Course Title:
Course Number:
INTEGRATED REFRIGERATION/AIRCONDITIONING SYSTEMS: EVALUATION & DIAGNOSTICS
IRD-1
  Through lecture and hands-on exercises, this course will present a complete overview of studentsí prior knowledge and prior studies of HVAC/R electricity through schematic reading and circuit wiring for thermostats and control panels; diagnosing electrical accessories; air conditioning systems diagnosis; airside system diagnosis, integrated diagnostics.
Course Outline: Download/print this course outline
DAY 1 SUBJECT: Course Introduction and Expectations; Prior Knowledge Evaluation and Review of Prior Studies of HVAC/R Electricity
SUBJECT CONTENTS: State the instructor’s expectations and student responsibilities
Identify areas of electrical knowledge requiring further study. (Star B7)
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz
Performance-based (Hands-on live equipment)
   
DAY 2 SUBJECT: Single Phase Motor Testing and Diagnostics, including: amping-out motors; testing motor starting relays, centrifical switches and capacitors. Schematic reading and circuit wiring for contactors, switching relays and motor control.
GOAL: Measure contactor coil and contact resistances
Check appropriateness of contactor in systems
OBJECTIVES: Verify transformer output and operation. (Star B8)
Check control fuses. (StarB8)
Verify thermostat operation. (StarB8)
Diagnose contactors and switching relays.
Check all operational and safety controls (pressure controls; lube-oil protection
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz
Performance-based (Hands-on live equipment)
   
DAY 3 SUBJECT: Three Phase Motor Testing and Diagnostics, including: checking for phase balance; amping out and megging motors; motor starters/controllers and overload protectors. Schematic reading and circuit wiring for thermostats and control panels.
GOAL: Inspect motor bearings and shaft
Inspect motor wiring and insulation with megger
OBJECTIVES: Determine motor type and requirements (horsepower, voltage, type or wiring, etc.) (Star B9)
Size the motor and frame. (Star B9)
Inspect termination & Identify single phase motor terminals or leads; reterminate. (Star B9)
Test motor starting relays, and centrifugal switches.
Test capacitors.
Wire a single phase motor to a control panel.
Verify supply voltage and amp-out single phase motors.
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 4 SUBJECT: Diagnosing Electrical Accessories, Controls and Control Circuits, including: transformers; Thermostats; contactors; switching relays; pressure controls; lube-oil protection switches; and solenoid and four-way valves
GOAL: Inspect condition of breaker Perform visual inspection of and check circuit board inputs and outputs
OBJECTIVES: Meg a three phase motor. (Star B9)
Read a three phase motor wiring diagram
Verify three phase voltage and power supply (Star B8/B11).
Diagnose distribution problems, phase and current imbalance, phase loss, phase reversal, phase shift, power factor (Star B8)
Amp-out a three phse motor and check for current imbalance. (Star B11)
Diagnose motor starters and overload protectors. (Star B8)
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz
Performance-based (Hands-on live equipment)
   
DAY 5 SUBJECT: Diagnosing Electrical Condenser Fan Controls
GOAL: Perform visual/auditory inspection of the unit oil residue, frost, wear on copper tubing, damaged piping, hissing sound
OBJECTIVES: Diagnose electrical controls for condenser fans. (Star B12)
Test solenoids and valve operation for liquied line, de-icing, hot gas bypass, and four-way reversing valves, etc. (Star B11)
Verify operation of resistance heating elements (crankcase heaters, de-icing heaters, etc.)
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 6 SUBJECT: Diagnosing Solid State Controls
GOAL: Check charge based on condenser subcooling
OBJECTIVES: Determine function of board or module. (Star B10)
Set jumpers or dip switches as required. (Star B10)
Follow vendor procedures to install board. (Star B10)
Perform visual inspection of board. (Star B10)
Check inputs and outputs. (Star B10)
Program unit. (Star B10)
Replace board. (Star B10)
METHODS/
TECHNIQUES :
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 7 SUBJECT: Midterm Evaluation and Review
GOAL: Check charge based on highside and lowside pressure temperature relationships
OBJECTIVES: Pass a multiple choice exam with a minimum grad of 75% accuracy.
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
   
EVALUATION: Quiz Whitman Johnson
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 8 SUBJECT: Air Conditioning System Diagnostics: Introduction and Prior Knowledge Evaluation.
GOAL: Check charge based on evaporator superheat
Lock out and tag; isolate pressure sensitive components
OBJECTIVES: Identify types of air conditioning systems (i.e., self contained, split, built up, etc.) (Star D22)
State saturated conditions at off cycle for an R-22 system
State standard low-side design conditions for an R-22 system
State standard high-side design conditions for an R-22 system
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 9 SUBJECT: Airside System Diagnostics.
GOAL: Check ventilation system capacity
OBJECTIVES: Measure air duct openings
Calculate free area of air duct outlets
Measure air velocity
Measure and/or calculate supply/return air volume
Measure air duct static, velocity and total pressure.
Check fan/blower speed.
Check for wear condition and tension or blower belts (Star D21)
Verify matching blower belts.
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 10 SUBJECT: Air Conditioning Cooling System Diagnostics: Lowside
GOAL: Troubleshoot fans and air handling equipment Lock out and tag air handling equipment
OBJECTIVES: Check lowside operating conditions, pressure, temperature and temperature split. (Star D21)
Analyze operating conditions based on design criteria.
Diagnose variations between operating conditions and design criteria.
Analyze system charge based on lowside operating conditions.
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz
Performance-based (Hands-on live equipment)
   
DAY 11 SUBJECT: Air Conditioning Cooling System Diagnostics: Highside
GOAL: Check system capacity and charge based on psychrometrics
OBJECTIVES: Check highside operating conditions, pressure temperature and temperature split. (Star D21)
Check pressure and temperature drop across dryer. (Star D34)
Troubleshoot/install metering devices. (Star D 33)
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)
   
DAY 12 SUBJECT: Integrated Diagnostics
OBJECTIVES: Inspect indoor air quality using air snifters
Check belt tension; replace belts
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz
Performance-based (Hands-on live equipment)
   
DAY 13 SUBJECT: Final Examination and Review
GOAL: Final Exam
OBJECTIVES: Pass a multiple choice exam based on the course and UA STAR sample questions with a minimum accuracy of 75%.
METHODS/
TECHNIQUES:
Lecture, Hands-on, Lab-rooms required: Systems room, Electrical Room
RESOURCES: Customized study guide and training materials (BMMSA)
Mechanical Systems Diagnostics
UASTAR Study Guide
EVALUATION: Weekly Quiz Performance-based (Hands-on live equipment)