INSTRUCTIONS AND COMPETITION DETAILS INSTRUCTIONS ET DÉTAILS DU CONCOURS REFRIGERATION AND AIR CONDITIONING RÉFRIGÉRATION ET CLIMATISATION POST-SECONDARY NIVEAU POSTSECONDAIRE
1. Test Project Details This project is designed to test the range of skills used by a Refrigeration / Air Conditioning Technician to install, commission and service refrigeration and air conditioning equipment. 1.1 Duration of contest The competitors will have 12hours to complete Two (2) Modules A) Refrigeration System, Installation & Commissioning (85 marks, time allowed 11hours) B) Air Conditioning/Refrigeration System Fault Finding (15 marks, time allowed 1hour) 1.2 Timetable A time table will be issued to you one month prior to competition by your Skills/Competences Canada Provincial/Territorial offices 2. Competition Module Details Each module (A, B) is described within this document. The module description will contain all of the competition instructions, including diagrams and the specific information on the refrigeration and air conditioning systems to be used in the competition. Where system pipe work is installed, the competitor must allow an expert to witness a 15 minute System Pressure test and also a 10 minute Evacuation test to ensure system pipe work integrity. 2.1 Making Scale The marking summary will be recorded on the Skills Canada CIS. 2.3 Check Points An important part of this competition, are the procedures you use to carry out various tasks. Therefore, at various points in this competition you must ask a Judge to observe and check your work. Once checked, the judge must place their initial in a progress box. 2.2 Additional Documentation You should also be fully aware of the following documents; Health and safety requirements Competition rules and procedures Page 2
2.3 Additional Information Concerning Safety Requirements During the competition, all competitors MUST follow the safety rules listed below along with the local Health and Safety requirements of the host province. SHOES Fully enclosed work shoes or boots must be worn at all times. CLOTHING Legs must be covered at all times, by either long work trousers or overalls. Upper body must be covered at all times. Arms must be covered with long sleeves, when brazing and using refrigerant. SAFETY GLASSES or GOGGLES Must be worn when necessary to protect your eyes for example when soft soldering, filing, reaming, hack-sawing, cutting, drilling, grinding and using refrigerant, dry nitrogen and compressed air. Tinted or clear safety glasses/goggles must be worn when brazing. GLOVES Suitable gloves must be worn when brazing and using refrigerants When test instruments are used to measure voltage or amperage, the competitor must wear the approved electrical gloves. Competitor must wear mechanic style or equivalent gloves at all other times SAFETY Competitors must not switch on (apply power) to any electrical equipment until they receive permission from a judge. This does not include hand power tools. Any competitor that is identified as not wearing the correct safety attire or is engaging in any unsafe practice will be stopped and advised on the correct safety practice by the judge. If unsafe working practice is repeated the judge may STOP the competitor and report the issue to the safety officer. The competitor may not be allowed to continue until the safety issue is resolved. The competitor will lose associated safety marks. If the competitor continues to ignore the safe working practice, they may be removed from the competition area for a safety briefing for 10 minutes by the National Technical Committee. Page 3
Competition Details - Module A Refrigeration System Installation and Commissioning Maximum Time Allowed - 11 hours 85.0 Marks The competitor is required to position and install the supplied refrigeration equipment according to the diagrams that will be supplied. The competitor is required to commission the system within the time limit. You are required to record the operational conditions and settings on a commissioning log sheet that will be included within this section. Drawings that relate to this module are as follows. 001 Piping Schematic 002 Electrical Schematic Components to be installed will include the following; Major system components Condensing unit Electric Defrost Unit Cooler Refrigeration system flow controls and valves including Liquid line filter drier Sight glass Liquid Line solenoid Valve Discharge Bypass Pressure Regulator Externally equalized Thermostatic expansion valve Accumulator Refrigerant Tubing System Electrical system components including Safety & operating pressure controls Manual pump-down Page 4
System Design Specifications The following system design specifications for the installation should be used for commissioning and control setting and are as follows: Refrigerant = R404A Maximum ambient temperature = 33 C / 91 F DB, 28 C / 82 F WB Design saturated suction temperature = -15 C / 5 F Low Pressure Control cut out 2-5 PSI Low Pressure Control cut in 50% of Design SST High Pressure cut out the system when the SCT reaches 55 C / 131 F. Install and Commission Refrigeration System All competitors will be required to perform the following tasks to complete this module. Tasks 3, 4, 5 and 6 have a judge sign off sheet, which needs to be filled in and signed prior to moving ahead on each task. 1. Install Refrigeration System All competitors will be supplied with all necessary equipment and materials to complete the installation of the refrigeration system in accordance with test project drawings and Standard for Refrigeration & Air Conditioning. 2. Install Electrical System All competitors will be supplied with all necessary equipment and materials to complete the installation of the electrical system in accordance with test project drawings and Standard for Refrigeration & Air Conditioning. Page 5
3. Pressure Test System Under the supervision of an appointed judge; carry out a staged pressure test of the refrigeration system to 45 C or 113 F. The test pressure should not drop from the starting point in the fifteen (15) minutes after the pressure test is isolated from the nitrogen cylinder. If the pressure test has not been achieved, the competitor can continue to fix the leak and achieve the pressure test, however the full mark for Pressure Test will be lost. The competitor cannot continue to charge refrigerant until pressure test is passed. PLEASE FILL IN THE JUDGE CHECK POINT SHEET BELOW BEFORE PROCEEDING ANY FURTHER Use this area to show your calculation To be filled in by COMPETITOR Calculated Pressure Test Value PSI To be filled in by JUDGE ONLY Competitor Province: Pressure at Start of Test: psi Starting Time: Pressure at End of Test: psi Finishing Time: Refrigeration System Pressure Test Judge Page 6
4. Evacuation Under the supervision of a Judge, evacuate the refrigeration system in accordance with manufacturer s instructions using the Deep Vacuum Method. The evacuation point should not exceed a value of 1000 micron or equivalent vacuum in the Ten (10) minutes after the vacuum pump is isolated from the system under test. If the vacuum fails the vacuum hold test, they can retest to achieve the required vacuum. If the competitor chooses not to retest and achieve the required vacuum level, the competitor will lose full marks but will be allowed to continue their test project providing they have achieved a minimum 2000 micron or equivalent vacuum. To be filled in by JUDGE ONLY Competitor Province: Evacuation level at Start of Test: Microns Starting Time: Evacuation Level at End of Test: Microns Finishing Time: Refrigeration System Evacuation Test Judge 5. Charging With Refrigerant Under the supervision of a Judge; break the vacuum with refrigerant and continue to charge the system with the required weight of refrigerant to ensure operation according to the specification above, and in accordance with industry standards. Competitor Province: To be filled in by JUDGE ONLY Cylinder Gross Weight Prior to charging: Evacuation Level at End of Test: Weight of refrigerant added to system: Refrigeration System Charge lb/oz lb/oz lb/oz Judge Page 7
6. Electrical testing Under the supervision of a Judge; perform all the following essential safety checks to ensure the electrical circuit is safe to energize. To be filled in by JUDGE ONLY Competitor Province: Line to Neutral reading accepted: Yes/No Ground continuity test is performed and passed: Yes/No Neutral continuity test performed and passed: Yes/No Polarity Active tests: Yes/No Line to Ground reading accepted Yes/No Neutral to Ground reading accepted Yes/No Electrical safety checks carried out by competitor Judge and circuit is safe to energize: 7. Commission the System Competitors are to commission the system for operation in accordance with the design specifications supplied. Complete the commissioning report at the back of this document when the system is fully operational and leave it with the test project. Page 8
SKILLS CANADA 2016 REFRIGERATION SYSTEM COMMISSIONING REPORT Competitor # Date System LT # Ambient Temp: F Cond. Unit Model # Serial # Compressor Model # Serial # Evaporator Model # Serial # Design Voltage Actual Voltage Refrigerant Type Electrical Component Nameplate Running Amps Amps L1 L2 Compressor Condenser Fan Motor Evaporator Fan Motor Evaporator Suction Pressure: PSIG Convert PSIG to: F Evaporator Suction Gas Temp: F Evaporator Suction Superheat: F Compressor Suction Pressure: PSIG Convert PSIG to: F Compressor Suction Gas Temp: F Compressor Suction Superheat: F Condensing Pressure: PSIG Convert PSIG to: F Liquid Line Temp: F Liquid Line Subcooling: F Condenser TD: F Discharge Line Temp: F System functions as per Specs: Y/N Discharge Gas Superheat: F Air-On Evaporator: F Air-Off Evaporator: F Box Temp: F Evaporator TD: F Sight Glass Clear: Y/N Sight Glass Dry: Y/N CPR Adjusted: Y/N System Left In Safe Condition: Y/N System Notes Time Submitted Judge Page 9
Competition Details - Module B HVAC/R System Troubleshooting Maximum Time Allowed - 1 hour 15.0 Marks The competitor is required to troubleshoot 4 pieces of equipment and record findings. Note: There is only 1 fault in each system. No repairs are to be made to the equipment. Competitor Province: Record your findings below Fault A Fault B Fault C Fault D Page 10