ITI's which provides courses for Mechanic Refrigration and Air Conditioning

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Familiarization with workshop & machineries. Safety precautions. Familiarization of refrigeration tools, instruments & equipments. Care and maintenance of tool, instruments and equipments

Introduction to trade, general safety precautions and first aids, history of Refrigeration and Air conditioning. Function, working, use, specifications of refrigeration tools, instruments and equipment. 

2

Fitting: Familiarization of tools, instruments and machines used in fitting. Marking/Layout practice as per Blue Print. Cutting, filling, drilling, grinding & Chipping by using hand tools and power tools.

Fitting: Study the different types of Fitting hand tools, power tools, precision measuring instruments & their use. Equipments used in fittings like drilling machines, grinding machines, types, specifications and care and maintenance. 

3

Fitting: Filing flat, square & curved surfaces. Slots, grooves angular profile, Drilling clear and blind hole, Threading &Tapping, Counter sinking, counter boring, drill bit grinding and reaming. Use of Hand and Power drills

Fitting: Study the function, construction, working of fitting hand tools, precision measuring instruments & their use. Specification & their application.

4

Sheet Metal: Familiarization of tools, instruments and machines used in sheet metal. Marking, measuring, cutting, bending, folding, riveting, joints, soldering in sheet metal.

Sheet metal: Study the function, construction, working, use, and application, specification of Sheet metal tools, instruments and equipment. Care and maintenance of tools.

5

Electrical: Familiarization of Electrical tools. Wire joint practice, Soldering and Brazing practice. Verification of Ohm’s law. Identification of phase and neutral of AC supply.

Electrical: Electrical terms such as AC and DC supply, Voltage, Current, Resistance, Power, Energy, Frequency etc. Safety precautions to be observed while working on electricity.

6

Construction of RL, RC and RLC circuits, measurement of electrical parameters and calculation of impedance and power factor.

Inductors and capacitors. Effects of inductor and capacitors in an AC circuit. Inductive reactance, capacitive reactance, Impedance and power factor. Lagging and leading power factors.

7

Familiarization with split phase AC motors and identification of the terminals. Identification of starting and running coil. Resistance measurements of windings.

AC motors and their types. Advantages of AC motor over DC motor. Revolving field theory. Phase splitting theory. Capacitor method and inductor method used to split the single phase.

8

Starting of capacitor start capacitor run motor through DOL starter, measurement of starting current and running current and changing of DOR.

Capacitor starts capacitor run motor working principle and construction. Starting capacitor and running capacitor Shaded pole motors, working principle and construction

9

Electronics: Identification of Electronic components and tools & instruments, colour coding of resistors, verification of ohms law, use of voltmeter, ammeter, multi meter, Practice of soldering & de soldering

Electronics: Introduction to Electronics. Basic Principles of semiconductors, Principles and application of Diodes

10

Identification of transistors, resistors, capacitors, diodes, S.C.R, U.J.T, I.Cs. used in refrigeration & AC, Full wave and bridge rectifier circuit, voltage regulators.

Rectification, Zener diode as voltage regulator – transistors parameters- CB, CE, CC, configuration, amplification. SCR

11

Multi-vibrator circuits and RC wave shaping circuits. Wiring of SCR, UJT for power control circuits, applications of OP –AMP, Applications of photo transistor

Photo diodes, photo transistors, multi – vibrator, CR & LR circuit. SCRs, UJTs, ICs.

12

Welding: Identification of gas welding equipments & accessories, setting up of---
a) AIR-LPG,
b) O2-LPG
c) O2-C2H2.

Welding: Introduction to basic principles of commonly used Welding processes, Arc welding, oxy fuel gas welding /cutting, brazing & soldering

13

Welding tools and equipment care and safety. Setting oxy-acetylene plant, lighting and adjustment of flame-simple joint on M.S.

Welding tools and equipment type specification and use. Safety method in welding. Method of gas welding, gas used and flames adjustment.

14

Basic refrigeration. Familiarization & use of general and special tools used in refrigeration work practice.

Basic Refrigeration: Study the function, working, use, specifications of refrigeration tools, instruments and equipment.

15

Identification of various Refrigeration equipments, components of vapour compression system like compressor, condenser, expansion valve and evaporator etc.

Science related to refrigeration, work, power, energy, force, Heat and Temperature, Different temperature scales, Thermometers, Units of heat, sensible heat, latent heat, super heating and sub-cooling, saturation temperature , pressure, types, units

16

Working on soft copper tubing like, cutting, bending, flaring, swaging, pinching, brazing.

Types of Refrigeration systems, Ton of Refrigeration, Study the construction and working of vapor compression cycle, low side & high side of vapour compression system.

17

Brazing of tube joints (Cu to Cu, Cu to Steel, Cu to Brass) using--
(i) Air-LPG
(ii) 02-LPG
(iii) 02-C2 H2 set up & use of the above gases with the right torches, Brazing Filler Rods

Construction and working of V.C Cycle, fundamental operations, sub cooling and super heating.

18

Refrigerator (Single Door) Familiarization of electrical and mechanical components of refrigerator.

Refrigerator ( Single Door) Function, construction ,working of single door refrigerator, specifications, trouble shooting, care and maintenance

19

Refrigerator. ( single door) Familiarization of electrical and mechanical components of single door refrigerator.

Refrigerator (Single Door) Study the construction & working of single door Refrigerator. Study the electrical components of refrigerator.

20

Testing of compressor, Identification of motor terminals, Starting of compressor without relay & starting with Relay, testing OLP and other electric safety devices. Reassembly the components & Test performance

Importance of flushing in evaporator and condenser, necessity of replacing capillary and drier. Evacuation, leak testing, gas charging method in refrigerator, Refrigerants used in Refrigerators and its properties.

21

Frost free refrigerator: Tracing Electrical circuit, checking and testing of electrical accessories like, thermostat, Timer, Defrost Heaters, Bimetal etc., checking air distribution system, servicing of refrigerator, testing of components. Test the performance of refrigerator.

Frost Free Refrigerator: Study the construction and working of Frost Free (2 or 3 door) Refrigerator parts particularly, the forced draft cooling, Air Duct circuit, temperature control in Freezer & cabinet of Refrigerator, the automatic defrost system.

22

Identify three and four door no frost refrigerators, Stripping of components. Tracing electric circuit, Installation, testing components, evacuation, leak testing, gas charging, testing, fault finding, rectifications, evacuation and gas charging.

Study the construction and its working of two and three door frost free refrigerator. Care and maintenance, installation method.

Project Work

Sem. II

Trade Practical

Trade Theory

1

Compressor: Dismantling of Hermetic compressors, Identification of components, Servicing, cutting gaskets, lapping and assembling of compressors used in refrigerators, window & split A.C, and assembling

Compressor: Function, construction, working, application of compressor like, Reciprocating, rotary, scroll type.

2

Dismantling & assembling of Hermetic compressors like, reciprocating, rotary, wobble, swash plate & scroll type compressors.

Study the construction & working of centrifugal compressor, wobble & swash plate compressor. Compressor efficiency factors, wet compression, oil, properties, lubrication methods.

3

Motors: Starting of compressor motor by RSIR, CSIR, PSC & CSR method. Check and test relay, capacitors & OLP’s, Faults and rectification, installation

Motors: Motors used in refrigeration And Air conditioning system, types, construction, working & their starting methods. Function of Starting relay, Capacitors, OLP’s.

4

Familiarization with Squirrel cage induction motor and identification of terminals.

Production of rotating magnetic field by three phase AC supply. Working principle of three phase induction motor.

5

Condenser: Familiarization with condensers used in Refrigerators, Bottle coolers, visible coolers, Deep freezer, window and Split A.C, Cleaning, Flushing and servicing of air cooled condenser, leak testing of condenser

Condenser: Function of condenser, types, Construction of air cooled condenser. Effect of chocked condenser. Advantages, de scaling of air cooled condenser.

6

De scaling of air cooled condenser

Types of air cooled condenser, application, and advantages.

7

Drier: Replacing drier & capillary tube, in refrigerator and window AC.

Drier: Function of drier, types, application and its advantage.

8

Expansion Valve: Install capillary tube, Test and adjust expansion valves.

Expansion valve: Expansion valve used in domestic refrigeration and air conditioning systems. Capillaries, Automatic and Thermostatic Ex. Valves.

9

Evaporator: Servicing of evaporators in refrigerators, bottle cooler, water coolers, window and split A.C, Installation, Leak test, remove oil from evaporator, Flushing, Defrosting.

Evaporator:  Working principle, Function, types of evaporators used in refrigerator, water coolers, bottle coolers, window and split A.C, Super heating in evaporators, Function of accumulator and types.

10

Refrigerant: Identification of refrigerant cylinders, Identification of unknown refrigerants, Recovery & Transfer of refrigerant,

Refrigerant: Classification of refrigerants, Properties, Chemical name and formulas, HFC, CFC. Ozone rule, substitute of CFC, Montreal protocol &India’s CFC/HCFC phase out schedules. Ozone rules 2000.

11

Safe handling Cylinders and Valves, Leak testing, Evacuation, Charging refrigerants in Refrigerator.

Refrigerant leak detection methods, Substitute refrigerants in lieu of CFC ARE their properties & comparison with CFCs, HFCs and HCs.

12

Retrofitting: Retrofitting of a CFC filled Domestic Refrigerator with Hydrocarbons (HC) using sealed components.

Retrofitting: Changes of components & practices while retrofitting CFC appliances with HC refrigerants. Properties of HCs

13

Thermal Insulation: Filling insulation materials in refrigeration systems.

Thermal insulation: Function, types, thermodynamic properties of heat insulation materials used in refrigeration and Air Conditioning systems

14

Window Air Conditioner: Identify the electrical and mechanical components, servicing and maintenance, trouble shooting, installation, tracing wiring circuit, evacuation, leak testing, and gas charging in window Air conditioner.

Window: Air conditioner. Their types, applications. Construction and working, care and maintenance,

15

Window air conditioner: Identify the electrical and mechanical components, servicing and maintenance, trouble shooting, installation, tracing wiring circuit, install gauge manifold in the system, evacuation, leak testing, gas charging

Window air conditioner: Study the construction and working of window A.C, Care and Routine maintenance, installation procedure

16

Split A.C: Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting in split A.C

Split A.C: Construction and working principle, types, trouble shooting & care and maintenance

17

Split A.C: (Wall Mounted) Identifying various components, electrical circuits, testing components, fault detection, install gauge manifold in the system, leak testing, evacuation, gas charging, Installation, trouble shooting.

Split A.C (Wall mounted) Construction and working principle, types, trouble shooting. Description of electrical components used in split A.C. Study the wiring circuit.

18

Split A.C: (Floor & Ceiling Mounted) Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging

Split A.C (floor & Ceiling mounted) Construction and working principle, types, trouble shooting. Description of electrical components used in split A.C. Study the wiring circuit.

19

Split A.C (Duct ): Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting

Split A.C (Duct): Study of the Duct able split AC, its Construction and working principle, types, trouble shooting.

20

Multi Split A.C: Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting.

Multi Split A.C: Study the construction and working, various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting. 

21

Car Air Conditioning: Identifying various components, electrical circuits, testing components, fault detection, install gauge manifold in the system, leak testing, evacuation, gas charging, Installation, trouble shooting, testing magnetic clutch, regular maintenance, compressor overhauling, condenser de scaling, add refrigerant.

Car Air Conditioning: Study various components, electrical circuits,

testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting, Magnetic clutch operation, free wheeling

22

Car air conditioning: Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting, testing magnetic clutch, regular maintenance.

Car air conditioning: Study various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, trouble shooting, Magnetic clutch operation, freewheeling, care and maintenance.

Project Work

Sem. III

Trade Practical

Trade Theory

1

Commercial Compressor: Dismantling of Commercial type reciprocating compressor, centrifugal compressor, checking of components & accessories. Checking & servicing valve plate and piston assembly, lapping valve plate etc. Preparing gasket, check belt tension and replacing.

Commercial Compressor: Function, types, Construction & working, applications of compressors used in commercial refrigeration. Volumetric efficiency, Capacity control, factor influencing volumetric efficiency.

2

Checking lubricating system, servicing oil pump, Checking and servicing of capacity control of the compressor

Compressor oil, types, properties, types of lubrication methods such as splash, forced feed.

3

Checking and servicing of bearing, shaft seal etc. Fitting and testing, cutting gasket, assembling of compressor, testing efficient.

Study the Construction and working principle of Centrifugal and Screw compressor. 

4

Water Cooled Condenser: Servicing of water cooled condenser & receiver. Checking leakage, Repairing and testing, De Scaling of condenser

Water Cooled Condenser: Study the water cooled Condenser, its type and capacity, construction and working, de scaling, application.

5

Servicing evaporative type condenser, checking, repairing and testing, Pump down of gas

Evaporative condenser- their function, construction and application. Liquid receiver, function. Drier, types and application.

6

Cooling Tower: Servicing of cooling tower & its, care and maintenance

Cooling Tower: Cooling tower, types, Construction, capacity, advantage & disadvantages of different types of cooling tower.

7

Servicing of water circulating pumps, dismantling, repairing and assembling.

Water Treatment: Water treatment necessary, Causes of water contamination control of scale deposit, corrosion, Slime and algae, Water softening

8

Expansion valve: Testing & Installation of thermostatic Ex. Valve. Internal & external equalizer connection, super heat adjustment in TXV

Expansion Valve: Expansion valve types and function, construction, working principle, & their advantage & disadvantages

9

Automatic EX valve fitting & checking, High side, Low side float valves checking and fixing

Selection of Ex. valves, and capillaries for various Refrigeration and Air Conditioning applications

10

Evaporator: Servicing of extended surface forced air cooled evaporators. Servicing of Water/ brine chillers, check De- Frost system, Oil removing.

Evaporator: Function, types, Plate & Tube forced air DX evaporators. Types of Defrost system .Water/ Brine chillers

11

Servicing of suction-liquid Heat exchanger

Suction-liquid Heat-exchanger, their function, construction, application & advantages

12

Water Cooler: Identify parts, Controls & accessories, electric circuit. Soldering of Cu tube on Stainless steel, trouble shooting of commonly faced problems like condenser fan failure, corrosion etc. install gauge manifold in the system, Leak testing, evacuation, Charging Refrigerant.

Water Cooler: Study the refrigeration cycle of water cooler, types, construction & working, Capacity & applications. Study the electrical and mechanical components of storage type water cooler.

13

Visible cooler and Bottle cooler

Visible cooler and Bottle cooler

14

Deep Freezer

Deep Freezer

15

Ice Cube Machine

Ice Cube Machine

16

Ice Candy Plant

Ice Candy Plant

17

Ice Plant

Ice Plant

18

Walk in cooler & reach in Cabinet

Walk in cooler & reach in Cabinet

19

Cold Storage 

Cold Storage

20

Installing compressor. Electrical wiring of the compressor and checking the wiring system of the plant

Cold storage- type construction, capacity and specification. Use of vibration eliminator and shock absorber, Study the lay out and electric wiring of the storage plant

21

Cold storage pressure testing, evacuation, charging & performance testing of the unit. Cold storage plant operation and its maintenance.

Method of pressure testing, evacuation & charging to the system and testing efficiency. Cold storage plant operation, its common trouble & remedies. Deep freezing, freezing tunnel, blast freezer its function and working, its application

Project Work

Sem. IV

Trade Practical

Trade Theory

1

Psychrometry: Find DBT, WBT, RH & other properties by using psychometric chart. Use of psycho meter.

Fundamentals of Central Air Conditioning, requirements of comfort A.C, study of psychometric terms, DBT, WBT, RH, enthalpy, dew point, and specific humidity.

2

Use of Anemometers for measuring Air flow, use of monometers, measuring air flow, pivot tube for air flow measurement.

Types of Central air conditioning (Direct and indirect system) Construction, working, components, faults, care and maintenance

3

Servicing of Fans & blowers, motors, used in Air conditioning system

Description of blowers& fans, function and types, static and velocity pressure measurements

4

Duct: Installation of ducts, construction of ducts, understanding Duct lay out drawings, selection of ducts, and insulation in ducts. Longitudinal and transverse joints

Duct: Function, types, materials, duct designing, duct insulation, air distribution methods, air flow, AHU, fan, blower.

5

Air Filters: Servicing and maintenance of different filters, Installation of filter

Air Filters: Function of air filters, types, construction, maintenance, effect of chocked Air filter

6

Split A.C (Duct)

Split A.C (Duct)

7

Multi Split A.C (Duct)

Multi Split A.C (Duct)

8

Package A.C.: Identifying various components, electrical circuits, testing components, fault detection, install gauge manifold in the system, leak testing, evacuation, gas charging, Installation, Trouble shooting.

Package A.C.: Study Package AC, types, construction and working principle, trouble shooting, and various applications. Duct system, AHU.

9

Identifying various components, electrical circuits, testing components, fault detection, install gauge manifold in the system, leak testing, evacuation, gas charging, Installation, Trouble shooting.

Care and maintenance, installation method, capacity calculation.

10

Split Package: Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Installation, Trouble shooting.

Split Package: Construction and working principle, types, Study various electrical and mechanical components, trouble shooting

11

Centralised/industrial Air-conditioning. Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging, Trouble shooting, Servicing AHU.

Centralised/industrial Air conditioning. Construction and working principle, types, maintenance of Industrial Air conditioning plant

12

Pump down of gas, add oil to compressor, add gas in the system, trouble shoot and repair air conditioner. Check temperature and pressure controls.

Temperature and pressure controls used in AC plant, its construction, working, safety devices, cooling towers, chilled piping lines

13

Direct Ex. System: Identifying various components, electrical circuits, testing components, fault detection, leak testing, evacuation, gas charging

Direct Ex. System: Understanding Direct expansion system. Operation & Preventive Maintenance Schedule of central AC plant.

14

Check and test VRF system

Details of VRF system.

15

Indirect/Chiller System: Identifying various components, electrical circuits, testing components, fault detection, install gauge manifold in the system, leak testing, evacuation, gas charging, Installation, Trouble shooting.

Indirect/Chiller System: Understanding central station AHU and FCU, Air washers used in chilled water system, understanding lay out, modulating valves for temperature control. Expansion tanks.

16

Chilled water piping and insulation. Servicing of FCU and water controls valves.

Study of Humidification & De-humidification

17

Servicing and trouble shooting of direct, indirect A.C Plant, erection of commercial type condensing unit, vibration eliminator, water proofing insulation.

Construction and study of commercial A.C plant, package chiller, screw chiller, reciprocating chiller.

18

Check controls used in Packaged AC systems, trouble shooting

Controls used in AC system, Electromechanical, pneumatic and electronic.

19

Installing compressor and other components, electrical wiring in central AC and checking HVAC

Introduction to heat load calculation in AC building. Sensible & latent heat load. Basic of HVAC and its applications

20

Automobile AC (car): Repair and maintenance of Car AC system, servicing, testing magnetic clutch operation, compressor overhauling, leak testing, evacuation, gas charging, oil charging. Testing wiring system

Automobile AC: Study the refrigeration cycle in automobile AC, its Construction, working of car AC, Magnetic clutch operation, freewheeling

21

Repair and maintenance of car AC system, servicing, testing magnetic clutch, leak testing, evacuation, gas charging, check air flow, measure temperature and pressure. Check solenoid valve

Construction & working of car AC, Magnetic clutch operation, frees wheeling. Effects of speed of engine. Trouble shooting in car A.C.

22

Studying / Execution of Repair and Preventive maintenance of different Commercial units at site

Planning for Preventive maintenance and scheduling of maintenance activities in large AC and Refrigeration plant