Modern Refrigeration and

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Modern Refrigeration and Air Conditioning
Althouse Turnquist Bracciano
PowerPoint Presentation by Associated
Technical Authors
PublisherThe Goodheart-Willcox Company,
Inc.Tinley Park, Illinois
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Chapter 29
Servicing and Troubleshooting Simplified
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Learning Objectives

• Explain the definitions of servicing and
  troubleshooting.
• Follow a standard procedure in servicing and
  troubleshooting.
• Approach a problem in a logical and systematic
  sequence.
• Obtain from the owner and others the specific
  problems.
• Determine the remedy for the problem by the use
  of a three-step procedure.

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Learning Objectives

• Demonstrate the proper servicing and
  troubleshooting procedures.
• Properly use the various types of manufacturers
  troubleshooting charts.
• Follow approved safety procedures.

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Servicing andTroubleshooting
29.1

• Troubleshooting refers to an analysis of a
  problem. The analysis is generally guided by a
  chart provided by the manufacturer of the
  equipment.
• Servicing is the work needed to correct the
  problem identified in the troubleshooting
  sequence an attempt to bring the system back to
  design operating standards.

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Servicing andTroubleshooting
29.1

• Here, the service technician is recording the
  operation data that will be used when checking
  the manufacturers troubleshooting guide.

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Troubleshooting Procedure
29.2

• The key requirement for a service technician is
  the ability to follow a standard procedure in
  order to save time, money, and frustration.
• Example of standard procedure
• Obtain a description of the problem from the
  owner.
• From the problem description, determine the
  possible causes.
• Identify the specific remedy for the problem.

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Troubleshooting Procedure continued
29.2

• Whenever possible, obtain a service manual or
  troubleshooting chart for the unit.
• The manual or chart is written by the company
  whose equipment is being serviced may be
  available from the owner or your employer.
• There are a variety of charts most follow the
  same basic sequence
• Problem Trouble, complaint, etc.
• Possible cause Probable cause, things to check,
  etc.
• Remedy Repair, things to do, etc.

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Troubleshooting Procedure continued
29.2

• On arrival at the customers site, become
  familiar with the system.
• Visually inspect.
• Examine all components and wiring for evidence of
  malfunction. If such evidence is found, check the
  electrical wiring and component diagram.
• Always approach the problem in a logical and
  systematic sequence.
• Never make a quick decision that may only
  temporarily fix the problem. This will result in
  a call back for the same reason as the original
  call.

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Owners Descriptionof the Problem
29.2.1

• The first column of a troubleshooting chart
  normally lists problems. This is usually the
  complaint the owner provides to the technician.
• Carefully listen to owners complaint. Obtain as
  much information as possible including how the
  system is operating now and how it operated
  before the malfunction. Obtain from others in the
  building any additional information as to system
  function.

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Checking Possible Cause
29.2.2
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Checking Possible Cause
29.2.2

• The next step is to check the possible cause
  column of the troubleshooting chart and analyze
  it in terms of the major components of the
  system.
• Each problem/complaint related to a malfunction
  has specific possible cause(s).
• Investigate the possible cause column thoroughly.
  Once the possible cause of the problem is
  determined, a specific cause may be detected.
• The specific faulty part can then be identified.

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Suggested Remedy
29.2.3

• The final column of a troubleshooting chart may
  be labeled remedy or something similar. The
  technician is to perform the appropriate task(s)
  from this column.
• There are many steps to follow in repairing
  refrigeration or air conditioning equipment. Each
  step is checked in a step-by-step manner.
• Procedures depend on the specific remedy
  selected, type of part or device being checked,
  and specific system.
• Caution Always follow basic service and safety
  procedures as you repair a system. Proper tools,
  gauges, electrical analyzing devices, and other
  equipment must be used.

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Troubleshooting Charts
29.3

• The troubleshooting chart is a helpful map. Use
  the specific troubleshooting chart from the
  manufacturer. Any components added to the system
  must be considered. Caution Safe operating
  practices should be followed before and during
  any troubleshooting or service.
• Figure 29-5 in the text is an example of a
  troubleshooting chart for domestic and light
  commercial systems. The introductory section
  lists common complaints, causes, and repairs.
  This is a written analysis of four common
  complaints referring to compressor malfunctions.

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Troubleshooting Charts continued
29.3

• Figure 29-6 in the text is an example of a
  troubleshooting chart for industrial-type
  refrigeration equipment. It is assumed only those
  qualified would use chart and that equipment had
  been operational.
• Figure 29-7 in the text is an example of a
  troubleshooting chart for ice flaker machine. It
  provides the sequence of operation and a
  schematic drawing of the unit. Note It is
  essential to know machine operation prior to
  using the troubleshooting chart or servicing.
• Figure 29-8 in the text is an example of a format
  other than the standard three-column
  troubleshooting chart. The three-step concept may
  still be used.

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Customer Relations
29.4

• The role of the technician has changed to
  include
• Knowledge of refrigeration and air conditioning
• Meeting the customers needs.
• Knowledge of business operations.
• Contractual agreements.
• The key to a successful business operation is
  good customer relations. These are based on
  evaluations by the consumer for whom service is
  provided and include attitude, sense of trust,
  value, and satisfaction with job performance.

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Customer Relations continued
29.4

• Good customer relations are accomplished through
  verbal communication, general attitude, and
  appearance.
• Always be courteous when dealing with customers,
  even if things are not going well. Treat the
  customers needs as an emergency in their eyes
  it is.

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Technician Appearanceand Conduct
29.4.1

• Appearance and conduct contribute to the company
  image.
• A neat personal appearance creates a sense of
  confidence necessary in dealing with customers
  and impacts their attitude toward the service
  performed.
• Arrive on time and display good work habits.
• Accurate and efficient work and respect for
  customers property build trust and satisfaction
  with service.

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Technician Appearanceand Conduct continued
29.4.1

• Positive remarks concerning the company
  contribute to good customer relations.
• Show respect for the company vehicles and
  equipment.

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Arriving on the Job
29.4.2

• On arriving at the job, identify yourself and
  your company. State the reason for the call.
• Politely ask the customer specific questions
• What has occurred?
• When was it first noticed?
• How many times has it occurred?

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Arriving on the Job continued
29.4.2

• Write on the service contract or work order any
  information the customer volunteers concerning
  previous problems with the equipment. Note any
  interest shown by customer in add-on equipment or
  new contractual agreements.
• When servicing is completed, the proper billing
  forms should be presented to the customer for
  signature. If applicable, indicate to the
  customer what may be done in the future so
  problem will not occur again.

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Arriving on the Job continued
29.4.2
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Maintenance Service Contracts
29.4.3

• Many consumers are familiar with a maintenance
  service contract and recognize the benefit of
  them.
• Allows owner to extend service contract.
• Contracts vary depending on company.
• A service agreement may cover all repairs and
  replacements needed in a given period of time.

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Maintenance Service Contracts continued
29.4.3

• A service agreement should specifically indicate
  what a twice-a-year tune-up and cleaning (for
  example) includes
• Identify tasks to be performed.
• Identify what benefits the owner will receive
  from the contract.
• Identify the specific equipment make, warranty
  date, model number, and serial number.

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Maintenance Service Contracts continued
29.4.3

• Note the no-risk, three-month money-back
  guarantee. This encourages homeowner to sign
  contract.

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Maintenance Service Contracts continued
29.4.3

• Another type of service agreement asks a number
  of questions, including whether the customer can
• Inspect air conditioning system.
• Replace filters.
• Clean coils.
• Check motor and compressor.
• Lubricate motor.
• Calibrate thermostat.
• The agreement also states that if the owner
  cannot perform these tasks, the company will do
  so. For a given cost, company will also furnish
  all parts, labor, and materials necessary.

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Contractual Agreement
29.4.4

• Often purchased as result of the initial service
  call.
• The form is filled out by the technician after
  speaking with the owner.
• Provide repair services as well as periodic
  maintenance.
• A typical contractual agreement is shown in
  Figure 29-11 in the text. Note Technician is to
  indicate equipment ages for air conditioning and
  heating units. The age of equipment determines
  the actual cost of the maintenance and service
  contract.

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Contractual Agreement continued
29.4.4

• Agreements vary from company to company.
• Some agreements cover domestic appliances others
  cover commercial appliances.
• A contractual agreement gives the company a
  chance to sell additional services, reducing the
  owners cost of operating the unit.
• Example Humidistat may be sold as an add-on.
  Used in southern states by homeowners who are not
  available in the summer to change the air
  conditioning setting based on humidity.

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Contractual Agreement continued
29.4.4

• To complete the forms for the service agreement,
  be familiar with the various types of services
  offered. Understand and explain the benefits of
  the agreement for the customer.
• Contracts are legal agreements that specify terms
  and conditions of service.

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Inspection Report
29.4.5

• Many contractual agreements provide for two
  inspections of equipment each year, and for
  answering any service calls the owner places to
  the company.

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Inspection Report continued
29.4.5

• A typical inspection report that provides a
  breakdown of the procedures to be followed and
  points to be checked by the technician.

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Inspection Report continued
29.4.5

• For example, there are ten steps a technician
  would follow in checking a residential central
  air conditioning system
• Visually check the coil front and back and spray
  with a self-rinsing coil cleaner.
• Cut the drain line near evaporator. Use a wet-dry
  vacuum to remove any water or particles of dirt.
  Reconnect the drain line by placing a piece of
  clear plastic tubing in the line at the cut.
• Vacuum the drain pan and insert algaecide
  tablets.
• Visually check the contact points for excessive
  burn. Note Any contactors that have been used
  will show noticeable marking.

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Inspection Report continued
29.4.5

• Check the coil for erosion. Plants, shrubs,
  branches should be clear of unit for good airflow
  across the coil. Rinse and clean the coil with
  clear water.
• With the heat on, read the ampere draw on each
  element.
• Disconnect and reconnect time delays that have
  been installed. The starting time should be
  checked.
• Check temperature differential. Should be between
  16ºF (9ºC) and 20ºF (7ºC).
• Visually check the ducts for leaks.
• Note all settings before inspection. Devices can
  be reset when the inspection is finished.

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Inspection Report continued
29.4.5

• Any unusual parts requiring future replacement
  should be indicated on the inspection report.
  They can be brought on the next visit.
• The inspection report becomes a record in the
  office, enabling a follow-through in future
  service calls to the site.
• A good maintenance record reduces the number of
  callbacks and emergency service calls.
• The record should result in fewer problems with
  equipment and less cost for general maintenance
  of the system.

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Questions

• Name three areas that troubleshooting charts
  commonly cover.

System problem, possible cause, and remedy.

• What is one of the first troubleshooting
  procedures that a technician should complete
  before testing a system?

Visually inspect the system.

• Name two important areas of a service contract.

Identify tasks to be performed identify the
specific make, model number, and serial number.
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Questions

• What is one way that a contractor may benefit by
  offering a service contract?

It gives the company a chance to sell additional
services.

• Name five of the ten steps a technician should
  follow when checking a residential air
  conditioning system.

Clean condenser coil clean the drain line check
the contactor for burnt contacts check the
condenser for proper airflow (no obstructions)
and check the time delay circuits.(these are
example steps, there are five other steps)
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Safety
29.5

• Check the company service manual for proper
  wiring diagrams prior to servicing the unit.
• Make certain the main breaker is open.
• All power must be off prior to attempting service
  of any refrigeration system.
• Follow basic tests and procedures related to
  electrical leakage and current.
• Prior to working on the electrical components of
  a system, check the systems voltage. This
  reduces the danger of electrical shock or damage
  to instruments.

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Safety continued
29.5

• Never wear loose jewelry, rings, watches, or
  bracelets while servicing equipment. They may
  come in contact with electrical terminals or
  wires, causing electrical shock.
• When welding, soldering, or brazing, provide
  plenty of ventilation.
• Fluorocarbons are nonflammable. However, a
  mixture containing fluorocarbons may be flammable
  because of the other components of the mixture.
• Refrigeration systems should be evacuated,
  purged, and left open prior to welding to avoid a
  possible increase in hydrostatic pressure and
  decomposition of the refrigerant.

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Safety continued
29.5

• In any area where fluorocarbons have been
  emitted, always properly evacuate the air and
  replace it with fresh air.
• Always wear proper shoes and clothing to prevent
  slipping on wet surfaces.
• Avoid loose-fitting clothing. It may become
  entangled in moving parts, such as fans.

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Glossary

• servicing
• Performing the work needed to correct a problem.
• troubleshooting
• Analysis of a problem.