Cpairc 1

JOB PROFILE CHART (JPC)
SECTOR MECHANICAL ENGINEERING

SUB SECTOR HEATING VENTILATION AIR CONDITIONING (HVAC)
JOB AREA INSTALLATION, SERVICING, TROUBLESHOOTING & REPAIR

(SINGLE PHASE AIR-CONDITIONING EQUIPMENT)
JOB LEVEL TWO (2) JOB AREA CODE ME-020-2:2012
COMPETENCY COMPETENCY UNIT
WINDOW UNIT
VENTILATION FAN
RISKS & HAZARD REFRIGERANT (1PH)
(1PH) INSTALLATION
CORE ASSESSMENT HANDLING INSTALLATION &
& MAINTENANCE
MAINTENANCE
ME-020-2:2012(C01) ME-020-2:2012(C02) ME-020-2:2012(C03) ME-020-2:2012(C04)
AIR COOLED SPLIT

UNIT (1PH)
INSTALLATION &
MAINTENANCE
ME-020-2:2012(C05)
12
COMPETENCY PROFILE (CP)
Sub Sector HEATING VENTILATION AIR CONDITIONING (HVAC)

INSTALLATION, SERVICING, TROUBLESHOOTING & REPAIR
Job Area
(SINGLE PHASE AIR-CONDITIONING EQUIPMENT)
Level TWO (2)
CU Title CU Code CU Descriptor CU Work Activities Performance Criteria
1. Risks & hazard HVACD-01 The installation, starting up 1. Identify expected 1.1 Expected
assessment and servicing of ventilating sequential steps for sequential steps for
and air-conditioning completion of work completion of work
equipment can be identified for the
hazardous and requires specific type of
specific knowledge and work
training.
Improperly installed, 2. Carry out potential risk 2.1 Potential
adjusted or altered and hazard assessment hazard/risk
equipment by an untrained determined
person could result in
serious injury, loss of limb 3. Evaluate the risks and 3.1 Risk rating
or even death.The decide whether existing determined
13
competency of risks & precautions are adequate

hazard assessment focus or more should be done
on identification of the
safety precautions to 4. Carry out safety 4.1 Precaution required
eliminate/control hazards for precautions required to to eliminate risk
each expected sequential eliminate/ identified
steps for completion of work control hazards planning 4.2 The specific service
work is completed
safely according to
safety regulations
2. Refrigeration HVACD-02 Refrigerant Handling focus 1. Perform types of system 1.1 System approach
handling on identification of system approach identification correctly
approaches to minimise determined for the
refrigerant emissions to the specific service
atmosphere prior to opening
an air conditioning system 2. Perform refrigerant 2.1 Method of
for servicing recovery for the specific refrigerant
service recovery correctly
confirmed for the
14
specific service
3. Prepare refrigerant 3.1 All refrigerant is

handling records recovered from the
system and
properly stored with
zero emission to
the atmosphere
prior to opening the
system for servicing
3. Ventilation fan (1ph) HVACD-03 Ventilation fan (1ph) can be 1. Perform ventilation fan 1.1 Type of ventilation
installation & standalone equipment or installation fan determined for
maintenance part of air conditioning installation
system and its function is to according to
move air for ventilation. The customer order
competency involved is
focus on identification of the 2. Perform ventilation fan 2.1 Ventilation fan
types of ventilation fan for servicing installed correctly
installation, servicing, according to
15
troubleshooting and Manufacturer’s

preparation of service IOM
report. 2.2 The fan performs
according to
Manufacturer’s
IOM
2.3 The Customer
acknowledgement
of completion of fan
installation
3. Perform ventilation fan 3.1 Ventilation fan

troubleshooting serviced properly
according to
Manufacturer’s IOM
3.2 The fan perform
according
after the servicing
16
3.3 Customer
acknowledgment of
the completion
servicing works
4. Perform ventilation fan 4.1 Ventilation fan

repairing troubleshooting was
correct in
rectification of the
fault, and fan was
restored to perform
as per
4.2 Customer informed
of status of
troubleshooting
progress , follow up
action required or
completion
17
4. Window unit (1ph) HVACD-04 Window unit (1ph) is stand 1. Perform window unit 1.1 Types of window
installation & alone air conditioning installation unit identified for
maintenance equipment and its function installation
is to cool and dehumidify air according to
for human comfort. The customer order
competency involved is
focus on window unit air 2. Perform window unit 2.1 Window unit
conditioner installation, servicing installed correctly
servicing, troubleshooting according to
and preparation of service Manufacturer’s
report. IOM
2.2 The window unit
performs according
to Manufacturer’s
IOM
2.3 The Customer
acknowledgement
of completion of
the window unit
18
installation
3. Perform window unit 3.1 Window unit

troubleshooting serviced properly
according to
3.2 The window unit
perform according
after the servicing
3.3 Customer
acknowledgment of
the completion of
the servicing works
4. Perform window unit 4.1 Window unit

repairing troubleshooting was
correct in rectified
of the fault, and
19
window unit was

restored to perform
as per
of status of
troubleshooting
action required or
completion
5 Air cooled split unit HVACD-05 Air Cooled Split Unit (1ph) is 1. Perform air cooled split 1.1 Split unit installed
(1ph) installation & standalone air conditioning unit installation correctly according
maintenance equipment and its function to manufacturer’s
is to cool and dehumidify air IOM
for human comfort. The 1.2 The split unit
competency involved is performed
focus on window unit air according to
conditioner installation, manufacturer’s IOM
servicing, troubleshooting 1.3 The customer
20
and preparation of service acknowledgement

report of completion of
the split unit
installation
2. Perform air cooled split 2.1 The split unit

unit servicing serviced properly
according to
2.2 The split unit
perform according
after the servicing
2.3 Customer
acknowledgment of
the completion of
the servicing works
21
3. Perform air cooled split 3.1 Split unit

unit troubleshooting troubleshooting was
correct in
rectification of the
fault, and window
unit was restored to
perform as per
manufacturer’s IOM
of status of
troubleshooting
action required or
completion
4. Perform air cooled split 4.1 Split unit repaired

unit repair and perform
according to
22
4.2 Customer’s
acknowledgement of
repair work
performed
23
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector HEATING VENTILATION AIR CONDITIONING (HVAC)

SERVICING, TROUBLESHOOTING & REPAIR
Job Area
(THREE PHASE AIRCONDITIONING EQUIPMENT)
Competency Unit Title RISK & HAZARD ASSESSMENT
Risk and hazard assessment can be defined as a process involve several procedures that need to be
Competency Unit done in order to ensure safe working condition namely identifying hazard, assessing the risk and
Descriptor
controlling the risk.
Training 145
Competency Unit ID 01 Level 2 Credit Hours
Duration hours
Attitude / Safety / Training Delivery

Work Activities Related Knowledge Applied Skills Assessment Criteria
Environmental Hours Mode
1. Identify i. Equipment 12 Hours Lecture  Safety
expected Installation, precautions
sequential Operation, identified to
steps for Maintenance (IOM) eliminate/ control
completion of service procedure  Risk definition
work ii. Standard operation confirmed
procedure  Risk matrix table
generated
i. Identify equipment i. Follow safety 23 Hours Demonstration

Installation, policy
Operation, ii. Initiates ideas
Maintenance for safety
(IOM) service improvement
procedure
24
ii. Identify steps for
specific service on
the particular
equipment prior to
commencement
of work
iii. Confirm steps for
specific
installation,
maintenance and
service of the
particular
equipment
2. Carry out i. Past incidents/ 14 hours Lecture  Risk assessment
potential risk accidents methodology
and hazard information determined
assessment ii. Information about according to
equipment (e.g. hazardous policy
plant, operating  Risk definition
instructions) determined
iii. Material Safety  Incident/ accident
Data Sheets repetition
iv. Methods of probability
Identifying hazard assessed
and hazardous  Current activities
situations at work areas/
v. Accident work sites
Investigation
25
vi. Necessary actions determined
to eliminate or  Safety precautions
control the risk to eliminate/
vii. Other risk factors control identified
should also be as
they may contribute
to the risk such as
 Work premises
 Working
environment
including their
layout and
condition
 Capability, skill,
experience and
age of people
ordinarily
undertaking work
 Systems of work
being used
 Range of
reasonably
foreseeable
conditions
26
i. Examine past i. Follow safety 24 hours Demonstration
incidents/ policy
accidents ii. Understand the
information concerns of
ii. Examine current others
iii. Participates in
activities at Work
safety training
areas/ work sites
iv. Initiates ideas
iii. Review Material
for safety
Safety Data
improvement
Sheets
iv. Predict
hazardous event
could take place
v. Identify factors
that may be
contributing to
the risk
vi. Review health
and safety
information that
is reasonably
available from an
authoritative
source and is
relevant to the
particular hazard
vii. Evaluate the
likelihood of an
27
injury occurring
and the likely
severity of an
injury or illness
that may occur
viii. Identify the
actions
necessary to
eliminate or
control the risk
ix. Identify records
that it is
necessary to
keep to ensure
that the risks are
eliminate or
controlled
x. Identify other risk
factors may
contribute to the
risk
28
3. Evaluate the i. Simplified 14 hours Lecture  Risk assessment
risks and decide numerical risk methodology
whether existing estimation determined
precautions are technique  Risk definition
adequate or ii. Risk matrix determined
more should be
done i. Rate potential i. Follow safety 24 hours Demonstration
risk and hazard policy
. ii. Estimate how ii. Understand
likely each the concerns
hazard could of others
cause harm iii. Participates
iii. Assess existing in safety
precautions training
iv. Determine iv. Work with
whether the others in a
company need professional
to do more to manner
reduce the risk
4. Carry out safety i. Expected 10 hours Lecture  Documentation of

precautions sequential steps safety training
required to for completion of  Reporting on
eliminate/ work accident, near
control hazards ii. Potential miss and first aid
planning risk/hazard case
iii. Safety policy  Documentation
iv. Safety audit
29
v. Fleet safety on accident, near
vi. Hearing miss and first aid
Protection case
vii. Fall protection  Generate
viii. Log Out Tag out company crisis
ix. Hazard management
Communication plan
x. Respiratory  Regular checking
Protection in done to ensure
xi. Confined Space that the control
xii. Documentation on measures stay in
accident, near place and clear
miss and first aid responsibilities
case
xiii. Documentation of
workers safety
training
xiv. Initiates ideas for
safety
improvement
xv. Crisis
Management
i. Perform i. Follow safety 24 hours Demonstration
expected policy
sequential steps ii. Wear safety
for completion of PPE when
work specified
ii. Determine iii. Report
30
potential of risk accidents, near
rating for each miss and first
sequential step aid case
of work iv. Participates in
iii. Perform safety safety training
precautions to
eliminate/control
hazard/risk for
each sequential
step of work
iv. Monitor safety
precautions
implementation
31
Employability Skills
Core Abilities Social Skills
01.01 Identify and gather information 1. Communication skills

02.01 Interpret and follow manuals, instructions and SOP’s 2. Conceptual skills
02.04 Prepare brief reports and checklist using standard form 3. Interpersonal skills
03.05 Demonstrate safety skills 4. Learning skills
05.04 Delegate responsibilities and/or authority 5. Leadership skills
05.03 Allocate and record usage of financial and physical resources 6. Multitasking
06.02 Comply with and follow chain of command 7. Self-discipline
06.01 Understand system 8. Teamwork
06.03 Identify and highlight problems 9. Self –reliance
10. Meticulous
11. Diligence
12. Compliance
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
Basic HVAC (Heating Ventilation Air Conditioning) hand tools 1:20

Risk matrix 1:20
Material Safety Data Sheets 1:20
Computer 1:20
32
References:
1. A.B. Constantinos, B. Francesco, H. Sten Olaf & etl.,(2000). Report No 22: Risk Assessment In Relation To Indoor Air Quality.
Luxembourg; European Communities. ISBN: 92-828-9284-0
2. Committee on Risk Appraisal in the Development of Facilities Design Criteria , National Research Council , & et.al. , 1991. Uses of Risk
Analysis to Achieve Balanced Safety in Building Design and Operations (Studies in Management of Building Technology: A Series)
[Paperback]. National Academies Press. ISBN:0309046807
3. A. Eitan & K. Abraham, (1988). Engineering Risk and Hazard Assessment, Vol. 1. 1 ed., CRC Press. ISBN:0849346568
33
Sub Sector HEATING VENTILATION AIR CONDITIONING (HVAC)- DOMESTIC
INSTALLATION, SERVICING, TROUBLESHOOTING& REPAIR
Job Area
(SINGLE PHASE AIRCONDITIONING EQUIPMENT)
Competency Unit Title REFRIGERANT HANDLING
Refrigerant handling focus on identification of system approach to minimise refrigerant emissions to the
Competency Unit Descriptor
atmosphere prior to opening an air conditioning system for servicing
Training 111
Competency Unit ID Level 3 Credit Hours
Duration Hours
Attitude / Safety Training Delivery

/ Environmental Hours Mode
1. Perform types i. Types of system 12 Hours Lecture  Types of
of system approach for the refrigeration
approach specific service circuit
identification - Isolation determined
- Pump down according to
- Recovery system approach
ii. Types of  Knowledge on
refrigeration circuit company
iii. Opening up a environment
refrigeration policy
system without  Core information
venting of on refrigerants
refrigerant to the
atmosphere
iv. Approach to
reduce emissions
of refrigerant
34
v. Refrigerant
recovery options
i. Diagnose i. Safety minded 23 Hours Demonstration

refrigeration ii. Observes
problems safety
ii. Determine precautions
refrigeration iii. Wear safety
work required PPE when
iii. Isolate part of specified
refrigeration iv. Follow safety
system for &
repair environmental
iv. Carry out policy
system pump
down
v. Select
refrigerant
recovery
options
2. Perform i. The 3 R’s of 14 Hours Lecture  Refrigerant

refrigerant service practices system shortage
recovery for ii. Operation of level recognised
the specific Recovery/recycle  Suitable
service Machine for liquid refrigerant
or vapour recovery recovery method
iii. Operation of applied
35
Reclaim Machine  Leakage found
iv. methods of and fixed
refrigerant  Refrigerant
recovery system
 Recovery evacuated and
 Recycle dehydrated
 Reclaim properly to
v. Operation of ensure that non
recovery/ recycle/ condensable
reclaim machine gases and
vi. Core Information moisture are
of types of removed
refrigerant – R22,
R404a, R134a,
R407C, R410a,
R123
vii. Refrigerant safety
viii. Impact of
refrigerant
emission to the
atmosphere
ix. Ozone depletion
x. Global Warming i. Determine i. Observant to 24 Hours Demonstration
xi. Core information condition of the Impact of
on refrigeration oil refrigeration refrigerant
xii. Regulations that system emission to
governs refrigerant ii. Determine the
recovery number of atmosphere
36
xiii. Recovery machine storage cylinder ii. Observant to
safety required for Ozone
xiv. High pressure refrigerant depletion
refrigerant recovery iii. Observant to
recovery iii. Determine Global
xv. Low pressure types of Warming
refrigerant refrigerant iv. Comply with
recovery iv. Confirm Regulations
xvi. Proper handling refrigerant that governs
and disposal for recovery refrigerant
refrigerants and oil method to apply recovery
xvii. Internal and v. Operate v. Observant to
external storage recovery/ recovery
xviii. Storage capacity recycle / reclaim cylinder
of recovery machine capacity
cylinder vi. Ensurerefrigera
xix. Recovery cylinder nt system
safety functionality
vii. Remove service
gauges without
releasing
refrigerant to
atmosphere
viii. Apply
refrigerant
recovery
procedure
ix. Comply with
37
Regulations that
governs
refrigerant
recovery
3. Prepare i. Details of all 14 hours Lecture  Refrigerant

refrigerant maintenance work handling recorded
handling and repairs such as with all details
records  Quantities, kind of  Changes and
refrigerant replacements of
charged (new, re- components of the
used or recycled) system identified
on each occasion,  Produce refrigerant
and quantities handling records
transferred from
the system on
each occasion
 analysis results of
re-used
refrigerant
 Source of re-used i. Determine i. Observes 24 Hours Demonstration
refrigerant refrigerant safety
 Changes and handling precautions
replacements of records
ii. Wear safety
components of requirement
ii. Determine PPE when
the system specified
quantities and
 Results of kind of iii. Follow safety
periodic routine refrigerant &
tests charged environmental
 Significant iii. Determine
38
periods of non- analysis results policy
use. of re-used
refrigerant
iv. Determine
source of re-
used refrigerant
v. Determine
changes and
replacements of
components of
the system
vi. Determine
results of
periodic routine
tests
vii. Determine
significant
periods of non-
use
viii. Produce
refrigerant
handling
records
39

10. Meticulous
11. Diligence
12. Compliance
40
DOE regulation on ozone depleting substances 1:1

Refrigerant Recovery Manuel 1:1
ASHRAE Standard – safety code for mechanical refrigeration 1:1
Clean Air Act 1:1
Refrigerant MSDS 1:1
Recovery Machine, fittings, hoses, pressure and vacuum gauge 1:1
Reclaim machine, fittings, hoses, pressure and vacuum gauge 1: 2
Basic hand tools –spanners, ratchets, screw drivers, etc 1: 2
41
Job Area
Competency Unit Title VENTILATION FAN (1PH) INSTALLATION & MAINTENANCE
Ventilation fan (1ph) is a component of the air conditioning system and its function is to move air for
Competency Unit ventilation or distribution of air.
Descriptor The competency involved is focus on identification of the types of ventilation fan for installation,
servicing, troubleshooting and preparation of service report.
Training Credit
Competency Unit ID Level 3 141 Hours
Duration Hours
Attitude / Safety / Training Delivery Assessment

Work Activities Related Knowledge Applied Skills
Environmental Hours Mode Criteria
1. Perform i. Types of 14 Hours Lecture  Types of
ventilation fan ventilation fan ventilation fan
installation  Propeller fan correctly identified
 Tube axial according to
fan checklist
 Inline  Types of single
centrifugal phase motor
ii. Types of single starting selected
phase motor according to
starting wiring diagram /
 Shaded pole name plate
 Permanent  Cutting tools
split selected correctly
capacitor according to
42
 Split phase i. Differentiate types i. Adhere to 24 Hours Demonstration building material
 Capacitor of ventilation fan electrical  Fan assembly fit
start ii. Identify types of safety according to hole
iii. Cutting hole sizes single phase motor handling size
iv. Types of building starting procedure  Fan disassemble
material such as iii. Determine ii. Observe Fall according to
 Brick opening size / protection instruction
 Wood location for safety manual
 Metal installing fan  Electrical cabling
v. Appropriate iv. Select appropriate route properly
cutting tools such cutting tools based according
as construction electrical
 Jigsaw material to cut the specification
 Hacking intended opening  Fan is operating
vi. Fan disassemble v. Select fastening in proper
technique screws for functional order
vii. Single phase mounting fan
wiring works vi. Install fan into
opening /location
vii. route Electrical
cabling to power
source
viii. Test run ventilation
fan
ix. Verify fan
performance
x. Generate report on
completion of fan
43
installation
2 Perform i. Types of 10 hours Lecture  Ventilation fan

ventilation fan ventilation fan components
servicing components such identified
as according to
 Damper maintenance
 Blower requirement
 Bearing  Types of cleaning
 Mounting chemical selected
ii. Types of cleaning based on material
chemical such as of components
 Soap  Types of lubricant
 Detergent selected according
iii. Types of lubricant to manufacturer
such as requirement
 Oil  Types of cleaning
 Grease rags selected
iv. Types of cleaning according to
rags such as component
 Cotton i. Obtain ventilation i. Resourceful of 25 Hours Demonstration assembly
v. Types of brush fan service electrical safety  Types of brush
such as requirement handling selected according
 Paint checklist procedure to component
brush ii. Determine ii. Fall protection assembly
 Condenser ventilation fan safety
brush components iii. Hazard
iii. Select suitable communication
44
rags for cleaning on chemicals
the specific
component
iv. Select suitable
cleaning
chemical
v. Clean ventilation
fan blade
vi. Clean ventilation
fan housing
vii. Determine types
of lubricant
viii. Carry out
ventilation fan
bearing greasing
ix. Check ventilation
fan electrical
connection for
tightness
x. Check ventilation
fan performance
xi. Prepare
ventilation fan
service
completion report
45
3. Perform i. Types of faults 10 Hours Lecture  Fault sources
ventilation fan  Unable to run determined based
troubleshooting  Noisy on customer
 Vibration complaints
 Motor  Fan installed,
overheated operated, and
 Jammed maintained
 Short circuit according to
 Insufficient air manufacturers
flow installation,
ii. Faults report operation and
iii. Manufacturers maintenance
installation, manual
operation and  Review
maintenance Manufacturer’s
manual i. Study i. Observe safety 20 Hours Demonstration troubleshooting
iv. Operating manufacturer precaution guide
principle troubleshooting ii. Wear safety  Identify defective
v. Wiring diagram guide clothing or parts replacement
ii. Identify types of PPE where required for fault
faults required rectification
iii. Rectify the fault iii. Resourceful of  Understand
immediately electrical operating
iv. Prepare faults safety – lock principle
report out / tag out  Understand wiring
(LOTO) diagram
iv. Fall protection schematics
safety
46
4. Perform i. Types of worn 14 Hours Lecture  Types of worn
ventilation fan out / defective out / defective
repairing parts parts identified
 Motor according to
 Fan blade faults
 Capacitor rectification
 Bearing  Electrical
 Damper instrument
 Electrical testing to
completeness confirm faults
(Cabling &  Correct parts
switches) identified for the
ii. Type of electrical faults
test instrument  Method and part
 Multi meter replacement are
 Ampere correct for faults
meter rectification
iii. Identification of  Report is
defective part accurate and
required complete for
iv. Method of fault rectification
replacement with
appropriate tools
 Disassembly
 Re-assembly
47
i. Determine i. Observe safety 24 Hours Demonstration
ventilation fan precaution
scope of repair ii. Wear safety
required clothing or
ii. Select PPE where
appropriate required
electrical iii. Resourceful of
instrument for electrical
testing safety – lock
iii. Confirm required out / tag out
parts specification (LOTO)
iv. Check required iv. Fall protection
parts specification safety
availability
v. Apply appropriate
method for parts
replacement work
vi. Test ventilation
fan functionality
after repairing
vii. Prepare
ventilation fan
repairing record
for reference
48

10. Meticulous
11. Diligence
12. Compliance

Support tools 1:20
Electrical tools 1:20
Special tools 1:20
49
References:
1. Paul Roe Jordan(1955), Ventilation manual for sheet metal contractors;: A treatise on the type of ventilation which sheet metal
contractors are called upon to plan and install,
2. Gerald R Bodman(1995), Ventilation fans: Types and sizes (NebGuide)
3. David P Shelton(1982), Ventilation fans: Types and sizes (NebGuide)
4. James E. Brumbaugh(Aug 6, 2004), Audel HVAC Fundamentals, Air Conditioning, Heat Pumps and Distribution Systems
5. George Edward McElroy(1923), Air-measured methods for experimental work on fan-pipe installations (Report of investigations / United
States Department of the Interior, Bureau of Mines)
6. Charles L. Hubbard(Apr 27, 2009), The Ventilation Hand Book: The Principles and Practice of Ventilation as Applied to Furnace Heating
Ducts, Flues and Dampers For Gravity Heating Fans and ... With the Method of Ventilating Ships
7. Paul Roe Jordan(1955),Ventilation manual for sheet metal contractors;: A treatise on the type of ventilation which sheet metal
contractors are called upon to plan and install,
50
Job Area
Competency Unit Title WINDOW UNIT (1PH) INSTALLATION & MAINTENANCE
Window unit (1ph) is a component of the air conditioning system and its function is to cool and dehumidify air
Competency Unit Descriptor for human comfort. The competency involved is focus on capacity of the window unit for installation, servicing,
troubleshooting and preparation of service report.
Training Credit
Competency Unit ID Level 3 148 hours
Duration Hours

1. Perform window i. Window unit 14 Hours Lecture  Capacity of
unit installation manufacturer window unit
installation, correctly installed
operation and according to
maintenance customer order
manual  Electrical circuit
ii. Window unit has sufficient
capacity current carrying
 1.0HP ~ capacity
9000 Btu / according to full
Hr load amps
 1.5HP ~ requirement
13000 Btu /  Determine height
Hr and width of
 2.0HP ~ window / opening
51
18000 Btu / is correct for the
Hr unit case
iii. Full load Amps  Air conditioner
iv. Size of power i. Identify i. Observe safety 24 Hours Demonstration mechanism
cables window unit precaution removed from
v. Name plate capacity ii. Wear safety casing properly
vi. Building ii. Determine full clothing or according to
structure load Amps PPE where manufacturer
vii. Window unit iii. Determine required instruction
manufacturer size of power iii. Resourceful of  Empty casing
installation, cables electrical securely mounted
operation and iv. Interpret safety – lock in the window /
maintenance information of out / tag out opening
manual name plate (LOTO)  Unit is sloping
viii. Height and v. Assess iv. Meticulous in outside according
width of building cutting safety to manufacturer
window / structure handling instruction
opening strength v. Careful in  Fasten the
according to vi. Recognise removing air cabinet to the
manufacturer window unit conditioner opening / window
specification manufacturer mechanism frame with screw
ix. Method of air installation from casing to run through the
conditioner manual avoid any hole
mechanism vii. Determine damage  Air conditioner
removal from height and mechanism
casing width of installed correctly
x. Method to fix window / according to
empty case in opening is manufacturer
52
the window / correct for the instruction
opening unit case  No gaps on the
xi. Method to fix viii. Select perimeter of
air conditioner appropriate casing
mechanism cutting tools  Unit in proper
into casing based functional order
xii. Method to fix construction  Method of air
insulation or material to cut conditioner
weather the intended mechanism
stripping opening removal from
xiii. Basic electrical ix. Position empty casing
work case in the  Method to fix
xiv. Building window / empty case in the
structure opening window / opening
xv. Height and x. Place the  Method to fix air
width of empty casing conditioner
window / to sloped mechanism into
opening outside (equal casing
according to to a half  Method to fix
manufacturer bubble on a insulation or
specification tool ~ water weather stripping
level)
xi. Fasten the
empty casing
to the opening
/ window
frame with
screw run
53
through the
hole
xii. Raise and sit
the air
conditioner
mechanism
into casing
xiii. Seal all gaps
with insulation
or weather
stripping
xiv. Plug on and
power up the
air conditioner
xv. Test window
unit
functionality
and
performance
xvi. Confirm
window unit
installation
completion
xvii. Prepare report
on completion
of window unit
installation
54
2. Perform window i. Window unit 13 Hours Lecture  Window unit
unit servicing components components
 Air filter identified
 Drain pan & according to
drain pipe maintenance
 Cooling & requirement
condenser  Types of cleaning
coil chemical selected
 Compressor based on material
 Unit cabinet of components
 Condenser  Types of lubricant
fan selected
 Blower according to
ii. Types of cleaning manufacturer
chemical such as requirement
 Soap  Types of cleaning
 Detergent rags selected
iii. Types of lubricant according to
such as component
 Oil assembly
 Grease  Types of brush
iv. Cleaning rags selected
v. Types of brush according to
 Paint brush component
assembly
 Condenser
brush
55
i. Obtain window i. Follow electrical 25 Hours Demonstration
unit service safety handling
requirement procedure
checklist ii. Adhere to Fall
ii. Determine protection safety
window unit iii. Careful in
components to chemical
service handling
iii. Select suitable
cleaning
chemical for
window unit
servicing
iv. Select
appropriate
lubricant for
window unit
servicing
v. Select suitable
cleaning rags
for window unit
servicing
vi. Select suitable
brush for
window unit
servicing
vii. Clean window
unit filter
56
viii. Clean window
unit cooling coil
ix. Clean window
unit fan blade
x. Clean window
unit fan housing
xi. Grease window
unit oil fan
bearing
xii. Clean window
unit air grilles
xiii. Check window
unit electrical
connection for
tightness
xiv. Clean window
unit condenser
coil
xv. Clean/clear
window unit
condensate
drain pipe of
any blockage
xvi. Test window
unit
functionality
and
performance
57
xvii. Prepare
window unit
servicing
completion
report
3. Perform window i. Window unit 12 Hours Lecture  Fault sources
unit manufacturers determined based
troubleshooting troubleshooting on customer
manual complaints
ii. Types of window  Fan installed,
unit faults operated, and
 Unable to run maintained
 Noisy / according to
Humming manufacturers
 Vibration installation,
 Motor or operation and
compressor maintenance
overheated manual
 Motor or
compressor
jammed
 Short circuit
 Insufficient air
flow
 Room
temperature
not cool
58
 Leaked
 Remote
control not
function
 Overflow of
Condensation
water
 Short cycling
of compressor
or motor
 Condensation
on the damper
iii. Faults report
iv. Operating
principle
v. Wiring diagram
i. Recognise i. Observe safety 24 Hours Demonstration
window unit precaution
manufacturers ii. Wear safety
troubleshooting clothing or
manual PPE where
ii. Recognise required
window unit iii. Resourceful of
operating electrical
principle safety – lock
vi. Recognise out / tag out
window unit (LOTO)
wiring diagram iv. Fall protection
59
schematics safety
iii. Determine types
of window unit
faults
iv. Determine
window unit
defective parts
replacement
required for fault
rectification
v. Rectify window
unit fault
vi. Prepare fault
report if window
unit fault cannot
be rectified
immediately
4. Perform window i. Condenser coil 12 Hours Lecture  Types of worn out /
unit repairing performance defective parts
evaluation identified according
ii. Evaporator coil to faults
evaluation rectification
iii. Functionality of  Electrical tools and
blower fan / HVAC tools testing
motor to confirm faults
iv. Functionality of  Correct parts
condenser fan / identified for the
motor
60
v. Functionality of faults
Metering Device  Method and part
vi. Functionality of replacement are
Compressor correct for faults
vii. Functionality of rectification
Thermostat
(Room
Temperature
Controller)
viii. Functionality of
I.C board
ix. Functionality of
Remote
controller
x. Functionality of
Electrical Starter
xi. Functionality of
Capacitor
xii. Functionality of
Air Damper
xiii. Functionality of
Refrigeration
Circuit
xiv. Electrical
completeness
(Cabling &
switches)
xv. Type of electrical
61
test tools and
ACMV tools
 Multi meter
 Ampere
meter
 Meggar
meter
 Pressure
Gauge
Manifold
xvi. Method of
replacement with
appropriate tools
 Disassemb
ly
 Re-
assembly
i. Determine types i. Observe safety 24 Hours Demonstration
of worn out / precaution
defective parts ii. Wear safety
ii. Select clothing or PPE
appropriate where required
electrical tools iii. Resourceful of
and HVAC tools electrical safety
for testing – lock out / tag
iii. Determine out (LOTO)
required parts to iv. Fall protection
replace safety
62
specification
iv. Apply
appropriate
method for parts
replacement
work
v. Test window unit
functionality and
performance
after part
replacement
vi. Confirm window
unit functionality
and performance
after part
replacement
vii. Prepare window
unit repairing
record for
reference
63

10. Meticulous
11. Diligence
12. Compliance
64
Window unit air conditioner (Various Capacity and Size) 1:20

Support tools 1:20
Electrical tools 1:20
Special tools 1:20
References:
1. Home Heating & Air Conditioning Systemsby James L. Kittle(Apr 1, 1990)

2. Troubleshooting and Servicing Modern Air Conditioning and Refrigeration Systemsby John Tomczyk(Sep 1, 1995)
3. Air Conditioning and Refrigeration Repairby Roger A. Fischer and Ken Chernoff(Aug 1, 1988)
4. Servicing comfort cooling systems: fundamentals of installation, troubleshooting, and repairby William Walton Woodroof(1983)
65
Job Area
Competency Unit Title AIR COOLED SPLIT UNIT (1PH) INSTALLATION & MAINTENANCE
Air Cooled Split unit (1ph) is a component of the air conditioning system and its function is to cool and
Competency Unit
dehumidify air for human comfort. The competency involved is focus on the capacity and types of the air cooled
Descriptor
split for installation, servicing, troubleshooting and preparation of service report.
Training Credit
Competency Unit ID Level 3 148 hours
Duration Hours

1. Perform air i. Air cooled split unit 12 Hours Lecture  Capacity of air
cooled split capacity cooled split unit
unit (Indoor)  1.0HP ~ 9000 Btu correctly installed
installation / Hr according to
 1.5HP ~ 13000 customer order
Btu / Hr  Electrical circuit
 2.0HP ~ 18000 has sufficient
Btu / Hr current carrying
 2.5HP ~ 24000 capacity according
Btu / Hr to full load amps
 3.0HP ~ 28000 requirement
Btu / Hr  The indoor unit is
ii. Full load Amps install in the best
iii. Size of power location for air
cables distribution
66
iv. Air cooled split unit  The indoor unit is
(Indoor) installation securely mounted
technique  The unit operate
v. Location for quietly
installing indoor  The refrigerant
and outdoor unit piping has no
vi. Mounting brackets condensation
 Condensate water
can flow smoothly
i. Determine air i. Observe 26 Hours Demonstration thru the drain pipe
cooled split unit safety  The outdoor unit
capacity precaution has proper heat
ii. Determine ii. Wear safety rejection
location for clothing or  All piping are
installing indoor PPE where securely and
and outdoor required neatly routed
unit iii. Resourceful of
iii. Select electrical
appropriate safety – lock
tools for cutting out / tag out
opening for (LOTO)
refrigerant iv. Fall protection
piping safety
iv. Fabricate
mounting
brackets for
outdoor unit
v. Select fastening
67
screws for
mounting indoor
unit
vi. Execute indoor
and outdoor
installation
vii. Connect
refrigerant
piping
viii. Purge/evacuate
refrigerant
piping
ix. Perform leak
test connections
and fittings
x. Route electrical
cable from
power source to
indoor and
outdoor unit
2. Perform air i. Air cooled split 12 hours Lecture  Air cooled split
cooled split unit components unit components
unit  Washable air identified
servicing filter according to
 Refrigerant maintenance
pipe requirement
 thermal  Types of
68
insulation cleaning
 Drain pan chemical
 Drain pipe selected based
 Cooling coil on material of
(indoor unit) components
& condenser  Types of
coil (outdoor lubricant selected
unit) according to
 Compressor manufacturer
 Indoor Unit requirement
mounting /  Types of
outdoor unit cleaning rags
bracket selected
 Condenser according to
fan component
 Blower fan assembly
ii. Types of cleaning  Types of brush
chemical such as selected
 Soap according to
 Detergent component
iii. Types of lubricant assembly
such as
 Oil
 Grease
iv. Cleaning rags
v. Types of brush
such as
 Paint brush
69
 Condenser
brush
i. Obtain service i. Resourceful 26 hours Demonstration

requirement of electrical
checklist safety
ii. Determine air handling
cooled split procedure
unit ii. Fall
components to protection
service safety
iii. Select suitable iii. Hazard
cleaning communicati
chemical for on on
split unit chemicals
components
service
iv. Select suitable
lubricant for
split unit
components
service
v. Select suitable
cleaning rags
for split unit
components
service
vi. Select suitable
70
brush for split
unit
components
service
vii. Clean split unit
filter
viii. Clean split unit
cooling coil
ix. Clean split unit
fan blade
x. Clean split unit
fan housing
xi. Carry out split
unit fan
bearing oiling
xii. Clean split unit
air grilles
xiii. Check split
unit electrical
connection for
tightness
xiv. Clean split unit
condenser coil
xv. Clean/clear
split unit
condensate
drain pipe to
avoid blockage
71
xvi. Test split unit
functionality
and
performance
xvii. Prepare split
unit service
completion
report
3. Perform air i. Types of faults 12 hours Lecture  Fault sources
cooled split  Unable to run determined based
unit  Noisy / motor on customer
troubleshooting or compressor complaints
humming  Fan installed,
 Vibration operated, and
 Compressor maintained
,condenser fan according to
or blower manufacturers
motor installation,
overheated operation and
 Compressor, maintenance
condenser fan manual
or blower
motor jammed
 Short circuit
 Insufficient air
flow
 Room
temperature
72
not cool
 Leaked
 Remote control
not function
 Overflow of
Condensation
water
 Short cycling of
compressor,
condenser fan
or blower
motor
 Condensation
on the damper
ii. Faults report
iii. Manufacturers
installation,
operation and
maintenance
manual
iv. Operating principle
v. Wiring diagram
i. Recognise split i. Observe 25 hours Demonstration
unit safety
manufacturer’s precaution
troubleshooting ii. Wear safety
guide clothing or
ii. Recognise split PPE where
73
unit operating required
principle iii. Resourceful of
iii. Recognise split electrical
unit wiring safety – lock
diagram out / tag out
schematics (LOTO)
iv. Determine types iv. Fall protection
of split unit safety
faults i. Meticulous in
v. Determine split paying
unit defective attention to
parts details
replacement ii. Thorough in
required for fault diagnosis of
rectification fault and
vi. Rectify split unit troubleshooting
fault
vii. Prepare fault
report if split
unit fault cannot
be rectified
immediately
4. Perform air i. Types of worn out 10 hours Lecture  Types of worn

cooled split / defective parts out / defective
unit repairing such as parts identified
 Condenser according to
fan Motor faults rectification
74
 Blower fan  Electrical tools
motor and ACMV tools
 Compressor testing to confirm
 Room faults
temperature  Correct parts
controller identified for the
 I.C board faults
 Remote  Method and part
controller replacement are
 Electrical correct for faults
Starter rectification
 Fan blade
 Capacitor
 Bearing
 Damper
 Capillary
tube
 Liquid
strainer/ drier
 Dirty of
condenser
/evaporator
fin coil
 Electrical
completenes
s (Cabling &
switches)
 Thermal
75
insulation
ii. Type of electrical
test instrument
and ACMV tools
such as
 Multi meter
 Ampere
meter
 Megger
meter
 Manifold
pressure
gauge
iii. Identification of
defective part
required
iv. Method of
replacement with
appropriate tools
 Disassembly
 Re-assembly
i. Determine types i. Observe safety 25 hours Demonstration
of split unit worn precaution
out / defective ii. Wear safety
parts clothing or
ii. Select PPE where
appropriate required
electrical tools iii. Resourceful of
76
and ACMV tools electrical
for testing safety – lock
iii. Confirm out / tag out
required parts (LOTO)
specification iv. Fall protection
iv. Check required safety
parts iii. Meticulous in
specification paying
availability attention to
v. Apply details
appropriate iv. Thorough in
method for split diagnosis of
unit parts fault and
replacement troubleshooting
work
vi. Test split unit
functionality
after repairing
vii. Prepare split
unit repairing
record for
reference
77

10. Meticulous
11. Diligence
12. Compliance

Basic HVAC (Heating Ventilation Air Conditioning) hand tools 1 : 20
Support tools 1 : 20
Electrical tools 1 : 20
Special tools 1 : 20
78
References:
1. John S. Page (1978), Estimator's Man-Hour Manual on Heating, Air Conditioning, Ventilating, and Plumbing, Second Edition (Man-Hour
Manuals)
2. Dick Wirz (2009), Commercial Refrigeration: For Air Conditioning Technicians
3. Richard Jazwin (August 1, 2001), Troubleshooting and Servicing HVAC&R Electrical Systems
4. R S Means Company(Paperback - Sep 2001), Square Foot & Assemblies Estimating Methods (Means Square Foot & Assemblies
Estimating)
79

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JOB PROFILE CHART (JPC)

SECTOR MECHANICAL ENGINEERING

JOB AREA INSTALLATION, SERVICING, TROUBLESHOOTING & REPAIR

COMPETENCY COMPETENCY UNIT

AIR COOLED SPLIT

Sub Sector HEATING VENTILATION AIR CONDITIONING (HVAC)

CU Title CU Code CU Descriptor CU Work Activities Performance Criteria

competency of risks & precautions are adequate

3. Prepare refrigerant 3.1 All refrigerant is

troubleshooting and Manufacturer’s

3. Perform ventilation fan 3.1 Ventilation fan

4. Perform ventilation fan 4.1 Ventilation fan

3. Perform window unit 3.1 Window unit

4. Perform window unit 4.1 Window unit

window unit was

and preparation of service acknowledgement

2. Perform air cooled split 2.1 The split unit

3. Perform air cooled split 3.1 Split unit

4. Perform air cooled split 4.1 Split unit repaired

Sub Sector HEATING VENTILATION AIR CONDITIONING (HVAC)

Attitude / Safety / Training Delivery

i. Identify equipment i. Follow safety 23 Hours Demonstration

4. Carry out safety i. Expected 10 hours Lecture  Documentation of

Core Abilities Social Skills

01.01 Identify and gather information 1. Communication skills

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

Basic HVAC (Heating Ventilation Air Conditioning) hand tools 1:20

Attitude / Safety Training Delivery

i. Diagnose i. Safety minded 23 Hours Demonstration

2. Perform i. The 3 R’s of 14 Hours Lecture  Refrigerant

3. Prepare i. Details of all 14 hours Lecture  Refrigerant

Core Abilities Social Skills

01.01 Identify and gather information 1. Communication skills

ITEMS RATIO (TEM : Trainees)

DOE regulation on ozone depleting substances 1:1

Attitude / Safety / Training Delivery Assessment

2 Perform i. Types of 10 hours Lecture  Ventilation fan

01.01 Identify and gather information 1. Communication skills

Tools, Equipment and Materials (TEM)

ITEMS RATIO (TEM : Trainees)

Attitude / Safety / Training Delivery

01.01 Identify and gather information 1. Communication skills

Window unit air conditioner (Various Capacity and Size) 1:20

1. Home Heating & Air Conditioning Systemsby James L. Kittle(Apr 1, 1990)

Attitude / Safety / Training Delivery

i. Obtain service i. Resourceful 26 hours Demonstration

4. Perform air i. Types of worn out 10 hours Lecture  Types of worn

01.01 Identify and gather information 1. Communication skills

Tools, Equipment and Materials (TEM)

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