Mechanical Services

CPC32413 Plumbing and Services Training Package Assessment Record / <Insert your institute logo here>

MECHANICAL SERVICES

SPLIT SYSTEMS

ASSESSMENT BOOK

PLUMBING AND SERVICES TRAINING PACKAGE

CPC08

STUDENT NAME……………………………… CHISHOLM INSTITUTE

PLUMBING DEPARTMENT

GROUP………….. DANDENONG CAMPUS

Student ID: / Student Name:
Unit Code: / UEENEEJ105A , UEENEEJ172A
Unit Description: / Position, assemble, and start up single head split a/c and water heating pump systems
Recover ,pressure test, evacuate, charge and leak test refrigerant- split systems
172A / 105A / 1. ACTIVITY / SC / NYC
1.1-1.3,1.6
1.4
1.2 ,1.4,1.5
1.7-1.9,2.10
2.2,2.3
2.6-7
2.8-9
2.11
T9e / 1.1-1.3,1.5
1.5,1.6
1.2,1.4,
1.7,1.8,1.11
1.9, 1.10, 3.3 T8 l,j
2.4
T8 h / A. Prepare, Communicate and work effectively and safely with others.
B. Locate, interpret and apply relevant information, standards and specifications to
C. Apply safety requirements throughout the work sequence, including the use of personal protective clothing and equipment
D. Obtain materials, tools and equipment and check. Inc preparatory work.
E. Ensure licensed electrician connects/isolates to electrical supply and licensed plumber is used
F. Pressure test with nitrogen and test for leaks and rectified
G. Vacuum down system (correct procedure must be followed) ; vac gauge
H. Release refrigerant
I. Test system using correct procedure.
2.5
T8d,e,h
T9a
T9a,d,e,f,h
T9 c
2.6
2.4
T13a,b / 2.3 T8 a-f
3.4
2.2,2.6,2.7
T9 a,d,e,f
4.2 T9 b,g
3.2 T10 a-f / J. Using ¼” and ⅜” copper pipe, insure the pipework is installed to specs
K. Pump down system
L. Disconnect pipes inc elec
M. Reconnect pipes
N. Assemble air conditioning unit to full working condition(correct procedure must be followed)plumbing and electrical
O. Pressure test for leaks
P. Commission Unit as per manuf. instructions
Q. Vacuum down system
R. Decommission ;pipework , condensate drains, and electrical as manufactures instruction
S. Explain procedure for recovering refrigerant in a system( contaminated refrigerants)and place refrigerant into suitably labelled containers
2.5-7
T9c,d / 4.2
2.8 ,3.6, 4.3
2.13
4.4 / T. Make part as per instructions
U. Material used
V. 3/8" copper pipe x 200mm long – 5 off
W. 3/8" copper pipe x 100mm long – 1 off
X. 3/8" tees – 2 off
Y. 3/8" Flare nut
Z. Bend all pipe 90 degrees in center ⁭ Expand on end of 2 of the 200mm lengths (anneal copper to avoid splitting)
AA. Clamp off one end of one 100mm length and seal with silver solder
BB. Assemble in a rectangle with tee facing inward and 100mm lengths on tee facing upward
CC. Using a flare nut, assemble last 100mm length and flare end
DD. Silver solder all joints using MAPP gas and LPG/OXY torch
EE. Pressure test to 2000kPa, R410A
1000kpa R22
FF. Disassemble an air conditioning unit
GG. Pressure test system
HH. Reassemble unit to its original condition
II. Compliance with regulations, standards and organizational quality procedures and processes
JJ. Work area is cleared with correct disposal of waste and tools and equipment are cleaned, checked, maintained and stored according to workplace procedures and manufacturers’ instructions, and sustainable practices.
KK. Documentation has been completed in accordance with workplace requirement

Where would the thermostat be located? ( mark on drawing)

T5 -105A T8g – 172A

1.1 Psychrometric Problems

Question 1: T8a,b T1 b – 172A

Find

(a) The dew point temperature of air at a dry bulb temperature of 35ºc and wet bulb temperature of 24ºc at atmospheric pressure.

(b) The relative humidity

Solution

Referring to the psychrometric chart.

a.
b.

Question 2: T3a,b,c,d,e – 172A

Find the relative humidity of air under the following conditions;

(a) 20º

(b) 30º

Solution

Referring to the psychrometric chart.

a.
b.

Question 3: T2a,b,c,d,e – 172A T6g – 172A

A sling psychrometer gives temperature readings of:

35º

Find and explain

(a) Relative humidity

(b) Specific volume

(d) Dew point temperature

(e) Heat flow and transfer

Solution

Referring to the psychrometric chart.

a.
b.
c.
d.
e.

Unit Sizing Chart

Unit / Capacity (KW)
1 / 2.5
2 / 3.5
3 / 4.5
4 / 5.5
5 / 6.5
6 / 7.5
7 / 8.5
8 / 10

Question 4:

Calculate the correct size Split Air Conditioning required to suit this room:

Design Conditions

Summer Ambient: 34C Winter Ambient: 5C

Summer Internal: 22C Winter Internal: 21C

Δt ………….. …..12C Δt …………… 16C

Note:

· Refer to sizing Chart for unit number:

· Wall non-insulated

· Roof non-insulated

WORK SHEET:

RESIDENTIAL
AIRCONDITIONING SURVEY FORM
A.R.E.M.A / (Prepared in association with the C.S.I.R.O.)
NOTE: Not to be used for Commercial Projects
Client / Summer Ambient ºC / Winter Ambient ºC
Address / Summer Control ºC / Winter Control ºC
Phone / Summer Diff. K / Winter Diff. K
No / Transmission Loads / Summer Gains / Winter Losses
ITEM / QUALITY / FACTOR / WATTS / FACTOR / WATTS
1 / All Glass / m² / x 76 = / x 100 =
2 / Outside Walls
Uninsulated / m² / x 28 = / x 37 =
Insulated with Double Foil / m² / x 11 = / x 14 =
3 / Inside Walls / m² / x 14 = / x 18 =
4 / Vented Floors / m² / x 9 = / x 22 =
5 / Insulated (50mm) Ceiling or Flat Roof / m² / x 14 = / x 9 =
6 / Fresh Air (Floor Area) / m² / x 10 = / x 13 =
A / TOTAL TRANSMISSION LOAD / Sensible Heat / Sensible Heat
7 / For K Temp. Difference / 12 K / 16 K
8 / Desired K Temp. Difference / K / K
9 / K Difference Adjustment / Line 8 ÷ Line 7
B / ADJUSTED TRANSMISSION LOAD / Total A x Line 9
C / People (Minimum - 4) / No 4 / x 75 = / - / Nil
SOLAR LOAD / QUANTITY / FACTOR / WATTS
10 / South / m² / Int.Shade Ext.Shade / NO WINTER GAIN
x 35 / 15 =
Nth N.E.EAST / m² / x 130 / 65 =
N.W / m² / x 190 / 95 =
West / m² / x 220 / 125 =
Sth. West / m² / x 140 / 70 =
D / All area except worst aspect / m² / x 35 / 15 = / NIL
E / Enter worst aspect
F / Total Sensible Load / Add Total lines B, C, D and E
G / Add Duct Loss / Multiply Line F and G
H / Final Sensible Load / Add Line F and G

Question 5: T4a,b,c– 172A

Determine the cooling and heating capacity of a split system air conditioner and plot the cooling and heating process line on the psychometric chart.

Cooling Heating

Air flow l/s Air Flow l/s

Air On 25C db – 18C wb Air On 21C db – 50% RH

Air off 11C db – 10C wb Air off 44C db

Sensible Qs – 3898 w Sensible Qs – 3856 w

Psychrometric Chart

WORK SHEET:

Question 6: T1 a – 105A T1 d,e,f – 172A

What is Ozone and protection Act

Question 7: T1 b – 105A

What type of refrigerants damage the Ozone layer?

Question 8: T1 e – 105A

In what year are CFC based refrigerant to be phased out?

Question 9: T1 a – 172A

What is Air-Conditioning?

Question 10:

The human comfort zone is in the ______range and ______

relative humidity range.

Question 11:

What is the study of moisture called?

Question 12:

What is the purpose of filtration?

1.
2.

Question 13:

What type of fan is installed in a split system air conditioner (indoor evaporator)?

Question 14: T6 k,l – 105A

Where in the system of a split system air conditioner is a propeller fan installed?

Question 15:

What is the name of the device for measuring wet and dry bulb temperatures?

Question 16:

On a sling psychrometer which has the lower temperature reading?

Question 17:

What is the psychrometric chart?

Question 18:

What is moisture content?

Question 19:

What is sensible heat (Qs )?

Question 20:

What is latent heat (Q)?

Question 21: T1 c –105A

Name the factors that contribute to a cooling load for a building?

1.
2.
3.
4.
5.
6.

Question 22: T6 m,n – 105A

Why is it not a good idea to oversize your system?

Question 23: (T6 f,g,h,I,j – 105A T7 b,c,d,e,f,g,h,i – 105A) T7a,b,c – 172A

What components are on the HPHT part of the basic refrigeration system and heat pump systems?

Question 24:

What is the purpose of the compressor?

Question 25:

What is the purpose of the condenser?

Question 26: T6 p – 105A

What is the purpose of the flow control device?

Question 27: T6 o – 105A

What is the purpose of the evaporator?

Question 28:

What does the reversing valve do in split air conditioning system?

Question 29:

Where in the system would you install a filter drier?

Question 30:

What is the purpose of crankcase heater?

Question 31: T6b,c,d,e – 172A

What is the percentage of liquid and vapor in a cylinder incorporating saturated liquid/

Saturated vapor

Question 32: T6a,b,e,f – 172A

What is the saturation pressure and temperature of:

R22 @ 22º ______kPa

R410 @ 812kPa ______ºC

Question 33:

What is the purpose of pipe insulation?

Question 34:

When would you install a condensate pump?

Question 35: T8 a – f – 105A

How would you connect refrigeration piping?

Question 36:

On a R22 system why would you have the pipe on grade towards the compressor?

Question 37:

When silver brazing why would you use an inert gas?

Question 38:

What flow rate would you use for nitrogen when silver brazing?

Question 39:

Name the four (4) methods of leak detecting?

1.
2.
3.
4.

Question 40: T4 a – 105A

Do you need a license to purchase refrigerant?

Question 41:

On an add-on Air Conditioner where should the coil be located?

Question 42:

When evacuating a system what pressure should you go to?

Question 43:

When should you change the vacuum pump oil?

Question 44:

What is the angle of the flare on a refrigeration flaring tool?

Question 45:

How would you tell the difference between R22 and an R410a manifold set?

Question 46: T4 a – 105A T1 c – 172A

Who can legally install a Split Air conditioner?

Question 47 T2 b,c,d – 105A

Explain what you think of co gen, solar , wind, bio mass, geo thermal, tidal, hydro, and nuclear, in relation to a/c?

Question 48 T3 a,b,c,d,e,f,g,h,I T1 b – 172A

What are your responsibilities, Government and environment protection with regards to working on a heritage listed building?

Question 49 T2 a T4 b T6 e – 105A

A does MEPS stand for?

B list the applicable standards and codes with respect to a/c?

Question 50 T1 d – 105A

As the world population increases will this affect energy demands

Question 51 T6 a,b,c,d – 105A

Explain the difference between a split and ducted air conditioning and name all categories and there application

Question 52 T7 a – 105A

List typical applications of split water and heat pump systems

Question 53 T5a-k – 172A

Research the topic pressure and explain and define:

Basic gas laws, pressure gauge types, pressure scales, conversions, hazards, care and maintenance, calibrations and typical locations

Question 54 T10a-q – 172A

Research and explain service gauges and the use of?

Question 55 T11a,b,c– 172A T12a,b,c,d, – 172A

Explain the differences between the different refrigerant gases and appropriate available on the market in Australia including their different properties and chemical groups and their safe use

PRACTICAL ASSESSMENTS

ASSESMENT TASK 1 – install single head a/c

· Locate installation instructions

· Complete SWMS

· Prepare work area

· Install a/c as per installation instructions, inc pipework, and insulation

· Pressure test and record results

· Complete evacuation procedure

· Charge the system

· Leak Test and commission system

ASSESSMENT TASK 2 – NITROGEN WELD

· Locate Instructions

· Complete SWMS

· Fabricate copper welding task using Nitrogen

· Test to appropriate pressure

ASSESSMENT TASK 3 – Reclaim

· Locate instructions

· Complete SWMS

· Ensure unit is operating correctly

· Follow Reclaim instructions

· Weigh-in correct amount of refrigerant

· Leak Test and commission unit

Agreement/Acknowledgement

I accept the conditions of the assessment I am about to participate in.

I understand that follow up assessments may be required if it is found I need further training in part or all of this competency.

I shall undergo the necessary training if required by the teacher / assessor to successfully satisfy all standards as stated in the evidence guide of the relevant unit of competency found in the CPC32413 Plumbing and Services Training Package.

Unit Code: / UEENEEJ105A , UEENEEJ172A
Unit Description: / Position, assemble, and start up single head split a/c and water heating pump systems
Recover ,pressure test, evacuate, charge and leak test refrigerant- split systems

Training recommendation notes:

Student/Participant comments:

I declare / (apprentice name) has been assessed
to be competent/not yet competent for the unit/s
t code and title here>
Teacher’s signature / Date
Student’s signature / Date

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PTMGA Page 32

CPC32413 Plumbing and Services Training Package Assessment Record / <Insert your institute logo here>
Job safety analysis / Signed off:
Contractor: / Date:
Task: / Accepted: / Yes / q / No / q
Area:
Procedure (in steps) / Possible hazards / Safety controls
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

T8 g – 105A T8c – 172A, T9b– 172A

U:\40-Engineering Technology & Trades\45-Plumbing & Water Industry Services\3-Plumbing\Governance\mapping 5th may 2015\Mechanical\Split AirCon Ass Book_Apprentice Version_2_ 20.4.15.doc