5

Tools & Equipment

for servicing and
repair
Training Material Reference
Tools & Equipment for servicing and repair – 2012.ppt
Target Group
Trainers and Technicians
Duration of the Session
45 minutes
Purpose of the Session
To familiarize the participants about the tools and equipments required for good quality
servicing leading to customer satisfaction, including adopting Good Servicing Practices
(GSP) in RAC servicing sector.
Terminal Performance Objectives
At the end of the session, the participants should know:
1. Various tools and equipments used for inspection, measuring, testing and carrying out
the works during servicing / repair of the refrigeration and air-conditioning appliances
2. Regular precautions while using tools and equipments
Key Message being delivered through this Session
There is a need to upgrade the facility in terms of tools and equipments for quality servicing
and to handle new refrigerants. Use of proper tools and equipments would lead to accuracy,
reliability, responsiveness and credibility, which are select elements of quality service.
In open market many tools and equipments are available but their accuracy and quality is
a big question and hence right tools for right job are necessary. For example the vacuum
gauge is available from $ 20 to $1000 and each one has its own benefits that come through
accuracy and reliability. To cite another example, the capillary tube can be cut in many ways
but use of capillary cutter ensures that no burr is left out at the end.
Therefore, in order to have a set of correct tools & equipments each technician must
understand the importance & benefits derived from them. Since HCFC refrigerants are under
replacement it is very essential to understand the actual need of each tool & equipment as
level of accuracy required in alternatives is relatively very high.
Tools & Equipments (if any) required for the session
One complete set of RAC tool kit. Special tools must be shown to them in the class
alongwith teaching. Half of the group can perform capillary tube cutting in theory
room & use deburring tool after cutting the copper pipe etc.
 5 Refrigeration Tools & Equipment:
Tools & Equipment for servicing and repair

This is the title slide and small discussion can be made on having the right tools and
equipment. An example can be given of any business investment v/s. profit and can be
compared with RAC service workshop and money spent and profit wants to earn. Better
to have good tools for better earning.

Tools
This slide highlights the following tools and items needed for electrical measurements and
servicing:

Quick Test Board

Special portable test board suitable for safe inspection of any appliance/ compressor. Test
board consists of Bell push and piano type switches & LED’s to check continuity (series test)
of appliance / compressor wiring. It also helps for testing plug point (neutral, phase wire
position, earthing, neutral wire condition). Two-pin socket provided for connecting Ampermeter
& Voltmeter. Special Green lead (wire) provided for ground test of appliance / compressor.
This all is provided in this single compact board that is safe to handle.

Dummy Relay or Test Terminals

Dummy Relay or test terminals is used for safe checking of compressor directly without error
of incorrect terminal sequence or loose contact etc. One can add push button and/or two
terminals for capacitor fixing.

Digital Clamp Meter (Multi function)

Digital Clamp Meter can measure resistance 0-200k-ohm, DC voltage up to 1000 V, AC
voltage up to 750 V, AC current 0 - 30 Amperes without breaking wire or switching off the
appliance. It is also used as continuity / diode tester with audible beep. Easy to see display,
peak hold / button data hold of all stages.

Digital Thermometer with puncture probe

Accurate electronic single display with in/out door temperature indicator display between -50
to 70°C with sufficiently long probe. The probe can be inserted into a grill directly to find out
its temperature. Fahrenheit / Centigrade conversion switch.
 5 Tools
Tools & Equipment for servicing and repair

The items showed in this slide are:

Line Tester (500 V)

With this tool one must purchase of a good brand & not to try the local cheaper product.

Wire stripper
It is observed in the past that technicians use their teeth to peel off the wire insulation
instead of using the tool. So it is much better to use wire stripper to remove insulation
and will not cut the strings of the wire..

Ratchet Wrench
This is also one of the important tool. To open or close the service, cylinder valve one
can rotate clock wise or anti clock wise. In case of this tool lot of field technicians
have been seen using wrong tool i.e. screw spanner. After few openings with a screw
spanner the cylinder valve forms the circular shape and slippery goes on. One can use
valve keys for operating the cylinder valve

Igniter
Igniter is used to ignite the brazing torch instead of match sticks which is safe.
Tools

Pinch off plier

Pinch-off pliers is used for crimping/ pinching the tube before sealing. Various types of
pinching-off pliers are available. One type of pinching pliers is shown to you in the slide. The
gap between the jaws of the pinching pliers can be adjusted to minimum closed position by
screwing bolt given at the other end of pliers. Secure the position by tightening the locking nut
provided along with. This type of pinch off pliers is handy & easy for pinching different tubes
size. The main instruction for pinch of plier is that some technicians put the flame towards the
bit of the plier, which must be avoided. If the bit goes more hot or spring becomes extra hot
then tool get damage. So this must be avoided and be explained during the training.

Piercing Plier/Valve
One of the best tool for recovery of refrigerants but not to be used during vacuum. And it must
not be clamped on the brazed portion or MS pipe, otherwise the needle will get damage. It
must not be over-tightened as the rubber seal will press and while releasing the refrigerant it
can leak.

Male and female quick coupler

Male & Female couplers are practical as they eliminate need for flaring of tubes and save time,
avoid leakages that can occur through ordinary valves during servicing. They are suitable for
widely used 1/4” copper tubes.
 5 Tools
Tools & Equipment for servicing and repair

Tube cutter
These tube cutters are available in different design and sizes. Tube cutter is usually
used on smaller, annealed (soft) copper tubing while the hacksaw is preferred for cutting
the larger hard copper tubing. The tubing should be straight and cut squarely (90 deg)
to eliminate an off canter flare. If a saw is used, a wave set blade of 32 teeth per inch
will do the best job Care must be taken while using tube cutter. Adjust the tube between
roller and blade with little pressure. Rotate the tube cutter. After one round tight the knob
quarter turns. Rotate the cutter full turn. Again tight the knob. And repeat this again till
pipe is cut. Do not put extra pressure with knob to avoid kinking of tube and for safety
of blade.
Deburring tool
After the tubing has been cut, its ends must be scraped or reamed with a tool. Many
tube cutters have a reamer This tool is also important one and most neglected one. It
is observed that technicians were using nose plier or the back part of file for cleaning
inside burr formed while cutting. This makes the copper pipe thin from the inner end
leading to poor swage or poor flare. With this tool you can clean the inside as well as
outside burr and keep the wall thickness intact. One more instruction can be practice
that keep the tool at the bottom hand and tube on the upper hand, so that all the burs
can be collected in the deburring tool and prevent burr entering in the system.
Capillary tube cutter
Very important tool for RAC technicians. It can cut the capillary at an angle and with no
burs. It save time and burr free cutting. One can make taper cutting with capillary cutter.
Trainers must explain here that do not use wire cutters instead of capillary cutter as the
wire cutter do not have angle inside the cutter. Secondly capillary cutter must not be put
on where the brazing material is otherwise the blade will get damage.
(Note: Trainer is supposed to show participants how to cut the capillary.)
Tools

Tube bender (lever type)

It takes Practice to become good at bending tubing. For the smaller sizes used in domestic
models it is not necessary to use special bending tools. However, a much neater job and a
much more satisfactory one is possible with such tools. The tubing should be bend so that it
does not place any strain on the fitting after it is installed. The tubing, at the bend, should not
be reduce (Kinked) in cross-section area. Be very careful when bending the tubing to keep it
round. Do not allow to flatten or buckle. The minimum radius for a tubing bend is between 5-10
times the diameter of tubing. Do not try to make the complete bend in one operation, but bend
the tubing gradually. . Technicians can use internal and external spring bender also as per the
situation. An external bending spring for ¼ in. OD tubing may be used as an internal bending
spring for 1/2in. OD tubing. Use the spring bender externally in the middle of long lengths of
tubing. Prefer use the lever type tube bending tool which will produce accurate bends and will
reduce danger of flattening or buckling tube while it is being bent.
Flaring tool with swaging kit
This tool is also important. Different types of swaging tools are available. Technicians should
use it properly as per instructions. This is a important operation which lead to quality brazing
joints. So good tool always save lot of money apart from good finish.
Currently used flaring blocks can be used however new flare blocks specifically designed
for higher pressures have an torque adjustment and provide a more consistent smoother
flare face. R410A flare blocks also have a clutch to avoid over tensioning which results in a
weakened flare face.
Expander
For expanding the pipes a hand expander can be used. This is also good tool for RAC technician.
Scrubber cum wire brush
Wherever external flux is used for brazing, that joint must be scraped all around with the help
of scrubber or wire brush. This help to remove sticky flux. The joint should be clean with wet
cloth to avoid corrosion formation on tube.
 5 Gauge Manifold – 2 way
Tools & Equipment for servicing and repair

Many types of refrigerant Gas manifolds are available in market. 2 way - Manifold
Function is as below:

1. The right side hand-knob (red high side) will control the flow of ports on the side
to the center port and the port on the left side (blue low side) providing hand-knob is in
the open position.
2. Should the flow be needed only through the center port (yellow line) close the
low side blue label hand-knob.
3. The low (blue) side operates in the same manner as on the (high) red side.
4. Pressure gauges and compound gauges are colour coded accordingly.
5. The gauges will indicate either vacuum or pressure depending whether hand-
knobs are in the open or closed position.
Gauge Manifold – 4 way

A 4-way manifold has few external joints connecting the vacuum pump, charging cylinder /
weighing scale and the vacuum gauge and is therefore more compact and leak proof.

A 4-way manifold saves time because there is no need to reconnect hoses for different
processes. The low and high sides, the vacuum pump and the charging device can be hooked
up right at the beginning of the job. The manifold is a central control for service. One needs
to just operate the appropriate valve.

The slide illustrates the manifold with the legends for the different components. Such a
manifold is fitted to different gas charging station.
 5 Brazing Equipment
Tools & Equipment for servicing and repair

For proper brazing using adequate temperature, the minimum requirement is a LPG
brazing kit. One example is the swirl jet or spit fire which can reach higher temperatures
than the ordinary LPG torches.

It is still better to have oxy-acetylene brazing torch – but economic consideration may
not allow this. Also being bulky equipment it is difficult to carry at site.

Oxy-LPG brazing torch are in market which are handy to carry at site.

Tongs and Asbestos lined heat deflector are used to handle the heated components
and assist during the brazing.
Refrigerant recovery machine with a recovery cylinder

It is important to reduce HCFCs emission as you know they deplete Ozone layer and have
high GWP - it is important to recover as much HCFCs as possible. Likewise, HFCs should
also be recovered as they have high GWP. For such recovery of refrigerants, a recovery
machine is required.
The image illustrates the recovery machine with oil-less compressor. Having drier at the entry
port of refrigerant. One more mesh filter is fitted inside the inlet valve and then the refrigerant
passes on to the system. Oil less recovery machine does not have the risk of addition of any
oil form the compressor.
Separate recovery cylinders should be used for recovery of different refrigerants. More details
on these items are given in the session on Recovery of Refrigerant.
 5 Portable Evacuation and Gas Charging Station with
weighing scale
Tools & Equipment for servicing and repair

The common features of the Evacuation and Charging (E&C) units are a vacuum pump
connected to a manifold through an electro mechanical / electronic anti suck-back
valve. The manifold has several inlet ports and outlet ports connected to high pressure,
compound or vacuum gauges. With these common features, there are two variant
possible:

1. With volumetric charging still having a calibrated correction dial to take care of
change in refrigerant volume due to temperature change (dial-a-charge).
2. With an electronic weighing scale and a hose to connect the refrigerant can /
cylinder to the manifold.

While buying the vacuum pump one must keep in mind double stage, with blast facility
and blank off to 50 microns.
Important Equipment
Electronic Leak Detector
The electronic leak detectors rapidly pinpoint the
leak source by eliminating contamination with
selected filter that avoids false alarm. Audio/
visual indications, sensitivity up to 0.5 g /Year,
lockout and clear facility (switches) are also
provided. Separate leak detectors are required
for each group of refrigerant.

Sound Level Meter (dB meter)

This equipment, housed in lightweight ABS
plastic case, is used to measure the noise & vibrations produced by compressor/ appliance.
It carries an LCD display that is simple/ convenient to read. To meet the IEC 651 standards
the characteristics of ‘A’ frequency and fast time weighing are incorporated. It has a built-in
adjustment for calibration. Its condenser microphone is very accurate and has long term
stability. The hold function helps to freeze the display values. To enable user to know over &
under values, a warning indicator is provided and also a low battery indicator. Use of this is
reliable when noise levels are concerned. However, the surrounding noise level must be at
least 12 dB levels lower than that of object under test, otherwise reading becomes incorrect.

Anemometer
Anemometer is an apparatus for measuring the speed of air. The commonest kind of
anemometer is a fan blades fixed in the circular ring.
The pressure on the inside of a blade when it is back to air overcomes the pressure on the
angular blades and the blades start rotating with the air speed. The mill moves a pointer
round a graduated dial. By timing a given number of revolutions, as shown by the pointer, the
speed of the air is easily calculated on the LCD screen.

Fire Extinguisher
Most important of all, do not forget to have a powder type fire extinguisher as only this can be
used on any type of fire (oil, electricity, papers etc.). It should be placed in a safe but rapidly
accessible location so as to make use of it in case of any eventuality. It is better to display
the location near the entrance of any workshop or keep it close to brazing kit. The label of the
extinguisher must be checked for its status.
 5 Important Equipment
Tools & Equipment for servicing and repair

Thermocouple or Pirani vacuum gauge

An instrument with precision reading is known as micron gauge. Micron vacuum gauge
capable of measuring 5-5000 microns should be used to measure the vacuum with
precision and also to test the pressure rise / vacuum holding. One can opt for analogous
or digital micron gauge.

Nitrogen cylinder with 2 stage regulator & hose

Nitrogen gas being inert, non-oxidizing, is recommended for flushing & leak testing of
a refrigeration system. The pressure of nitrogen in the cylinder is above 2000 psi, and
such pressure can cause serious accident. To avoid any unpleasant event, a 2-stage
regulator must be used for regulating its output pressure to safe working limits of about
15-20 bar (220-294 psig). A separate presentation for Trainers has been prepared and
will be explained how this regulator works and why it is better than single stage. After
reading these slides explain the technology to technicians.
Test Kit for Oil

TKO:
The test kit is a single bottle test kit designed to give visual indication as to the acid content
of both mineral and alkylbenzene lubricants. Simply place a sample of oil in the bottle, shake
and look at the colour. If it remains purple, the oil is safe. If it turns orange, the oil is marginal
and steps may need to be taken. If it turns yellow, the oil is acidic and needs to be changed
or other steps need to be taken. Always read the manufacturer’s instructions before use.

ETK:
The test kit is a single bottle test kit designed to give visual indication as to the acid content
of polyol ester (POE) lubricants. Simply place a sample of oil in the bottle, shake and look at
the colour. If it remains purple, the oil is safe. If it turns orange, the oil is marginal and steps
may need to be taken. If it turns yellow, the oil is acidic and needs to be changed or other
steps need to be taken.

Always read the manufacturer’s instructions before use.

 5 Test Kit for Oil
Tools & Equipment for servicing and repair

The retrofit process requires the removal of mineral based oil and replacement with
polyol ester based lubricants. When this is required, it is necessary to reduce the mineral
based oils to acceptable levels to assure proper system operation. The RTK (retrofit
test kit) provides a simple method of determining the level of residual mineral oil in a
system. It is ideal for field use as it provides a visual indication of three levels of mineral
oil concentration: Greater than 5%, between 1% and 5% and equal to or less than 1%.

Always read the manufacturer’s instructions before use.