TRAINING PROGRAM

FOR GOTEVOT TRAINERS

Air Conditioning and Refrigeration

Module Title:

INSTALLING PACU/CRE COMPONENTS

Technical General
Education and Organization of
Skills Technical
Development Education and
Authority Vocational
Training
 TABLE OF CONTENTS

Overview (PACU)........................................................................................................1

Read the items carefully and answer each question correctly. Write only the letter

on the space provided.................................................................................................7

Overview (CRE)..........................................................................................................9

Read the items carefully and answer each question correctly. Write only the letter

on the space provided...............................................................................................23

Surveying/Selecting an Area for Installation.............................................................25

Prepare for Installation of PACU...............................................................................28

Guidelines to be Considered in Installing PACU/CRE..............................................34

Installation of PACU..................................................................................................35

Test Run PACU/CRE System...................................................................................37

 Information Sheet 1

Overview (PACU)

I. Introduction

This system is commonly found in the residential and commercial applications. The basic
design of the unit makes it adaptable to many installation applications. The unit is self-
contained with all of its parts in a single housing, supply and return air duct connections are
provided on the front of the unit. Warm return air from the conditioned space is usually
drawn through the evaporator coil, cooled and then discharged back into the conditioned
space. Condenser air is usually drawn through the sides of the unit and then discharged
through the condenser coil by means of a propeller-type fan. The arrangement also allows
for cooling of the compressor as outside air passes over the compressor before being
discharged through the condenser coil.

A control box located within the system

contains all of the electrical components
like relays, capacitors, contactors – all of
which are pre-wired at the factory. The
installer simply needs to wire line voltage to
the system and install a remote thermostat.

Cooling capacity of packaged system

usually range from 2.5 tons to 50 tons.
Refrigerant 22 is the most commonly used
refrigerant in the system. Lower capacity
units use a capillary tube as metering
device while higher capacity units use a Figure 1. Typical packaged system installation.
thermostatic expansion valve. Courtesy Inter-City Products (U.S.A.)

The simplicity of the packaged

system requires a minimum amount
of field-installed plumbing, wiring
and duct work. The unit can be
installed in an attic with duct work
delivering the cool air to conditioned
space below. It can be installed on
concrete slab and connected to an
existing warm air heating duct or in
a basement or crawl space. Another
application of the packaged system
is in mobile home air-conditioning
systems.
Figure 2. Self-contained packaged air conditioner.
Courtesy Lennox Industries, Inc., Worldwide manufacturer
of comfort equipment.

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 Information Sheet 1
Split systems – is one in which the evaporator or air handling unit is installed separately
from the condensing unit. The condensing unit may be installed on the ground adjacent to
the conditioned space or on the roof of the structure. The evaporator may be installed in the
plenum or supply duct of an existing heating system in an attic or crawl space, or on the
roof, depending upon the installation requirements. The condensing unit and evaporator are
connected to each other by means of field-installed piping or precharged tubing kits.

Figure 3. Typical split system installation.

II. Components of Package-Type System

A. Outdoor Unit

The condensing unit consists of the

compressor, condenser coil, condenser fan
and motor and related electrical controls.

The case construction of the

condensing unit varies with each
manufacturer. Most units are made of
steel, rustproofed and painted with
weatherproof enamel. The use of plastics
has become increasingly popular in the
construction of condensing unit cases. In
most cases, the condensing unit case is
divided into compartments – one for
compressor, one for condenser coil and
fan and one for electrical control of the
system. Figure 4. Condensing unit of a residential air-
conditioner Courtesy Lennox Industries, Inc.

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 Information Sheet 1
1. Compressor – a fully hermetic compressor is usually in residential applications. In larger
commercial application, a semi-hermetic compressor is used. It utilizes R-22 as the
refrigerant. The compressor motor windings are cooled by the returning suction vapor,
which passes over and around motor windings. Compressor lubrication is provided
internally by the splash method. Some larger-capacity uses an oil pump to ensure
positive lubrication.

The permanent split capacitor motor is the most common compressor motor used in
residential and light commercial application. In dome applications where a high starting
torque is required, a hard kit consisting of starting capacitor is used. For overload
protection a bimetallic internal line break overload protection and a pilot duty internal
overload protector are used.

2. Condenser

II.1 Condenser coil – is usually manufactured of copper or steel tubing with attached
aluminum fins, which increase the area of heat transfer. The design of the coil
allows the ambient air to be drawn through the condenser coil the discharged
vertically or horizontally.

The amount of the maintenance required on condenser coils is minimal; keep the
coil and fin surfaces clean and straight to prevent excessive discharge pressure.

2.2 Condenser fan and motor – is usually of an axial or propeller design. It may be
installed in a vertical or horizontal position depending upon condenser design. The
condenser fan motor is usually a permanent split capacitor motor. In some
applications the motor may be a two-speed unit. A thermostatic control will allow the
motor to operate at a low speed when the ambient temperature is low. As the
ambient temperature increases and more condenser air is required the motor will
operate at a higher speed. This motor is permanently lubricated and requires no
maintenance, just keep the blades clean.

B. Indoor Unit

1. Evaporators – coils of evaporator are available in variety of designs that will fit any
installations. They are constructed of copper or aluminum tubing with attached aluminum
fins, which increase the area of heat transfer. Depending upon the design of the system,
air may be drawn through or blown through coil. Condensate water is collected in a tray
at the base of the coil and drained by gravity.

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 Information Sheet 1
1.1. “A” coil – is designed to be used in up-flow or
down-flow furnace installation. The shape of
the coil as shown in figure 5 permits the
furnace plenum to house greater coil areas.
Refrigerant flow is metered into the coil by
capillary tubes manifold off of the liquid line
and feeding both sides of the coil. Two, four
or more capillary tubes may be utilized,
depending upon the size of the coil. Coil
outlets are attached to a suction header that
directs the flow of refrigerant vapor into the
Figure 5. “A” coil evaporator.
suction line.
Courtesy Carrier Corp.
1.2 Slant coil – which is illustrated in figure 6 is
used in small capacity installations where
large coil surface is not required. Basically
the slant coil is half of an “A” coil and is
used in up-flow or down-flow air movement
applications. In some installations where
the plenum height of the furnace is
restricted, the slant coil may be used on a
horizontal duct system.
Figure 6. Slant coil.
Courtesy Carrier Corp.
1.3 Horizontal coil – is used in
horizontal flow, warm air furnace
applications. These units are also
equipped with their own housing
and, in conjunction with a blower
module, form an air handling
system designed for separate air
delivery system. A horizontal coil is
illustrated in figure 7.

Figure 7. Horizontal-type evaporator coil.

Courtesy Carrier Corp.

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 Information Sheet 1
2. Metering Devices

2.1 Capillary tube – most residential

and light commercial air-
conditioning systems utilize the
capillary tube as a metering
device. It is maintenance-free
and economical. And allows
system pressure to equalize
when the compressor cycles off
allowing a low starting torque
motor. Figure 8a shows several
capillary tubes are manifolded off
of the liquid line to provide an
equal distribution of refrigerant to Figure 8a.
all of the coil circuits.

Figure 8b Refrigerant distributor. a-Courtesy of

Sporian Valve Company, b-Courtesy Alco Controls.

Evaporator airflow – The comfort level of a conditioned space can be achieved or

materialized if the volume of circulating air is balanced properly. But this thing is not
always the case in all installations. In order to rectify the problem, two ways are to be
considered to change the airflow across the evaporator are:

a. use multi-speed evaporator fan motor

b. adjust pitch of blower motor pulley.

In air-conditioning applications the average capacities for evaporator airflow are

based on 350 to 400 cubic feet per minute (cfm) across the evaporator coil per ton
refrigeration capacity. For example 2 ton refrigerating capacity will require 800 cfm.

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 Information Sheet 1
When an air flow moves freely across the evaporator coil, the temperature difference
between the supply and return air should be observed.

a. low temperature range of 15ºF (-9.4ºC to -6.67ºC) to 20ºF

b. medium temperature range of 20ºF to 22ºF (-1.67ºC to -5.55ºC)
c. High temperature range from 22ºF to 25ºF (-5.55ºC to -3.89ºC).

During the operation see to it that all openings of air (dampers) are widely open and
evaporator air filter is cleaned. The system is already operating at least twenty-four hours
in order that the temperature and press stabilizes before taking temperature and
pressure readings.

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 Self-Check 1

Read the items carefully and answer each question

correctly. Write only the letter on the space
provided.

_____ 1. When all parts of the system are in one single housing, the system is said to be

a. split system
b. self-contained system
c. package system
d. remote system

_____ 2. The cooling capacity of package system usually range from

a. 1.0 to 2.0 tons

b. 25 tons to 50 tons
c. 3.0 to 4.0 tons
d. 50 tons only

_____ 3. The components of condensing unit are

a. compressor
b. condenser coil
c. condenser fan and motor controls
d. all of the above

_____ 4. An evaporator design to be use din up-flow or down-flow furnace installation

a. “A” coil
b. slant coil
c. horizontal coil
d. b and c

_____ 5. Controls the flow of refrigerant into the evaporator

a. metering device
b. condenser
c. evaporator coil
d. liquid valve

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 Answer Key 1

Answer key to Self-Check 1

1. b

2. b

3. d

4. a

5. a

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 Information Sheet 2

OVERVIEW (CRE)

I. Introduction

Commercial refrigeration represents the broadest scope of refrigeration industry along

with the widest variations in storage boxes, hardware, piping and electrical systems. The
application of commercial refrigeration equipment can range from the storage of perishable
merchandize to the temperature control of manufacturing processes involving non-
perishable items. In general, the size, design and installation of the commercial equipment is
dependent upon the particular application for which it will be used and the individual needs
of the user.

II. Indoor Unit – Types, Function/Operation

1. Commercial cabinets – a wide variety of cabinet designs are available to meet the
needs of the individual user. To promote easy maintenance, the finishes of commercial
cabinets are designed for easy cleaning.

a. Porcelain and stainless steel cabinets are widely used.

b. Plastic liners are commonly used for the interior construction.
c. Urethane or polysterene are used in cabinet insulation. It is installed in pieces or
foamed into place.
d. Mullion heaters are installed in cabinets to prevent condensation.
e. Magnetic vinyl door gaskets are commonly used to provide heat seal against leakage
or infiltration for heavy usage door systems.

2. Display cases – are used for displaying and storing perishable merchandize and may
be an open or closed design.

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 Information Sheet 2
1. Open display case - (Figure 1) is among the
most popular cabinet design today.
Merchandize stored in an open case is
refrigerated by means of cold blanket of
conditioned air. The evaporator of the design is
located at the bottom of the fixture and a fan
circulates the conditioned air. Moisture
condensed from warm air is removed from the
case through the drain. One of the primary
problems with open display cases is in
providing the additional refrigeration necessary
to meet the high losses of conditioned air that
result when top layer of cool circulating air
within the refrigerated cabinet comes into
contact with the warm air above it. This results
in an additional heat gain for the refrigeration
system of the display case that requires
additional refrigerant capacity to compensate
for the loss. Figure 1. Open display case.
Not only must the warm air be reduced to the cabinet temperature, but the
condensed moisture from the air must also be removed. For these reasons open
display cases must not be placed or located away from all external air sources, such
as fans, entryway, air ducts and other similar sources of external air movement.

2. Closed display case – or reach-in

cases store perishable merchandize
such as dairy products, soda, beer,
wine and other food products. It may
have a single or multiple door design.
In most applications, closed display
cases have self-contained condensing
units. A forced convection evaporator
is usually located on the top or rear
wall of the cabinet.

Figure 2. Closed display case.

Courtesy Hill Refrigeration

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 Information Sheet 2
a. Double-duty display case – has two refrigerated storage cabinets. The upper
compartment is used for display purposes and the lower cabinet, usually located
at the rear of the fixture, is used to store merchandize not yet ready for display.
The evaporator coil is located at the bottom of the fixture and the conditioned air is
circulated throughout the cabinet by means of a fan.

b. Floral cabinet – The size, type and design

vary with individual applications. It is
designed with glass areas for displaying
the merchandize it contains. Because
humidity is the prime concern in most
applications, large gravity evaporation
coils are installed across the top of the
fixture to prevent the store merchandize
from drying out. It is usually maintained at
a storage temperature of 40ºF (4.4ºC) to
55Fº (12.7ºC).

Figure 3. Floral cabinet

c. Frozen-food display case – can either be opened or closed in design. The open
type case is more suitable for marketing the stored merchandize because the
merchandize is openly displayed and the customer has easy access to the
product desired. The disadvantage of an open case is that the lower storage
temperature induces a greater infiltration of warm air, resulting to a higher
refrigeration load requirement. Open or closed frozen-food display cases may
have plate or blower evaporator coils and their condensing units may be self-
contained or remotely located. The maintained temperature may be 0ºF (17.7ºC)
or lower.

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 Information Sheet 2

Figure 4. An upright frozen-foods display case. Note, especially, the fans and airflow pattern.
(Courtesy Kysor/Warren Division of Kysor Industrial Co.)

d. Walk-in unit – is used primarily for the

short or long-term storage of perishable Figure 5. Walk-in refrigerator.
merchandize in applications such as (Courtesy Bally Engineered Structures,
restaurants, meat and vegetable markets, Inc.)
grocery stores and taverns. While older
walk-ins were constructed of hardwood
walls and floors, modern walk-ins are
constructed of metal walls and hardwood
floors. Its wall insulation is in the form of
polyurethane that is pumped, under
pressure, between the outer and inner
wall lining. The condensing unit may be
installed on top or along the side of the
cabinet, or it may be remotely installed
outdoor. The door systems are light in

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 Information Sheet 2
weight and magnetic gaskets are
commonly used to seal the door providing
a positive seal against heat leakage. An
interior light is operated by a switch
located outside the refrigerated cabinet. In
many applications, the fan cycles off to
prevent warm air from circulating inside
the box when the user turns on the light
and enters the cabinet. An indicator light
installed in the light switch will alert the
user that the interior light is on and that
the fan is off.

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 Information Sheet 2
II. Commercial Condensing Unit – The condensing unit in commercial installation will vary
according to the application.

1. Most applications utilize air-cooled condensers because of their easy maintenance and
reduced operating costs. It may be located indoors or outdoors and it ranges from small
fractional horsepower to large high horsepower condensing units with several hundred
tons of refrigeration capacity. It can be installed in self-contained refrigeration cabinets,
remote from the refrigerated space usually in the equipment room or on the roof of the
building.

2. Compressors

A Single-stage compressor – it is a
common practice in commercial
refrigeration applications to
operate several evaporators with
one compressor.

Figure 6. Single compressor with multiple evaporator

units.

B. Two-stage compression system –

a two-stage compression system
also known as a compound
system can be accomplished
through one of two methods:

1. The use of two compressors

with refrigerant discharge of
one compressor pumping into
the suction line of the second
compressor.
Figure 7. Compound system using two compressors.

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 Information Sheet 2
2. The use of one compressor with multiple cylinders. The suction vapor of this type
from the evaporator enters the four low-stage cylinders of a two-stage
compressor. The hot discharge vapor leaving the first stage cylinders is cooled by
a de-superheating expansion valve before it enters the compressor and the
second stage cylinders where it will be compressed and discharged into the
condenser.

Figure 8. Schematic two-stage system. Courtesy Copeland Corporation.

3. Expansion valves – Generally the

temperature control of each fixture
(or evaporator/cabinets) is
achieved by means of thermostat
that controls the opening and
closing of a solenoid valve installed
in the liquid line of the controlled
evaporator or by means of an
evaporator pressure regulator
valve installed in the suction line of
the controlled evaporator.
Whenever two or more vapors of
dissimilar pressures are throttled
so that they will enter the
compressor at a common pressure
(equal to that of the evaporator
with a lowest temperature), an
increase of superheat is
experienced that, in turn will
increase the work requirement of
the compressor.
Figure 9a. Single compressor with multiple
evaporator units.

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 Information Sheet 2

Figure 9b. Schematic refrigerant piping diagram. Courtesy Copeland Corporation.

Figure 9c. Installation of solenoid valves. The solenoid controls the cabinet temperature of the cabinet.
Valves and thermostats are using line voltages. Courtesy ALCO Controls.

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 Information Sheet 2
4. Refrigeration system accessories – in all cases the fundamental principles behind
the operation of refrigeration system are unchanged whether the system is small
or large, domestic or commercial, high-pressure or low-pressure. In order to
create a system that operates at maximum efficiency is a specific situation,
accessories must be added to the basic components of a refrigeration system.
Safety, convenience, and improved endurance are also considerations for the
installation of system accessories.

a. Liquid receiver - the purpose is to

store the liquid refrigerant until it is
needed by the system. The
receiver stores refrigerant while the
system is under service or repair. It
should be sized-up to hold the 85%
full charge of a system. This will
allow for the thermal expansion of
the refrigerant. Receivers are
designed in vertical or horizontal
position as shown in figure 10. The
outlet pipe of the receiver must
extend below the level of the liquid
contained within act as a liquid
seal to prevent vapor from entering
the liquid line. Gauge glasses are Figure 10a Vertical receiver. Courtesy
installed in the receiver to Refrigeration Research.
determine liquid level in the
receiver. It is also equipped with
inlet and outlet valves to isolate
receiver from the heat of the
system. For safety precautions, it is
equipped with pressure relief
devices, such as fusible plug to
receive excessive refrigerant Figure 10b. Horizontal receiver. Photo
by Bill Johnson.
pressure.

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 Information Sheet 2
b. Sight glasses – the purpose of
installing it is to determine the
condition of the liquid refrigerant in
the liquid line. Under normal
operation, the sight glass should
show a solid vapor-free column of
liquid refrigerant leaving the
receiver and entering the metering
device. The presence of bubbles in
the sight glass indicates the
presence of flash gas in the liquid
line, while the most common cause
is shortage of refrigerant. Other
possible causes, such as low
discharge pressure and undersized Figure 11. Sight glasses with flared or
liquid line should not be overlooked. soldered fittings.
Courtesy Virginia KMP Corp.
If the sight glass is located after the liquid line, and the filter drier becomes
restricted, bubbles may also appear in the sight glass. It is also equipped with
moisture indicator which will indicate a presence of moisture through chemical
reaction in the indicator creating a color change to indicate the system is wet.
At least eight (8) hours of running time should be allowed before the moisture
indicator can give an accurate reading.

c. Vibration Eliminators – are

installed in the compressor
suction and discharge lines to
prevent the transmission of
noise and vibration from the
compressor to the remainder
of the system or building
structure. On small system
where soft copper tubing is
used, vibration may be Figure 12. Flexible hose vibration eliminator.
adequately controlled by Courtesy Superior Valve Co., Div. Amcast
forming a coil or loop in the Industrial Corp.
suction line before it is
connected to the compressor,
or in the discharge line before
the condenser. A flexible
metallic hose vibration
eliminator is employed in
application where rigid tubing
is used. In installing it, it should
have the same inside diameter
with the tubing.

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 Information Sheet 2
d. Oil Separators. During normal
system operations a percentage
of oil leaves the compressor and
circulates the system. In a
properly designed system, the
amount of oil that leaves from
the compressor is equal to the
amount of oil that returns to the
compressor. As a result, proper
oil level in lubrication is
maintained in the compressor.
In the system where oil returns
is not adequate, an oil separator
may be installed to maintain
proper oil level in the
compressor. Other application
where oil separator may be
needed include:
 Low-temperature systems
 Flooded evaporators
Figure. 13. Oil separator operation.
 System utilizing capacity
control
 System that have lower suction or discharge line reserve
 System utilizing a refrigerant that does not mix well with oil

e. Mufflers – are installed in the

discharge line of a system to reduce
the resonant noise created from the
reciprocating action of the
compression pistons. Mufflers are
especially helpful when the discharge
line is of considerable length,
resulting in a maximum noise level. In
this case, the muffler should be
installed in the discharge line as
close to the compressor as the
installation will permit. It serves as an
expansion discharge gas, thereby
minimizing the transmission of hot
gas pulsation. In all applications, it is
recommended that the discharge Figure. 14. Hot gas muffler.
muffler is installed in a horizontal Courtesy Tecumseh Products Company.
position.
If it is installed in a vertical position and oil pick up tube must be installed at the
base of the muffler to reinject any oil that have accumulated in the muffler shell
into the system.

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 Information Sheet 2
f. Check Valve – its function is to
allow refrigerant flow in one
direction. The check valve remains
open while the refrigerant flows in
normal direction. If the refrigerant
attempts to reverse its flow, the
valve will close. Spring loading of
the valve prevents any noise or
chattering created by the propulsion
of refrigerant gas from the
compressor discharge valves. In all
application, it is important to refer to
the manufacturer’s installation
specifications to ensure the proper
mounting and directional flow. Figure 15. Check valve.
Courtesy Superior Valve Co., Division of
AMCAST Industrial Corporation.

g. Solenoid Valves - there are

installed in refrigeration and air-
conditioning system to control the
flow of refrigerant in a circuit or to
isolate components from the rest
of the system. The valve is
controlled electrically and will
open or close in response to an
electrical switch such as
thermostat.

Figure 16 Solenoid valve.

Courtesy Sporlan Valve Company.

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 Information Sheet 2
h. Strainers – are installed in
refrigeration and air-conditioning
system to trap foreign matters such
as scale, metal chips, and dust to
prevent it from entering the sealed
system and causing damage to
compressor as restriction of the
system components, such as
metering devices, solenoid valves
and pressure control valves. Many
systems are already equipped with
factory-installed strainer. If the
system component is not equipped
with a strainer an inline strainer
should be installed upstream of the
component. (Figure 17)

Figure 17A and B. Strainers for large

equipment. Courtesy Henry Valve Co.

i. Filter Drier – is installed on the

high side of the system at the
outlet of the condenser. The
purpose of a filter drier is to filter
any particles that could restrict
the capillary tube and trap
moisture. Same filter driers are
equipped with service ports so
that the access to the high side
of the system may be gained. A
filter drier should be replaced
whenever the sealed system is
opened. In installing of filter Figure 18. Graduated drier.
drier, make sure that the Courtesy Refrigeration Research Inc.
direction of the flow is proper as
indicated by an arrow inscribed
on the filter drier’s body.

j. Low-pressure control – is Figure. 19. Typical low-pressure control. Courtesy

used as a temperature control Johnson Controls, Inc.
device. The saturated
temperature of the refrigerant
in the evaporator is governed

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 Information Sheet 2
by the pressure at which it is
maintained. Changes in the
suction pressure will reflect
changes in the temperature of
the evaporator. The low
pressure control is activated
by changes in the suction
pressure and is utilized to
control the temperature of the
conditioned space by
indirectly controlling the
temperature of the
evaporator.

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 Self-Check 2

Read the items carefully and answer each question

correctly. Write only the letter on the space
provided.

_____ 1. Which of the following is used for displaying and storing perishable merchandize
and may be an open or closed design?

a. closed display case

b. display cases
c. double-duty display case
d. open display case

_____ 2. Which reach-in case stores perishable merchandize such as dairy products, soda,
beer, wine and other products?

a. closed display case

b. display cases
c. double-duty display case
d. floral cabinet

_____ 3. What is the maintaining storage temperature of floral cabinet?

a. 40ºF to 55ºF
b. 45ºF to 60ºF
c. 50ºF to 60ºF
d. 60ºF to 70ºF

_____ 4. Which in commercial application controls the opening and closing operation of the
solenoid valve?

a. expansion valve
b. thermostatic expansion valve
c. thermostat
d. relay

_____ 5. Which of the following stores the liquid refrigerant while the system is under
service or repair?

a. expansion valve
b. liquid receiver
c. thermostat
d. relay

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 Answer Key 2

Answer key to Self-Check 2

1. b

2. a

3. a

4. c

5. b

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 Information Sheet 3

Surveying/Selecting an Area for Installation

In surveying/selecting an area for installation, the following should be avoided to prevent

damage or harmful effect to the unit.

 Greasy areas (e.g. areas near a machine

 Salty areas (e.g. places/areas near the coast
 Area where sulfuric gas is present (e.g. hot areas)
 Areas near flammable gas (e.g. LPG)

The following are general rules which need to be considered in installing PACU/CRE
components.

a. It is important that the selection of location where the unit will be placed suits the
customer’s needs.

b. Install the unit in an area with good ventilation. Any obstacles affecting the airflow
near the air inlet and the air outlet will cause blockage to the airflow

c. Install the unit away from heat or vapor

d. Install the unit in an area away from television and audio units, cordless phones,
fluorescent lighting fixtures and other electrical appliances (at least 1 meter
clearance). This is to eliminate or reduce interference to other unit generated by the
motors running from air-conditioner.

e. Install the unit in an area that provides easy drainage for condensate.

f. Install the unit in an area not exposed to the rain or direct to sunlight (install a
separate sunblind if exposed to direct sunlight.

g. Fix the unit firmly if it is mounted in a high place. See to it that the area would be able
to endure the vibration from the unit.

h. Install the unit where it will not cause neighbors to suffer hot wind and noise
generated by the unit.

i. Install the unit where power source conform to the unit’s power requirement.

j. Install the unit to a place where free movement for servicing warrants.

k. Proximity of outdoor unit to indoor unit.

l. Follow local codes.

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 Self-Check 3

Test what you have learned about the

selection/survey of site for installation of
PACU/CRE

Direction: Read the question carefully. Write the letter of the best answer on the space
provided.

_____ 1. What is the most important thing to consider when selecting an area for
installation of PACU/CRE?

a. select and area that allow good drainage for condensate

b. select an area that is on a high place
c. select an area away from heat
d. select an area that bet suit to the needs of the clients

_____ 2. Why do we have to consider the proximity of outdoor unit to indoor unit?

a. to avoid pressure drop on the system

b. to have more tolerance in the installation
c. to have better design for installation
d. to allow better air circulation for the unit

_____ 3. Why is there a need to fix the indoor and outdoor unit of PACU/CRE in a high
place?

a. so that it would not fall

b. so that it would not collapse
c. so that it would endure vibration
d. none of the above

_____ 4. Why would you avid placing the outdoor unit near your neighbor?

a. to allow better circulation

b. to prevent the unit from blowing hot air on your neighbors
c. to allow better servicing
d. to have better drainage

_____ 5. Why should you prepare a location free from heat of the sunlight?

a. heat from the sunlight will be additional load for the system
b. to allow better circulation
c. to have better heat transfer
d. to have better drainage

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 Answer Key 3

Answer key to Self-Check 3

1. c

2. a

3. c

4. b

5. a

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 Information Sheet 4

Prepare for Installation of PACU

The mechanical or refrigeration part of the air-conditioning system is included either a

package or split system.

A. Package system – Package or self-contained equipment in which all components are

located in one cabinet or housing. The window-type air-conditioner is a small package
unit. Larger package system may provide 100 tons of air-conditioning capacity.

The package unit is available in several

different configurations for different
applications. Common configuration
includes:

1. An air-to-air application – is similar

to a window air-conditioner except
that it has two motors. This is the
most common type of package unit.
The term air-to-air is used because
the refrigeration unit absorbs its
heat from the air and rejects it into
Figure 1. Air-to-air package unit.
the air. See Figure 1.

2. Figure 2 shows an air-to-water-unit.

This system absorbs heat of the air
in the conditioned space and rejects
the heat into the water. The water is
wasted or passed through a cooling
tower to reject the heat to the
atmosphere.

Figure 2. Air-to-water-unit

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 Information Sheet 4
3. Water-to-water equipment (Figure 3)
has two water heat exchangers and
is used in large commercial
systems.

Figure 3. Water-to-water package unit.

This water is cooled and then

circulated through the building to
absorb heat (Figure 4). This system
uses two pumps and two water
circuits in addition to the fans to
circulate the air in the conditioned
space. To properly maintain this
system, you need to understand
how to service pumps and water
circuits.

Figure 4. The total water-to-water system must

have two pumps to move the water in addition to
the fans required to cool the water.

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 Information Sheet 4
4. Water-to-air equipment (Figure 5)
absorbs heat from the circulating
water circuit and rejects the heat
directly into the air. This equipment
is used for large commercial
system.

Figure 5. Water-to-air package unit.

The air-to-air system installation

requires that the unit be positioned
on a firm foundation. The unit may
be furnished with a roof curb for the
rooftop installation. The foundation
for another type of installation may
be located outside on the ground
next to the conditioned space.
Outside pads may be constructed of
a high-impact plastic, concrete or
metal. See Figure 6.

Figure 6. Rubber and cork pads may be placed

under a unit to reduce vibration.

B. Split Systems.

In split system air-conditioning equipment installations, the condenser is in different

location from the evaporator. It can be treated as two separate installation procedures.

1. Evaporator Section – The evaporator is

normally located closed to the fan
section regardless of whether the fan is
in furnace or in a special air handler or
blower. The air handler (fan section)
and coil must be located on a solid
base or suspended from a strong
support. Upflow and downflow
equipment has a fireproof, rigid base
for the air handler to rest on. When the
unit is installed horizontally, it may rest
on the ceiling joists in an attic or on a Figure 7. Air handler located in an attic crawl
space.
foundation of blocks or concrete in a
crawl space. (See Figure 7).

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 Information Sheet 4
2. Condensing Unit – The condensing unit location is remote from the evaporator. The
following must be considered carefully when installing the condensing unit.

a. Proper air circulation – the unit must have adequate air circulation. The air
discharge from the condenser may be from the side or from the top. Discharge air
must not hit any object and circulate back through the condenser or it will cause
high head pressure and poor operating efficiency.

b. Electrical and piping considerations – the refrigerant piping and electrical service
must be connected to the condensing unit. Before positioning the unit, it is a must
to study the electrical and piping line connection and make them as short as
practical, leaving adequate room for service.

c. Service accessibility – unit can make the difference between good service and
barely adequate service. Care should be taken to provide both visual and physical
access to all system components.

d. Proper drainage or rainwater and ground water – The natural drainage of the
groundwater and rainwater or roofwater should be considered in unit placement.

Caution: The unit should not be located in a low place where groundwater will rise to
the unit. This may short the controls to the ground and the wiring will be harmed.

e. Solar influence – If possible, position the condensing unit on the shady side of the
house to help cool the unit.

f. Appearance – The condensing unit should be located in an unobstructed location

where it will not make objectionable noise. It should be located at the end of the
house where there are no bedrooms.

Guidelines in Preparation for Installation of PACU

1. Before installing a system, a thorough inspection of the installation site should be

conducted to confirm where the outdoor unit and the indoor unit should be placed, how
the tubing, the electrical and the drain line should be run.

2. Review the manufacturer’s specification and installation guide to ensure that the
installation will conform to the recommended procedures and local codes.

3. Check the equipment and make sure that all components of the system are properly
matched for the application.

4. Do not remove any of the protective caps from the tubing couplers until the tubing is
ready for final installation.

5. Unpack the equipment at the job site to reduce the possibility of damage from excessive handling once uncrated,
check all components for possible damage.

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 Self-Check 4

Essay Type: Explain briefly the following questions.

1. Why do we have to conduct a thorough inspection of the installation site in preparation of

PACU/CRE installation?

_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

2. Why is there a need to keep the caps of tubing couplers before its installation?

_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

3. Why do we have to review manufacturing specification and installation guide?

_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

4. Why do we have to consider service accessibility in installing PACU?

_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

5. What is the reason why an outdoor unit should be installed in a shady place?

_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

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 Answer Key 4

Answer key to Self-Check 4

1. To confirm where the outdoor unit should be placed, the tubing, the electrical and
where the drain line should be run.

2. To make sure that tubing are free from moisture and contaminants.

3. To ensure that the installation will conform to the recommended procedures and
local codes.

4. To provide both visual and physical access to system components.

5. To prevent high head pressure and poor operating efficiency of the unit. Shade
area help cool the unit.

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 Information Sheet 5

Guidelines to be Considered in Installing PACU/CRE

A. Outdoor Unit – The secondary unit should be installed outdoors as close as possible to
the evaporation and electrical power source, keeping in mind the desires of the
customer, installation requirements and local codes. Consider the following factors:

1. The unit should be located in an area that is not subject to direct sunlight.

2. There should be enough space between the unit and any adjacent walls or
overhangs to ensure proper condenser airflow and avoid restrictions or short
circuiting.

3. The unit should be mounted on a sturdy base at least four to six inches above the
ground. To prevent the possible transmission of vibration noise, the base should not
be in contact with the building foundation.

4. The unit should be positioned to facilitate access to service panels and the easy
installation of refrigerant and electrical lines.

B. Indoor Unit – The following factors are to be considered in installing indoor unit:

1. There should not be any heat source or steam near the unit.

2. There should not be any obstacles blocking the air circulation.

3. A place where air circulation in the room is good.

4. A place where drainage can be easily done.

5. A place where noise prevention is taken into consideration.

6. Do not install the unit near the doorway.

7. There should be enough spaces from the wall, ceiling or other obstacles.

8. Indoor unit of the room air conditioner shall be installed on the wall in a height of at
least 2.3 meters.

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 Job Sheet 1

Installation of PACU

Tools, Equipment and Materials:

A. Tools

1. Set of wrenches
2. Concrete hole saw
3. Concrete drill/set of drill bits
4. Flaring tools/swaging tools
5. Set of screw driver

B. Equipment

1. Set of oxyacetylene
2. Scaffold equipment
3. PPE

C. Materials

1. Brackets/hangers
2. Silver flux
3. Nuts and bolts/screws

D. Procedure: Installation of PACU

1. Prepare nuts, bolts, the metal frame,

foundation, mounting frame and
indoor and outdoor units.

Figure 1. Suggestions on how condensing unit is

installed. It ensures the spaces indicated by arrows
from the wall, ceiling, fence and other obstacles.

2. Install the metal frame to the foundation or base and tighten the nuts.

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 Job Sheet 1
3. Install the condensing unit. See to it
that the hole within the base of the
condensing unit is fitted exactly on
the metal framed foundation.

Figure 2

4. Tighten the nuts.

Figure 3

5. Install mounting frame/wall hang

bracket. Tighten the screws.

6. Install the indoor unit.

Figure 4

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 Operation Sheet 1

Test Run PACU/CRE System

Introduction:

When the mechanical installation, electrical installation, piping installation, leak testing,
evacuating, charging were already accomplished, the next work activity is to test run the
system.

Objectives:

At the end of this practice, you will be able to:

1. prepare tools and equipment, supplies and materials for testing and running the system;

2. install system analyzer;

3. hook up ammeter and run the unit; and

4. take data on temperature, pressure, amperage and voltage reading.

Materials, Tools and Equipment

Materials Tools
 Pencil  Flat screwdriver
 Paper  Phillips screwdriver
 Ratchet wrench
Instruments
 Multimeter
 Ammeter
 System analyzer/gauge manifold

Procedure:

1. Backseat, suction service valve and discharge service valve.

Note: Always wear PPE.
2. Install system analyzer/gauge manifold.
3. Crack off backseat and purge low side and high side hoses through center fitting of
system analyzer.
4. Run the unit and get data.

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 Operation Sheet 1
CHECKLIST

Note: Use the following checklist to ensure the installation is in good order. Indicate Yes or No.

1. Indoor Section Yes No

 Air handler level
 Air filter in place
 Refrigerant piping in good order and insulated
 Primary drain pan piped correctly
 Electrical connection in the air handler tight
 High voltage correct
 Low voltage correct
 Fan motor and wheel can be removed easily

2. Outdoor Section
 Condenser level
 A firm foundation under the condenser
 Service panel in correct location
 Airflow correct and not recirculating
 Refrigerant piping in good order and insulated
 Electrical connections tight
 High voltage correct
 Low voltage correct
 Service valves open if any

3. Condensate Check
 In a drywell
 On the ground
 In a drain

4. Voltage Check (Fill the blanks)

 Line voltage to indoor fan section __________ V

 Line voltage to condenser __________ V
 Low voltage power supply voltage __________ V

5. Start the indoor fan motor and verify the voltage and current:

 Rated voltage ____________ V

 Actual voltage ____________ V
 Rated current ____________ A
 Actual current ____________ A
 Fan motor rated current ____________ A
 Actual current _____________ A

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 Operation Sheet 1

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6. Start the condensing unit and verify the voltage and amperage

 Rated voltage ____________ V

 Actual voltage ____________ V
 Compressor rated current _____________ A
 Actual current ____________ A
 Fan motor rated current ______________ A
 Actual current ____________ A

7. Take pressure and temperature

 Suction pressure ___________ kpa

 Discharge pressure ___________ kpa
 Suction temperature ___________ ºC
 Discharge temperature ___________ ºC
 Evaporator room temperature ________ ºC
 Room temperature (PACU) _______ ºC

8. After the test run, return tools and clean up mess.

Evaluation: While performing the activity, it is important for you to assess your performance
following the criteria below:

1. Installed system analyzer properly

2. Correct amperage rating

3. Correct temperature reading

4. Correct pressure reading

5. Correct adjustment of low pressure service valve and discharge pressure service valve

6. Wore PPE

7. Observe safety while doing the job

8. Perform proper housekeeping

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