Air Conditioning and Refrigeration

Skilled Migration Assessment Services Email: [email protected] / [email protected] Trades Recognition Services Email: [email protected] Tel:

1 February 2016

+61 3 9919 7365

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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INFORMATION ABOUT ASSESSMENT

Purpose The purpose of this practical assessment is for you to demonstrate your Air Conditioning and Refrigeration general practical skills and theoretical knowledge and to show that you can work safely and accurately to the industry requirements for this trade. Your performance in this task and your answers to trade-related questions will enable the assessor to determine your skills in this area.

You are to verify functionality and compliance of refrigeration and air conditioning installation encompasses working safely in the refrigeration and air conditioning industry and ensuring the equipment you work on complies with environmental, electrical and safety requirements before energisation. If compliance has been tested and verified you must then identify the functionality of that system to ensure correct operation of the equipment to maximise energy efficiency and customer satisfaction. To undertake this assessment you will be required to construct two refrigeration and air conditioning systems which comprise of:  

Direct expansion system utilising a TX Valve (Cool room) Direct expansion system utilising a capillary tube (Air Conditioner)

Each system will need to be constructed utilising the Lucas Nuelle systems in the refrigeration workshop ensuring the correct condensing unit is selected and piped up with the correct refrigerant hoses and fittings following the instructions provided w ithin this document. You will be assessed on your ability to work safely at all times under the guidelines of the WHS Act of 2012. Any activity which is deemed not to comply with the Act and TAFE SA requirements will result in “Not Yet Competent” assessment. You are required to wear safety equipment at all times whilst working within the workshop, failure to do so will result in not undertaking the assessment. The minimum requirements regarding safety are as follows:   

Safety glasses Long pants Safety boots

You will also be required to ensure that all tools and equipment are in place before you undertake the assessment. This must then be presented to your lecturer for sign off as you will be held responsible for any tools not present after your assessment. This assessment requires you to possess a Refrigerant Handling License from the Australian Refrigeration Council (ARC). Failure to provide this will result in you being unable to sit the practical section of the assessment. Licenses will be checked on the ARC website if no license is produced During any assessment, the assessor may also verbally ask some scenario based questions.

1 February 2016

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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INFORMATION ABOUT ASSESSMENT REFERENCE MATERIAL Australian Refrigeration and Air Conditioning Volume 1. G. Boyle Australian Refrigeration and Air Conditioning Volume 2. G. Boyle

CANDIDATES - WHAT TO BRING

Personal Protective Equipment To meet OH&S requirements, you must bring basic Personal Protective Equipment (PPE) for your practical skill assessment in your trade.

http://www.bronsonsafety.com.au/index.php/all‐products.html

Essential    

Eye protection (goggles, glasses) Foot protection (safety boots) Hand protection (gloves) Skin/body protection – Long Pants minimum requirement

Note: Basic PPE is mandatory and must be worn at all times while the practical skills assessment is being conducted. Optional 

Hearing protection (ear plugs, ear muffs)

You will also need to bring stationery with you on the day of assessment including:  

1 February 2016

Multiple colored pens or biros (do not use pencil) Pressure Temperature Chart (Electronic on mobile device is acceptable)

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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EQUIPMENT

You will be utilizing the Lucas Nuelle Refrigeration and Air Conditioning equipment which is designed to be utilized as a training/teaching aid. The system is connected through flexible refrigerant hoses and operates exactly how a system in the field will operate. You are to deem functionality and compliance through Pressure testing, Evacuation, Charging and Recovery procedures which are benchmarked via the Refrigerant Code of Good Practice 2007.

CANDIDATE TOOL LIST Equipment Applicants are able to bring along their own tools that are familiar to them but all tools and equipment will be provided by the assessor if required            

1 February 2016

Reclaim/Recovery Unit Vacuum Pump Vacuum Analyser Refrigerant Gauges Temperature Probe (K type) Digital Thermometer Valve Key 8” Shifter Flat head Screw Driver Multi Meter Insulation Resistance Meter Clamp Meter

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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OTSR Appliance Disconnect / Reconnect Practical Assessment Candidate Guide Fill in your details on the Danger Tag

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CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Fill in your details on the Out of Service Tag

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CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 1 Complete the Job Safety Analysis for the assessment

Job Safety Analysis/Risk Assessment Worksheet Name:

JSA number:

Campus:

Date the JSA was prepared:

Task/Activity Location: Student Signature

This JSA has been discussed with (Lecturer)

Date:

Lecturer (signature) Position:

Item Number

Work Activity Break the job down into steps

Hazard What could harm someone?

Risk Control What can be done to make the job safe?

Date: Person Responsible Who will make it happen?

Completion Date & sign off.

1. 2. 3. 4. 5. 6. 7. 8. 9.

V1.2 January 2016 J109A

Assessment

Refrigeration and Air Conditioning Page 3 of 19

Task 2 Construct a refrigeration (cool room) system utilising the Tx Valve and the following guidelines:  Ensure suction line is the correct size  Ensure suction line is insulated  Liquid line must include drier and sight glass  Ensure TX Valve bulb is attached in the correct position Before constructing the system please sketch a diagram of how you will construct it

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Page 4 of 10

Task 3 Conduct a pressure test on the refrigeration system utilising dry Nitrogen to an appropriate pressure for the identified refrigerant. All pressures must be stated in kPa Refrigerant: Current Ambient Temperature: Expected low side Saturated Temperature: Expected low side Saturated Pressure: Expected high side Saturated Temperature: Expected high side Saturated Pressure: What is the expected maximum pressure the low side may be subjected to? Keep in mind that pressure on the low side is higher when the system is not operating: Highest Low side Pressure: What is the expected maximum pressure the high side may be subjected to? Keep in mind that pressure on the high side is higher when the system is operating Highest high side Pressure: Is the low side able to be isolated from the high side? (Circle) YES

NO

What pressure will you test the system to? Low Side High Side Does the system leak? YES

NO

If “YES” where is it leaking from and how can you remedy this? Does the system comply with the pressure test? YES

NO

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 4 Evacuate the system as per requirements What is the accepted level of vacuum for evacuating a refrigeration system? a) 0 Microns b) 250 Microns c) 500 Microns d) 1000 Microns Does the Vacuum Pump work as expected? Static Vacuum Reading: Perform a “drop test” on the refrigeration system noting the level of vacuum before switching off the Vacuum Pump Level of Vacuum reached: Level of Vacuum after 10 minute Drop Test:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 5 Before charging the system with the correct refrigerant from the correct cylinder ensure that you check and weigh the cylinder for compliance. Refrigerant: Bottle Expiry Date: Refrigerant Cylinder Weight Tare Weight: Refrigerant Weight: Will you charge the refrigerant as a liquid or a vapour? Please state your reason:

Charge the system as per requirements: System Charge:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 6 Prepare to turn your system on, ensuring all necessary equipment is plugged in and operational. PLEASE NOTE:  There are two plugs for the system: condensing unit and evaporator  Heaters are OFF when the ring light around the thermostat is ON (press to change)  Fan switches are ON when they are UP (light should illuminate) Let your system settle and provide the following information: Ambient Temperature: Low Side Pressure: Low Side Temperature: Bulb Temperature: Superheat: Suction Line Superheat: High Side Pressure: High Side Temperature: Sub Cooling: Did you have to adjust Superheat? If so please provide the adjusted figure: Superheat: State the settings of the LP and HP safety device: LP Range: LP Differential: HP Cut Out: Are these settings correct for the system and refrigerant used?

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 7 Recover the refrigerant into the recovery cylinder provided ensuring that the cylinder is used correctly and safely. Cylinder Test Date: Maximum Cylinder Pressure: Tare Weight: WC: Maximum fill Weight: (WC x .8 x .8): Total Cylinder Weight Before Recovery Total Cylinder Weight After Recovery:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 8 Disconnect the refrigeration system and replace caps on all equipment, ensure that all hoses are coupled together and placed in the drawers as identified at the beginning of this assessment.

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 9 Construct an Air Conditioning system utilising the Capillary Tube and the following guidelines:  Ensure suction line is the correct size  Ensure suction line is insulated  Capillary Tube is connected via ¼” hoses one of which must be insulated  No drier is necessary Before constructing the system please sketch a diagram of how you will construct it

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

ver007

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Task 10 Conduct a pressure test on the Air Conditioning system utilising dry Nitrogen to an appropriate pressure for the identified refrigerant. All pressures must be stated in kPa Refrigerant: Current Ambient Temperature: Expected low side Saturated Temperature: Expected low side Saturated Pressure: Expected high side Saturated Temperature: Expected high side Saturated Pressure: What is the expected maximum pressure the low side may be subjected to? Keep in mind that pressure on the low side is higher when the system is not operating: Highest Low side Pressure: What is the expected maximum pressure the high side may be subjected to? Keep in mind that pressure on the high side is higher when the system is operating Highest high side Pressure: Is the low side able to be isolated from the high side? (Circle) YES

NO

What pressure will you test the system to? Low Side High Side Does the system leak? YES

NO

If “YES” where is it leaking from and how can you remedy this? Does the system comply with the pressure test? YES

NO

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

ver007

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Task 11 Evacuate the system as per requirements What is the accepted level of vacuum for evacuating an Air Conditioning system? e) 0 Microns f) 250 Microns g) 500 Microns h) 1000 Microns Does the Vacuum Pump work as expected? Static Vacuum Reading: Perform a “drop test” on the Air Conditioning system noting the level of vacuum before switching off the Vacuum Pump Level of Vacuum reached: Level of Vacuum after 10 minute Drop Test:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

ver007

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Task 12 Before charging the system with the correct refrigerant from the correct cylinder ensure that you check and weigh the cylinder for compliance. Refrigerant: Bottle Expiry Date: Refrigerant Cylinder Weight Tare Weight: Refrigerant Weight: Will you charge the refrigerant as a liquid or a vapour? Please state your reason:

Charge the system as per requirements: System Charge:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

ver007

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Task 13 Prepare to turn your system on, ensuring all necessary equipment is plugged in and operational. PLEASE NOTE:  There are two plugs for the system: condensing unit and evaporator  Heaters are OFF when the ring light around the thermostat is ON (press to change)  Fan switches are ON when they are UP (light should illuminate) Let your system settle and provide the following information: Ambient Temperature: Low Side Pressure: Low Side Temperature: Bulb Temperature: Superheat: Suction Line Superheat: High Side Pressure: High Side Temperature: Sub Cooling:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

ver007

Page 15 of 10

Task 14 Recover the refrigerant into the recovery cylinder provided ensuring that the cylinder is used correctly and safely. Cylinder Test Date: Maximum Cylinder Pressure: Tare Weight: WC: Maximum fill Weight: (WC x .8 x .8): Total Cylinder Weight Before Recovery Total Cylinder Weight After Recovery:

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

ver007

Page 16 of 10

Task 15 Disconnect the refrigeration system and replace caps on all equipment, ensure that all hoses are coupled together and placed in the drawers as identified at the beginning of this assessment.

Lecturer Signature:

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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Task 16 Investigate whether the three phase motor located on the wall are able to be energised safely utilising the appropriate test equipment. Ensure your equipment is functional before utilising: Insulation Resistance Meter (Megger) battery check: Insulation Resistance Meter (Megger) continuity check: Multimeter Voltage reading (Known supply) Multimeter “0” Ohm reading: Resistance of windings: U1 to U2: V1 to V2: W1 to W2: Do these readings suggest the windings are intact? Insulation Resistance: Meter Setting: U1 to Earth: V1 to Earth: W1 to Earth: Do these readings suggest the insulation is intact?

Earth Resistance (ensure motor is wired correctly): Earth of Motor to Plug Top: Does this reading suggest the resistance of the Earth is sufficiently low?

© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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© Victoria University

CRICOS Provider No. 00124K (Melbourne) 02475D (Sydney) RTO Code: 3113

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