defrost operations (3/3) 5. Demonstrate knowledge of principles of/apply principles of specific refrigeration system components (3/3) Low ambient controls Evaporator pressure regulators Crankcase pressure regulators Accumulators Oil separators Filters/dryers Liquid indicators 6. Install/service/troubleshoot/replace refrigeration systems (3/3) 7. Install/service/troubleshoot/replace ice makers (2/3) 8. Install/service/troubleshoot/replace water coolers (2/3) 9. Troubleshoot/replace the power element (2/2) 10. Service/troubleshoot/replace evaporator pressure control devices (2/2) 11. Troubleshoot/replace a two-temperature valve (2/2) 12. Service/adjust/troubleshoot/replace defrost components (2/2) Electric Hot gas 13. Pump-down refrigeration system (3/3) 14. Adjust high and low pressure control settings (2/3) 15. Install/service/troubleshoot/replace a defrost heater/timer (2/2) 16. Install/service/troubleshoot/replace solenoid valve (2/3) 17. Install/service/troubleshoot/replace thermostatic motor controls (2/3) 18. Troubleshoot electrical circuits of refrigeration systems (3/3) 19. Test for, locate, and repair a refrigerant leak (3/3) 20. Recover/recycle refrigerants (3/3) 21. Analyze refrigeration system operation (3/3) Pressure Temperatures 22. Install/service/troubleshoot/replace crankcase heater (2/3) 23. Install/service/troubleshoot/replace compressor (2/3) 24. Adjust superheat/subcooling (2/2) 29 Commercial Refrigeration 1. Single Compressor (1/1) Explain the importance of compressor/evaporator balance Describe the differences in compressor displacement between the various temperature ranges Explain basic low and high pressure control theory and operation Explain the operation of a vapor compression system and its effects on temperature and volume Explain the operation and components used for the pump down cycle. Explain the evaporator and the condenser side of a system Explain application and operation of evaporator pressure regulating valves Discuss the problems associated with compressors operating at lower evaporator temperatures: ‣ decreased volumetric efficiency ‣ higher discharge gas temperatures ‣ potential overloading during initial temperature pull-down Discuss the use of different compressor designs for increased efficiency and capacity Describe the methods used for cycling the compressor on and off. Explain methods of defrost Explain methods of head pressure control system Explain heat reclaim Explain the lubrication methods for a compressor Determine the terminal identification of a single-phase compressor Explain how to measure the compressor lubrication oil pressure Explain several manufacturers' model numbering system Define compression ratio and the effect suction and discharge pressure have on compression ratio Determine compressor capacity using the compressor's curve Determine the correct operating amps using the compressor's curve Describe the different types and designs of compressors: ‣ type: — hermetic — semi-hermetic — open drive ‣ design: — reciprocating — scroll — screw Explain requirements of food preservation: ‣ medium temperature ‣ low temperature Describe supermarket display cases Explain the difference between an across-the-line start and a part-winding start Identify the different types of compressors Select a compressor for a particular capacity and temperature range Check the operation of a compressor in a particular system 30  Compute the compression ratio for a particular system Adjust Evaporator Pressure Regulating (EPR) valve Check control circuits per manufacturers' specifications Check system charge, superheat and subcooling Check display case temperatures and determine if operating properly Set cut-in and cut-out for a special product Draw the wiring diagrams for an across-the-line start and a part-winding start Draw a ladder diagram of a system equipped with a pump down cycle Draw the schematic of a single-phase and a three-phase compressor motor Draw a ladder diagram of a system using a defrost time clock and defrost termination fan delay switch Measure the compressor windings and determine if they are correct Measure the operating amps and determine if it is correct Check operation of defrost cycle and adjust time clock Adjust head pressure controls for proper operation Check operation of equipment equipped for automatic pump down Air Handling 1. Air Flow Principles/Duct Design (3/3) Draw layout of return and supply runs Calculate equivalent length of trunk and branch ducts Calculate total effective length of duct runs Calculate total available static pressure Size trunk and branch ducts by equal friction method U  se duct calculator to find duct size, velocity, cfm, and friction loss Calculate air flow factors for heating and cooling Size registers, grilles, and diffusers Fabricate fittings Fabricate a "HAND" pittsburg Fabricate "HAND" slips and drives Identify and use all basic hand-held sheet metal tools Identify and use all basic hand-held tools for duct board 2. Mechanical and Electronic Filtration (3/3) Identify types of mechanical filters: ‣ disposable ‣ HEPA ‣ permanent foam, mesh, and fiber ‣ electrostatic ‣ high efficiency Describe operation of electronic air cleaners Install air cleaner system into existing ductwork Remove and clear prefilter and cells: ‣ check ionizer wires ‣ test power pack 31  3. Fans/Blowers (3/3) Identify different types of fans/blowers: ‣ centrifugal ‣ axial Determine the proper direction of rotation Explain the difference between tube axial and vane axial Identify the types of centrifugal fans/blowers: ‣ forward curved ‣ air foil ‣ backward curved ‣ radial tip Check for proper rotation Interpret the fans/blowers curve Select the fans/blowers via the curve Check fans/blowers performance via curves Check amp draws Air Distribution Systems 1. Demonstrate knowledge of/apply principles of air distribution systems (2/3) Mechanical Exhaust Natural Ventilation Supply Combustion Return Code requirements 2. Design air distribution systems (2/3) Duct calculator SMACNA 3. Fabricate and insulate air distribution system (2/3) SMACNA Non-combustible Combustible Hazardous 4. Identify/install/troubleshoot ducts, fittings, and accessories (2/3) SMACNA Ventilation Return Materials Supply Supports Exhaust Connectors Intake Sealants Combustion 5. Install/service air-cleaning devices (3/3) SMACNA 6. Install fire/smoke control, and safety devices (2/3) Smoke removal systems SMACNA Fire dampers 32  7. Install clothes dryer exhaust systems (2/2) SMACNA 8. Perform test and balance of air distribution systems (2/3) Hoods Thermometer Manometer Sling psychrometer Velometer SMACNA Anemometer 9. Read and interpret air distribution layout (2/2) Blueprints Calculations Drawings Cutting, boring, and notching (all occupations) Specifications 10. Install hoods and hood systems (1/2) Commercial kitchen Specialty hoods 11. Maintain indoor air quality (2/3) Duct cleaning Air contaminates Air filtration Ventilation air Humidification Vents and Chimneys 1. Design, fabricate, and install vents (2/3) Fossil fuel Clearances Solid fuel Code requirements Manufacturers’ specifications 2. Design, fabricate, and install chimneys (2/2) Masonry High heat Metal Manufacturers’ specifications Low heat Clearances Medium heat Code requirements System Installation and Start-Up 1. Heating Start-up, Checkout, and Operation (3/3) Understand the importance of manufacturers' installation and operation requirements Demonstrate use of tools and instruments Determine equipment electrical, mechanical and code requirements Verify equipment air flow and distribution requirements Check operation of all electrical control components Check operation of gas train components and measurements Check oil burner components and measurements 33  Check ignition systems Evaluate fuel supply systems Test for proper combustion Check electrical components for operation and wiring connections Check for correct heating input and adjust to manufacturers' specifications 2. Heat Pump Start-up, Checkout, and Operation (3/3) Understand the importance of manufacturers' installation and operation requirements Understand alternative fuel methods Demonstrate use of tools and test equipment Determine equipment electrical requirements Verify equipment air flow and distribution C heck operation of all electrical and mechanical components C heck system operation in the heating, cooling and defrost modes Check supplementary and emergency heat Instruct customer on operation and maintenance of system 3. Air Conditioning Start-up, Checkout, and Operation (3/3) U nderstand the importance of manufacturers' installation and operation requirements Demonstrate use of tools and test equipment Determine equipment electrical requirements Verify equipment air flow and distribution requirements C heck operation of all electrical and mechanical components Check system operation while following all safety procedures Pull and verify deep vacuum Perform leak check and make repairs Conform to all applicable governmental regulations System Servicing and Troubleshooting 1. Mechanical System Problems (3/3) Develop systematic way to diagnose system problems and demonstrate method Identify and describe possible causes of failure and how to eliminate causes Demonstrate use of tools and test equipment following safety practices Record system data for the mechanical system operation Verify mechanical system operation is acceptable Determine cause of failure in system components Determine actual system air flow using the appropriate test equipment Determine system air flow requirements 34  2. Electrical Troubleshooting (3/3) Interpret electrical diagrams into sequence of operation Describe electrical mechanical sequence from electrical schematic Develop a methodical routine for electrical troubleshooting Analyze electrical performance of each component Rewire an HVACR unit using an electrical diagram: ‣ air conditioner ‣ furnace ‣ heat pump Record electrical system data U  se electrical test instruments to diagnose electrical troubles and correct electrical system performance Troubleshoot a faulty compressor overload protector Change a schematic diagram to a ladder diagram in a drawing 3. Heating: Service and Problem Analysis (3/3) Explain combustion theory for gas combustion and oil combustion Identify and describe possible causes of failure and how to correct problems Determine and measure combustion air, ventilation air and unit/system air requirements Develop systematic method(s) to diagnose system problems and demonstrate method Determine the cause of failure in a heating system Record data and verify system operation 4. Heat Pump: Service and Problem Analysis (3/3) Test and evaluate the operation of the refrigeration cycle in cooling and heating modes Test the operation of the supplementary heat component(s) Test the operation of the emergency heat status for the heat pump system Record appropriate data to evaluate complete system operation Test proper operation of reversing valve Check operation of defrost controls Inspect wiring and tighten connections 5. Air Conditioning: Service and Problem Analysis (3/3) Explain proper temperatures and pressures at various system locations Explain proper fan/blower operation Explain heat exchanger inspection Explain thermostat setting and operation Explain sounds that could indicate a problem Explain how electrical measurements could indicate a problem Explain value of nameplate data and service records Discuss the required performance checks Discuss the method of measuring superheat, subcooling, evaporator and condenser splits Discuss the proper procedures for using a voltmeter and an ammeter Explain normal operation of air-conditioning systems Explain the effects of overcharge and undercharge of refrigerant Explain the effects of improper airflow Develop a systematic approach to diagnose mechanical or electrical problems. Check system for system leaks Check and clean heat exchangers 35  Check for proper refrigerant charge Check for proper thermostat and electrical controls Check oil sample for acidity Check and replace filter/driers Check available voltage and install high and low side manifold gauges Compare static pressure on a P/T Chart to determine unit refrigerant Start unit and allow to stabilize Measure superheat and subcooling Check evaporator and condenser splits Check amperage of each motor Analyze performance using manufacturers' specifications Check electrical component operation Check air flow from furnace of air handler Inspect electrical connections Troubleshoot A/C systems from electrical schematics Indoor Air Quality 1. Requirement and Maintenance of Air Quality (1/1) Define Indoor Air Quality (IAQ) as defined by ASHRAE Std. 62. Explain Sick Building Syndrome (SBS) and Building Related Illness (BRI). Explain the different factors that make up acceptable indoor air quality: ‣ pollutant levels ‣ air distribution effectiveness ‣ ventilation air quantities ‣ occupant comfort Preventative Maintenance 1. Basic Maintenance (3/3) Explain the various types of maintenance programs Explain broad tasks and frequencies for a quality maintenance program Explain why each step of the Preventative Maintenance Program is necessary Explain the benefits associated with proper equipment maintenance Demonstrate various maintenance tasks Develop a Preventative Maintenance Program for: ‣ absorption cooling unit ‣ package heat and cooling unit ‣ electric heat system ‣ refrigeration systems ‣ gas heat system ‣ split system condensing unit and evaporator ‣ heat pump system ‣ walk-in boxes ‣ hydronic systems ‣ water-cooled centrifugal chiller ‣ ice makers ‣ water-cooled reciprocating chiller ‣ oil heat system Develop a list of tools needed to perform the Preventative Maintenance Program Develop a Preventative Maintenance Check Sheet 36 Refrigerant Recovery 1. Introduction (3/3) D  escribe the environmental issues regarding refrigerant, including legislation, protocol, laws, and regulations Describe the basic refrigerant cycle Determine proper evacuation levels and leak rates Identify three different types of technician certification 2. Safety (3/3) Describe the problems associated with mixing of refrigerants Describe the methods of determining when a recovery cylinder is full D  escribe the problems associated with component isolation where unsafe hydrostatic pressures can occur Describe the problems associated with contaminants left in a refrigerant system after recovery 3. Refrigerant Recovery, Recycling, and Reclamation Methods (3/3) Describe how to manually pump down a system Describe how to isolate system components Describe system dependent and self-contained recovery equipment Describe the push-pull method Describe difference between recycled and reclaimed refrigerant Explain options in Industry Recycling Guideline (IRG-2) List the advantages/disadvantages, and application of liquid and vapor recovery List methods for decreasing recovery time 4. Refrigerant Recovery, Recycling and Reclamation Equipment (3/3) Identify proper equipment for a particular job Describe procedures for recovering multiple refrigerants with the same recovery unit Describe maintenance and efficiency testing procedures for recovery units Describe maintenance and testing for refrigerant recovery cylinders Identify recovery cylinders Explain when to change filter-driers in recycling equipment Explain methods of purging non-condensables when recycling Identify type of refrigerant in a given recovery cycle Perform procedures for recovery Perform procedures for recycling Perform maintenance on recovery machine Connect and operate recovery equipment 37 Refrigerant Retrofits 1. Alternative Refrigerant Retrofits (1/1) Determine if the alternative refrigerant and/or lubricant: ‣ is applicable for retrofitting specific system ‣ is ul listed ‣ is on the EPA SNAP list ‣ meets the equipment manufacturers' approval Determine the lubricant required for the alternate refrigerants Procure the manufacturer's changeover guidelines and follow the retrofit procedures Measure the residual mineral oil in a system being changed from a CFC to an HFC refrigerant Refrigerants and Lubricants 1. Refrigerants (3/3) Explain the different classes of refrigerants: ‣ CFC Refrigerants ‣ Other Refrigerants ‣ HCFC Refrigerants ‣ Azeotropic mixtures (ASHRAE 500 series) ‣ HFC Refrigerants ‣ Zeotropic blends (ASHRAE 400 series) ‣ HC Refrigerants Explain physical and chemical properties: ‣ flammability and toxicity ‣ refrigerant temperature glide ‣ materials compatibility ‣ environmental properties (ODP, GWP and TEWI) ‣ miscibility and oil return ‣ bubble point ‣ pressure and temperature data ‣ dew point Define pure refrigerants and azeotropic mixtures Define zeotropic mixtures Define zeotropic blends Identify the color and classification of refrigerants by Pantone Matching System (PMS) color number Explain fractionization of blends Look up saturation pressure and temperature: ‣ single element refrigerant ‣ zeotropic ‣ azeotropic ‣ blends Identify when saturation pressure and temperature do not match the refrigerant Calculate superheat and subcooling Calculate superheat and subcooling glide 2. Lubricants (1/2) Explain the function of lubricants in systems Explain the different types and applications of lubricants: ‣ alkylbenzenes (AB) ‣ polyolesters (POE) ‣ mineral oils ‣ polyglocols (PAG) 38  Explain properties of lubricants: ‣ materials compatibility ‣ iscosity ‣ miscibility and oil return ‣ water absorption ‣ pour point and flash point ‣ rust and oxidation inhibitors Describe proper oil disposal Draw oil sample from system Demonstrate proper handling of POE's Use acid test kit for mineral oil and AB Demonstrate proper use of a refractometer or oil sample test Comply with Industry Regulations 1. Codes and Standards (3/3) Describe the reasons for codes Describe the three model codes: ‣ Building Officials and Code Administrators (BOCA), National Mechanical Code ‣ Southern Building Code Congress International (SBCCI), Standard Mechanical Code ‣ International Conference of Building Officials (ICBO), Uniform Mechanical Code Identify the codes and standards for the applicable area, locality and state Discuss the relationship between codes and manufacturers' installation instructions Identify pertinent standards published by the following organizations: ‣ AGA ‣ IEC ‣ AMCA ‣ ISO ‣ ANSI ‣ SMACNA ‣ ARI ‣ UL ‣ ASHRAE 2. Regulations Affecting Ozone Depletion (3/3) Explain ozone depletion Explain significance of the Montreal Protocol Explain significance of the Clean Air Act Explain EPA requirements: ‣ technician certification ‣ shipping ‣ refrigerant recover, recycle, and reclaim ‣ leak detection ‣ disposal of systems ‣ significant new alternatives policy program (SNAP) ‣ labeling ‣ recordkeeping Know DOT requirements concerning transportation of refrigerants Determine if refrigerant container is DOT-approved and whether it needs to be retested Determine if recovery/recycle equipment is certified and meets requirements. Dispose of empty non-refillable cylinders Use recovery equipment and prepare system for disposal Obtain federal EPA technician certification 39  3. Other Regulations (3/3) Explain global warming Know OSHA Work Rules Explain Indoor Air Quality (IAQ) standards (ASHRAE Std.62) Explain impact of state and local codes on system application and retrofit Explain proper disposal of oil, components, and other materials Explain state and local licensing requirements Explain DOT regulations Professional Service 1. Customer Relations/Communication (3/3) Describe methods of dealing with irate customers Describe methods of dealing with technician delays and scheduling realities Describe methods of selling service agreements and replacement equipment Explain service(s) performed in layman's terms Explain how to obtain customer satisfaction Explain service contracts Demonstrate professional/personal appearance and attitude Discuss customer telephone etiquette Describe, list, calculate and present a typical billing invoice Demonstrate good customer relations 2. Character Education (3/3) Discuss the following personal traits: ‣ honesty ‣ conflict resolution ‣ integrity ‣ teamwork ‣ reliability ‣ ethics ‣ responsibility ‣ pride ‣ accountability ‣ initiative ‣ character ‣ time management 40  Sample Questions 1. What type of heat changes the state of a substance without changing its pressure or temperature? a. latent b. sensible c. specific d. super 2. What type of three-way valve has two inlets and one outlet? a. diverting b. mixing c. modulating d. redundant 3. What result occurs when there is an open circuit leading to a thermostat? a. continuous operation of an air conditioner b. continuous operation of the blower c. lack of operation of an air conditioner d. lack of operation of the blower 4. What is the velocity pressure of air moving through an 8” x 8” square duct at 2500 fpm? a. 0.16” b. 0.39” c. 0.54” d. 0.64” 5. According to the International Mechanical Code, what is the minimum chimney thickness for a high heat appliance with a round diameter of 14”? a. 0.057” b. 0.075” c. 0.099” d. 0.129” 6. What condition causes an HVAC unit to run with high head pressure? a. broken blower belt b. dirty condenser coil c. low refrigerant charge d. low outdoor ambient temperature 41  7. What type of joint runs 90° to the airflow? a. horizontal b. longitudinal c. transverse d. vertical 8. What device can be used to limit low-frequency sounds in an HVAC system? a. dampers b. duct lining c. mufflers d. turning vanes 9. As the length of the gas pipe increases, the gas pressure _____. a. decreases b. fluctuates c. increases d. remains the same 42  Sample Questions — Key 1. What type of heat changes the state of a substance without changing its pressure or temperature? a. latent Correct by definition b. sensible Incorrect by definition c. specific Incorrect by definition d. super Incorrect by definition 2. What type of three-way valve has two inlets and one outlet? a. diverting Wrong, but plausible b. mixing Correct c. modulating Wrong, but plausible d. redundant Wrong, but plausible 3. What result occurs when there is an open circuit leading to a thermostat? a. continuous operation of an air conditioner Wrong, but plausible b. continuous operation of the blower Wrong, but plausible c. lack of operation of an air conditioner Correct d. lack of operation of the blower Wrong, but plausible 4. What is the velocity pressure of air moving through an 8” x 8” square duct at 2500 fpm? a. 0.16” Wrong, but plausible b. 0.39” Correct c. 0.54” Wrong, but plausible d. 0.64” Wrong, but plausible 5. According to the International Mechanical Code, what is the minimum chimney thickness for a high heat appliance with a round diameter of 14”? a. 0.057”c Correct b. 0.075” Wrong, but plausible c. 0.099” Wrong, but plausible d. 0.129” Wrong, but plausible 6. What condition causes an HVAC unit to run with high head pressure? a. broken blower belt Wrong, but plausible b. dirty condenser coil Correct c. low refrigerant charge Wrong, but plausible d. low outdoor ambient temperature Wrong, but plausible 43 7. What type of joint runs 90° to the airflow? a. horizontal Incorrect by definition b. longitudinal Incorrect by definition c. transverse Correct by definition d. vertical Incorrect by definition 8. What device can be used to limit low-frequency sounds in an HVAC system? a. dampers Wrong, but plausible b. duct lining Correct c. mufflers Wrong, but plausible d. turning vanes Wrong, but plausible 9. As the length of the gas pipe increases, the gas pressure _____. a. decreases Correct b. fluctuates Wrong, but plausible c. increases Wrong, but plausible d. remains the same Wrong, but plausible 44  Curricula Crosswalk Crosswalk to PAHRA Technical Program Requirements, NCCER Modules, OCIB Technical Specifications, & Multistate Academic and Vocational Curriculum Consortium (MAVCC) Curriculum The following crosswalk is intended for guidance purposes only. It does not represent all curricula or resource materials that may be used for HVACR programs. It is intended as a reference for curriculum planning and mapping standards to available curricula. Curriculum/Resource Titles: (1) MAVCC – Fundamentals of Air Conditioning and Refrigeration (2) MAVCC – HVACR Electrical Systems (3) MAVCC – Residential HVAC System Design (4) MAVCC – Residential & Light Commercial HVAC (5) PAHRA – Technical Program Requirements (6) NCCER – HVAC Level 1 (7) NCCER – HVAC Level 2 (8) NCCER – HVAC Level 3 (9) NCCER – HVAC Level 4 (10) NCCER – Core Curriculum Trainee Guide For more information about MAVCC curricula, please go to www.okcimc.com. Module Name — Objective Unit/Module 1) Unit 1, 13, 16 4) Unit 9-12 HVAC/R Industry 5) TPR 2, Subtopic I 6) Module 03101, 03108 1. Introduction to Refrigeration 1) Unit 1 5) TPR 2, Subtopic I.A. 6) Module 03101 2. Introduction to Air Conditioning 1) Unit 1, 13, 16 5) TPR 2, Subtopic I.B. 6) Module 03101 3. Introduction to Heating 4) Unit 9-12 5) TPR 2, Subtopic I.C. 6) Module 03108 45  Module Name — Objective Unit/Module 1) Unit 1, 5, 13, 14, 16, 18 3) Unit 1, 2, 3 Thermodynamics and Heat Transfer Principles 5) TPR2, Subtopic II 6) Module 03102, 03107 1. Matter and Heat Behavior 1) Unit 13 3) Unit 1, 2 , 3 5) TPR 2, Subtopic II.A. 6) Module 03107 2. Fluids and Pressures 1) Unit 13, 16, 18 5) TPR2, Subtopic II.B. 3. Refrigeration Cycle/Diagrams 1) Unit 1, 13, 14 5) TPR 2, Subtopic II.C. 6) Module 03107 4. Measurement Systems 1) Unit 5 5) TPR 2, Subtopic II.D. 6) Module 03102 1) Unit 2, 4, 9, 16, 17, 18 Safety Skills 5) TPR 1, Subtopic III 10) Module 00101, 00109 1. Personal Safety and Work Practices 1) Unit 2 5) TPR 1, Subtopic III.A. 10) Module 00101 2. Handling of Pressurized Fluids 1) Unit 2, 9, 16, 17, 18 5) TPR 1, Subtopic III.B. 10) Module 00109 3. Handling Hazardous Substances 1) Unit 2 5) TPR 1, Subtopic III.C. 10) Module 00109 4. Electrical Safety 1) Unit 2, 4 5) TPR 1, Subtopic III.D. 10) Module 00101 1) Unit 3, 4, 7, 8, 16, 17, 18 2) Unit 2, 3, 11, 15 3) Unit 1, 2, 4 4) Unit 10, 11 Tools and Equipment 5) TPR 2, 3, 4, Subtopic IV 6) Module 03106, 03109 7) Module 03202 10) Module 00103, 00104 1. Hand Tools and Accessories 1) Unit 3, 4, 7, 8 5) TPR 2, Subtopic IV.A. 10) Module 00103, 00104 2. Electrical Testing Devices/Meters 2) Unit 2, 3, 11, 15 5) TPR 2, Subtopic IV.B. 6) Module 03106 46  Module Name — Objective Unit/Module 3. Refrigeration: Servicing and Testing Equipment 1) Unit 16, 17, 18 5) TPR 2 & 3, Subtopic IV.C. 4. Heating: Servicing and Testing Equipment 4) Unit 10, 11 5) TPR 2 & 3, Subtopic IV.D. 7) Module 03202 5. Air Flow: Measuring and Testing Equipment 3) Unit 1, 2 ,4 5) TPR 3 & 4, Subtopic IV.E. 6) Module 03109 1) Unit 7-12 3) Unit 4, 6 Piping Principles and Practices 5) TPR 2, 3, 4, Subtopic V 6) Module 03103, 103104, 03105, 03213 1. Piping Material and Fabrication