REFRIGERATION AND AIR

CONDITIONING TECHNICIAN
NSQF LEVEL - 5

1st Year (Volume I of II)

TRADE PRACTICAL

SECTOR: Capital Goods & Manufacturing

DIRECTORATE GENERAL OF TRAINING

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
GOVERNMENT OF INDIA

NATIONAL INSTRUCTIONAL
MEDIA INSTITUTE, CHENNAI
Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032.

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Sector : Capital Goods & Manufacturing
Duration : 2 - Years
Trade : R&ACT 1st Year (Volume I of II) Trade Practical - (NSQF Level - 5)

Developed & Printed by

National Instructional Media Institute

Post Box No.3142
Guindy, Chennai - 600032
INDIA
Email: chennai-nimi@nic.in
Website: www.nimi.gov.in

Printed by
National Instructional Media Institute
Chennai - 600 032

First Edition : February 2020 Copies : 1000

Rs.225/-

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 FOREWORD

The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every
four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial
Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower.
Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus
has been recently updated with the help of Mentor Councils comprising various stakeholder's viz. Industries,
Entrepreneurs, Academicians and representatives from ITIs.

The National Instructional Media Institute (NIMI), Chennai, an autonomous body under Ministry of Skill
Development & Entrepreneurship is entrusted with developing producing and disseminating Instructional
Media Packages (IMPs) required for ITIs and other related institutions.

The institute has now come up with instructional material to suit the revised curriculum for R&ACT 1st Year
(Volume I of II) Trade Practical NSQF Level - 5 in Capital Goods & Manufacturing Sector under
annual pattern. The NSQF Level - 5 Trade Theory will help the trainees to get an international equivalency
standard where their skill proficiency and competency will be duly recognized across the globe and this will
also increase the scope of recognition of prior learning. NSQF Level - 5 trainees will also get the opportunities
to promote life long learning and skill development. I have no doubt that with NSQF Level - 5 the trainers
and trainees of ITIs, and all stakeholders will derive maximum benefits from these IMPs and that NIMI's
effort will go a long way in improving the quality of Vocational training in the country.

The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation
for their contribution in bringing out this publication.

Jai Hind

Director General/ Addl.Secretary

Ministry of Skill Development & Entrepreneurship,
Government of India.

New Delhi - 110 001

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 PREFACE

The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then Directorate
General of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under Ministry
of Skill Development and Entrepreneurship) Government of India, with technical assistance from the Govt.
of the Federal Republic of Germany. The prime objective of this institute is to develop and provide instructional
materials for various trades as per the prescribed syllabi under the Craftsman and Apprenticeship Training
Schemes.

The instructional materials are created keeping in mind, the main objective of Vocational Training under
NCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials are
generated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practical
book, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) and
other support materials.

The trade practical book consists of series of exercises to be completed by the trainees in the workshop.
These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade
theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and
assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.
The wall charts and transparencies are unique, as they not only help the instructor to effectively present a
topic but also help him to assess the trainee's understanding. The instructor guide enables the instructor to
plan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.

In order to perform the skills in a productive manner instructional videos are embedded in QR code of the
exercise in this instructional material so as to integrate the skill learning with the procedural practical steps
given in the exercise. The instructional videos will improve the quality of standard on practical training and
will motivate the trainees to focus and perform the skill seamlessly.

IMPs also deals with the complex skills required to be developed for effective team work. Necessary care
has also been taken to include important skill areas of allied trades as prescribed in the syllabus.

The availability of a complete Instructional Media Package in an institute helps both the trainer and
management to impart effective training.

The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the Media
Development Committees specially drawn from Public and Private sector industries, various training institutes
under the Directorate General of Training (DGT), Government and Private ITIs.

NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Training
of various State Governments, Training Departments of Industries both in the Public and Private sectors,
Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but for
whose active support NIMI would not have been able to bring out this materials.

R. P. DHINGRA
Chennai - 600 032 EXECUTIVE DIRECTOR

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 ACKNOWLEDGEMENT

National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and
contribution extended by the following Media Developers and their sponsoring organisations to bring out this
Instructional Material (Trade Practical) for the trade of R&ACT 1st Year (Volume I of II) NSQF (Level - 5) under
Capital Goods & Manufacturing Sector for ITIs.

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Shri. T.C. Shantilal - VI, NSTI,

Trivandram.

Shri. Ravichandran - ATO, Govt ITI,

Perumbakkam.

Shri. P. Mohan - ATO, Govt ITI

North Chennai - 32.

Shri. P. Senthil - AAJ, RTD office

Madurai

Shri. N. Punniyakotty - ATO, Govt ITI,

Guindy, Chennai - 32.
NIMI,

Shri. K. A. Sreekanth - SI, Govt ITI Vayalar

Kerala.

Shri. Mobin Joseph - SI, Govt ITI

Pallickathode
Kerala

NIMI CO-ORDINATORS

Shri. Nirmalya nath - Deputy General Manager,

NIMI, Chennai - 32

Shri. V. Gopalakrishnan - Assistant Manager,

NIMI, Chennai - 32

NIMI records its appreciation for the Data Entry, CAD, DTP operators for their excellent and devoted services in
the process of development of this Instructional Material.

NIMI also acknowledges with thanks the invaluable efforts rendered by all other NIMI staff who have contributed
towards the development of this Instructional Material.

NIMI is also grateful to everyone who has directly or indirectly helped in developing this Instructional Material.

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 INTRODUCTION
TRADE PRACTICAL
The trade practical manual is intended to be used in practical workshop. It consists of a series of practical
exercises to be completed by the trainees during the course of R&ACT Trade supplemented and supported by
instructions / informations to assist in performing the exercises. These exercises are designed to ensure that
all the skills in compliance with NSQF LEVEL - 5 syllabus are covered.

The manual is divided into Seven modules. The Seven modules are given below:

Module 1 Fitting & Sheet metal

Module 2 Electrical

Module 3 Electronics

Module 4 Welding

Module 5 Basic Refrigeration

Module 6 Refrigerator (Direct Cool)

Module 7 Frost free refrigerator/Inverter Refrigerator

The skill training in the shop floor is planned through a series of practical exercises centered around some
practical project. However, there are few instances where the individual exercise does not form a part of project.

While developing the practical manual, a sincere effort was made to prepare each exercise which will be easy to
understand and carry out even by below average trainee. However the development team accept that there is a
scope for further improvement. NIMI looks forward to the suggestions from the experienced training faculty for
improving the manual.

TRADE THEORY

The manual of trade theory consists of theoretical information for the Course of the R&ACT Trade. The contents
are sequenced according to the practical exercise contained in NSQF LEVEL - 5 syllabus on Trade Practical.
Attempt has been made to relate the theoretical aspects with the skill covered in each exercise to the extent
possible. This correlation is maintained to help the trainees to develop the perceptional capabilities for performing
the skills.

The trade theory has to be taught and learnt along with the corresponding exercise contained in the manual on
trade practical. The indications about the corresponding practical exercises are given in every sheet of this
manual.

It will be preferable to teach/learn trade theory connected to each exercise at least one class before performing
the related skills in the shop floor. The trade theory is to be treated as an integrated part of each exercise.

The material is not for the purpose of self-learning and should be considered as supplementary to class room
instruction.

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 CONTENTS
Ex.No. Title of the Exercise Learning Page.
Outcome No.

Module 1 : Fitting & Sheet metal

1.1.01 Identify workshop and machineries 1
1.1.02 Demonstrate safety precautions and first aid 2
1.1.03 Demonstrate - fire fighting 8
1.1.04 Demonstrate on health hazards, and personal safety 10
1.1.05 Identify general tools Instruments & equipments with care and maintenance 13
1.1.06 Practice flat filing, marking, punching & sawing 18
1.1.07 Practice: Drilling ,reaming tapping & Dieing and check using precision 1, 2, 3.
measuring instruments 22
1.1.08 Cutting sheet by straight snip 28
1.1.09 Cutting Sheet by Bent snip 30
1.1.10 Bend fold and joints sheet metal 31
1.1.11 Joining sheet metal by using rivet set and snap 32
1.1.12 Joining sheet metal by soldering 35
1.1.13 Prepare a box with sheet metal or funnel as per drawing 36

Module 2 : Electrical
1.2.14 Demonstrate Electrical safety precaution and first aid 41
1.2.15 Identify, use and maintain Electrical tools 46
1.2.16 Prepare simple twist joints of wires / cables 50
1.2.17 Prepare married joint 52
1.2.18 Measure current, voltage, resistance, power, frequency and energy using analog 4
and digital meter 53
1.2.19 Test insulation and earth resistance using megger 57
1.2.20 Connect star and delta connection on a three phase motor 60
1.2.21 Measure three-phase power and power factor 62

Module 3 : Electronics
1.3.22 Identify the electronic components, tools and instruments 66
1.3.23 Colour coding of resistor 71
1.3.24 Verify ohm's law 73
1.3.25 Use Voltmeter, Ammeter and Multimeter 75
1.3.26 Practice soldering and de-soldering 5 76
1.3.27 Identify Transistors, Resistors, Capacitors, diodes, SCR, UJT, amplifier and IC's 80
1.3.28 Construct and test Full-wave rectifiers using diodes 81
1.3.29 Construct and test a Bridge rectifier 83
1.3.30 construct and test series voltage regulator circuit 85
1.3.31 Construct and test power supply using fixed voltage regulator Ics 87

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Ex.No. Title of the Exercise Learning Page.
Outcome No.

1.3.32 Identify and test SCR 89

1.3.33 Construct and test an electronic timer using UJT and SCR 91
1.3.34 Apply op - amp photo transistor and test performance 92

Module 4 : Welding

1.4.35 Identify gas welding equipment and accessories 94

1.4.36 Demonstrate safety precaution in handling of Oxy- Acetylene of
cylinder, regulator 96
1.4.37 Setting up Air - LPG, can type O2 - LPG and O2 - C2 H2 using
portable flame set. 99
Attaching gas regulators 6 101
Attaching blow pipe 102
Adjusting gas pressure 103
Lighting, setting, extinguishing oxy-acetylene flame and shutting the plant 104
1.4.38 Oxy- Acetylene gas cutting , brazing & welding on sheet metal. 106
1.4.39 Demonstrate care & safety of welding tools and equipments and back fire arrestor 109
1.4.40 Set- oxy acetylene plant, use two stage regulator adjusting &flame and
gas pressure 110
1.4.41 Perform brazing between copper to copper and copper to MS, copper to
aluminium pipes 111
1.4.42 Prepare square butt joint on and Lap joint on M.S sheet 112

Module 5 : Basic refrigeration

1.5.43 Identify & use of general hand tools, Instruments and equipment used in
refrigeration work shop 117
1.5.44 Identify special tools ,Instruments and equipment used in refrigeration work shop 118
1.5.45 Identify the components of vapour compression system and vapour absorption
system 124
1.5.46 Unroll, cut and bend on soft copper tubes 7 126
1.5.47 Swage and make a brazed joint on copper tubing 128
1.5.48 Make flare joints and test them with flare fittings 131
1.5.49 Pinch off copper tubing 133
1.5.50 Connect the copper tubes with locking fitting 134
1.5.51 Brazing of cu to cu, cu to steel cu to braze using Air - LPG 135
1.5.52 Brazing of cu to cu, cu to steel and cu to brass using Oxy LPG set 136
1.5.53 Brazing of cu to cu, cu to steel, cu to braze using Oxy- acetylene 137

Module 6 : Refrigerator (Direct Cool)

1.6.54 Identify the Electrical and Mechanical components of refrigerator 140

1.6.55 Check and replace electrical components in Refrigerator 142

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Ex.No. Title of the Exercise Learning Page.
Outcome No.

1.6.56 Test leak, evacuation and gas charging in refrigerators 146

Evacuate hermetic system in refrigerator 149
Charge Refrigerant in refrigerator 152
1.6.57 Check the wiring circuit of refrigerator 158
1.6.58 Install and inspect a new Domestic Refrigerator 161
1.6.59 Identify electrical components of direct cool refrigerator 164
1.6.60 Identify mechanical components of direct cool refrigerator 8, 9, 10 164
1.6.61 Installation of refrigerator 164
1.6.62 Checking alignment of door & replacing door gaskets 165
1.6.63 Tracing the Mechanical components of refrigerator 167
1.6.64 Tracing the electrical components of refrigerator 168
1.6.65 Testing of compressor 171
1.6.66 Identification of compressor motor terminals 173
1.6.67 Start Compressor with and without relay 175
1.6.68 Testing the performance of Refrigerator 176
1.6.69 Clean and flush for contamination in condenser coil, evaporator coil in
conventional refrigerator 177
1.6.70 Replacement of capillary tube and drier 180
1.6.71 Install gauge manifold in the system 182
1.6.72 Leak testing, evacuation and gas charging in refrigerator 184
1.6.73 Check electrical wiring of refrigerator 184

Module 7 : Frost free refrigerator/Inverter Refrigerator

1.7.74 Trace the electrical circuit and check frost free refrigerator 185
1.7.75 Checking fault finding and testing of electrical Components in frost free refrigerator 187
1.7.76 Check air distribution system in frost free refrigerator 11 190
1.7.77 Service components of frost free refrigerator 192
1.7.78 Testing performance of frost free refrigerator 194
1.7.79 Identify three and four door no frost refrigerator 195
1.7.80 Stripping the components of Inverter Refrigerator 180
1.7.81 Tracing electric circuit of Inverter Refrigerator and testing the components 197
1.7.82 Testing the components of inverter refrigerator 199
1.7.83 Leak testing ,evacuation & gas charging (Inverter Technology) 200

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 LEARNING / ASSESSABLE OUTCOME

On completion of this book you shall be able to

Sl.No Learning Outcome Exercise No.

1 Identify trade related hazards and safety procedures following

safety precautions. 1.1.01 to 04
2 Produce fitting jobs as per drawing (Range of operation:
marking, sawing filing, drilling reaming, taping and dieing etc.) 1.1.05 to 07
3 Produce sheet metal components (range of operation - marking,
metal cutting bending, riveting and soldering etc.) 1.1.08 to 13
4 Identify electrical safety. Join different wire, measure power,
currents, volts and earth resistance etc. Connect single phase, 1.2.14 to 21
3 phase motors i.e. star and delta connections.
5 Identify the electronic components and their colour code i.e
transistor, capacitor, diode, amplifier, I.C and able to work 1.3.22 to 34
soldering.
6 Perform gas welding, brazing, soldering observing related safety. 1.4.35 to 42
7 Identify RAC tools and equipments and recognise different parts
of RAC system. Perform copper tube cutting, flaring swaging, 1.5.43 to 53
brazing.
8 Test mechanical and electrical components. Perform leak test, 1.6.54 to
vacuuming, gas charging, wiring and installation of refrigerator. 1.6.61 &
1.6.63 to 64
9 Perform door alignment, door gasket fitting, replace door switch. 1.6.62
10 Test compressor motor terminal, start compressor direct with
relay and without relay, technique of flushing, leak testing, 1.6.65 to 73
replacing capillary and filter drier, evacuating and gas charging.
11 Check components of frost free refrigerator (electrical /
mechanical), wiring of frost free freeze and air distribution in 1.7.74
refrigerator sector. Leak detection, evacuators and gas charging.

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 SYLLABUS

1st Year (Volume I of II) Duration: Six Months

Duration Reference Learning Professional Skills

Professional Knowledge
Outcome (Trade Practical)
(Trade Theory)
with Indicative hours
P r o f e s s i o n a l Identify trade related 1. Identify workshop & machineries. Introduction to trade and related
Skill 25 hrs.; hazards and safety (06 hrs) industries.
procedures following 2. Demonstrate Safety precautions and General safety precautions and
Professional
safety precautions. First aid. (06 hrs) first aids, fire fighting equipments
Knowledge
and electrical safety.
07 hrs. 3. Demonstrate fire fighting (03 hrs)
History of Refrigeration and Air
4. Demonstrate working at height using conditioning.
PPE’s and identify the hazards and Function, use and specifications
take personal safety precautions. of refrigeration tools, instruments
(10 hrs) and equipment.
Grooming of technicians. (07 hrs)
P r o f e s s i o n a l Produce fitting jobs as 5. Identify general tools, instruments & Fitting
Skill 50 hrs.; per drawing (Range of equipments. Care and maintenance Different types of Fitting hand
P r o f e s s i o n a l operations: marking, of tool, instruments and equipments. tools, power tools, - their use.
Knowledge sawing, filing, drilling, (10 hrs) Function, construction,
14 hrs. reaming, taping and 6. Perform flat filing, marking, punching Specification & their application.
dieing etc.) and hack sawing to make a job as Machineries and equipments
per drawing. (15 hrs) used in fittings like drilling
machines, grinding machines –
types, specifications and care
and maintenance. (07 Hrs)
7. Perform flat filing, marking, punching, Fitting
hack sawing, drilling, tapping, Precision measuring instruments
reaming, dieing to make a job as per – Function, construction,
drawing and check using precision Specification & their application.
measuring instruments Viz. Vernier (07 hrs)
calliper, Micrometer, etc. (25 hrs)
P r o f e s s i o n a l Produce Sheet metal 8. Perform Sheet Cutting by straight Sheet Metal
Skill 25 hrs.; components (range of snip as per drawing. (02 hrs) Function, construction, working,
operation – marking, 9. Perform Sheet Cutting by bent snip use, and application,
Professional
metal cutting, bending, as per drawing. (02 hrs) specification of Sheet metal
Knowledge
riveting and soldering tools, instruments and
07 hrs. 10.Bend, fold and join metal sheets in
etc.) equipment. Care and
different process. (03 hrs)
maintenance of tools. Types of
11. Join sheet metal by using rivet set sheet metal joints (cold and hot)
and snap. (08 hrs) and their use. Rivet & rivetingtheir
12.Solder sheets of metal. (02 hrs) types and use. Solder and its
13.Prepare a box or funnel with sheet composition. (07 hrs)
metal as per drawing. (08 hrs)

P r o f e s s i o n a l Identify electrical safety. 14.Demonstrate Electrical safety Electrical

Skill 50 hrs.; Join different wire, precautions and First aid. (03 hrs) Electrical terms such as AC and
measure power, DCsupply, Voltage, Current,
P r o f e s s i o n a l currents, volts and earth 15.Identify, use and maintain electrical
Resistance, Power, Energy,
Knowledge tools. (03 hrs)
resistance etc. Connect Frequency etc.
14 hrs. single phase, 3 phase 16. Prepare simple twist joints of wires. Safety precautions to be
motors i.e. star and (03 hrs) observed while working on
delta connections. electricity. Conductors and
17.Prepare married joints of wires.
Insulators, Materials used as
(03 hrs)
conductors. Series and parallel
circuit, open circuit, short circuit,
etc.

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 18.Measure current, voltage, Measuring Instruments such as
resistance, power ’ frequency, voltmeter, ammeter, ohm meter,
energy using analog and digital watt meter, energy meter and
meter through a single phase frequency meter. Earthing and its
circuit. (08 hrs) importance. Earth resistance.
19.Test insulation and earth resistance Insulation and continuity test
using Megger. (05 hrs) (07 hrs)
20.Star & Delta connection on a three Inductors and capacitors. Effects of
phase motor and show line voltage, inductor and capacitors in an AC
line current, phase voltage and circuit. Inductive reactance,
phase current. (15 hrs) capacitive reactance, Impedance
and power factor. Lagging and
21.Three phase power & power factor
leading power factors. Single phase
measurement. (10 hrs)
and Three phase supply system.
Star and Delta connection and their
comparison. Line voltage, Line
current, Phase voltage and Phase
current.
Methods of improving power factor.
(07 hrs)
Professional Identify the 22.Identify electronic components, Electronics
Skill 50 hrs.; electronic tools & instrument. (05 hrs) Introduction to Electronics. Basic
components and 23.Colour coding of resistors. (03 hrs) Principles of semiconductors,
Professional
their colour code Principles and application of
Knowledge 24.Verify Ohm’s Law. (02 hrs)
i.e. transistor, Diodes. Solder – its composition
14 hrs. 25.Use voltmeter, ammeter and
capacitor, diode, and paste. (07 hrs)
amplifier, I.C and multimeter. (5 hrs)
able to work 26.Practice soldering & de soldering.
soldering. (10 hrs)
27.Identify transistors, resistors, Rectification, Zener diode as voltage
capacitors, diodes, S.C.R., U.J.T., regulator – transistors parameters-
amplifier and I.C. (03 hrs) CB, CE, CC, configuration,
28.Construct and test full wave rectifier amplification. SCR
using diodes. (02 hrs) Photo diodes, photo transistors,
29.Construct and test a bridge rectifier. multi – vibrator, CR & LR circuit.
(03 hrs) SCRs, UJTs, ICs. (07 hrs)
30.Construct and test series voltage
regulator circuit. (02 hrs.)
31.Construct and test power supply
using fixed voltage regulator Ics.
(05 hrs)
32.Identify and test SCR. (02 hrs)
33.Construct and test an electronic
timer using UJT & SCR. (03 hrs)
34.Apply OP-AMP, photo transistor
and test performance. (05 hrs)

Professional Perform gas 35.Identify gas welding equipments & Welding

Skill 50 hrs.; welding, brazing, accessories. (03 hrs) Introduction to basic principles of
s o l d e r i n g 36.Demonstrate safety precaution in commonly used Welding
Professional
observing related handling of Oxy-acetylene cylinders, processes, oxy fuel gas welding /
Knowledge
safety. regulators etc. (03 hrs) cutting, brazing & soldering,
14 hrs.
37.Setting up of AIR-LPG, O2-LPG and O2- nozzles, base metal and filler metal.
C2H2 using can type portable flame set. Use of flux.
(04 hrs) Welding tools and equipment type
38.Oxy-acetylene gas welding, brazing specification and use. Safety
andcutting on thin sheet metal.(10 hrs) method in welding. Method of gas
welding, gas used and flames

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 39. Demonstrate Care & Safety of welding adjustment and pressure setting
tools and equipments. Back fire of O2 and DA.
arrester. (03 hrs)
Difference between soldering and
40.Set Oxy-acetylene plant, use two Brazing in terms of temperatures,
stage regulator, adjustment of flame, filler materials, joint strengths and
gas pressure – O2 and DA. (04 hrs) applications. Use of Oxy
41. Perform brazing between Cu to Cu Acetylene, Oxy LPG, Air LPG and
and Cu to MS, Cu to aluminium pipes. two stage regulator for brazing/
(10 hrs) soldering. Description of back fire
42.Join metal plates by using gas arrester. (14 hrs)
welding (lap joint, butt joint, etc).
(13hrs)
Professional Identify RAC tools and Basic Refrigeration Basic Refrigeration
Skill 100Hrs.; equipments and 43.Identify & use of general hand tools, Basic principle of refrigeration,
recognize different instruments & equipments used in working, use, specifications of
Professional
parts of RAC system. refrigeration work. (12 hrs) refrigeration tools, instruments
Knowledge
Perform copper tube 44.Identify & use of special tools, and equipment.
28Hrs.
cutting, flaring, instruments & equipments used in Fundamentals of Refrigeration,
swaging, brazing. refrigeration work. (13 hrs) units and measurements,
Pressure & its Measurements.
Thermodynamics law. (07 hrs)

45.Identify various refrigeration Science related to refrigeration,

equipments and components of work, power, energy, force, Heat
vapour compression system like and Temperature, Different
compressor, condenser, expansion temperature scales,
device and evaporator. Identify and Thermometers, Units of heat,
Check vapour absorption refrigeration sensible heat, latent heat, super
cycle (VARC) (12 hrs) heating and sub-cooling,
46.Unroll, cut and bend soft copper saturation temperature
tubes. (04 hrs) pressure, types, units.
47.Swage and make a brazed joint on Types of Refrigeration systems,
copper tubing. (10 hrs) including Vapour absorption
48.Make flare joints and test them with refrigeration cycle (VARC), water
flare fittings. (10 hrs) - combination. Study the
49. Pinch off copper tubing. (04 hrs) construction and working of vapor
compression cycle, low side &
50. Use lock ringtool and various fittings
high side of vapour compression
of lockring for servicing of appliances
system. Applications of vapour
(10 hrs)
compression cycle.Coefficient of
51.Brazing of Cu to Cu, Cu to steel, Cu Performance (COP), Ton of
to brass using AIR LPG suitable in Refrigeration. (14 hrs)
RAC machine. (07 hrs)
Construction and working of V.C
52.Brazing of Cu to Cu, Cu to steel, Cu Cycle, fundamental operations,
to brass using OxyLPG. (07 hrs) sub cooling and super heating.
53. Brazing of Cu to Cu, Cu to steel, Cu Study of Ph, Ts, Pv diagram.
to brass using Oxy Acetylene. (11 hrs) (07 hrs)

Professional Test mechanical & 54.Identify electrical and mechanical Refrigerator ( Direct cool)
Skill 25Hrs.; e l e c t r i c a l components of refrigerator. (03 hrs) Function, construction ,working of
components. Perform 55.Check and replace electrical single door direct cool refrigerator,
Professional specifications,trouble shooting,
leak test, vacuuming, components of refrigerators. (04 hrs)
Knowledge care and maintenance.
gas charging, wiring & 56.Leak test, evacuation, gas charging
07 hrs. Requirement of Vacuum and level
installation of in refrigerators. (08 hrs)
refrigerator. of vacuum. (07 hrs)
57.Wiring circuit of refrigerator. (08 hrs)
58. Installation of refrigerator. (02 hrs)

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Professional Perform door Refrigerator ( Direct cool ) Refrigerator ( Direct cool )
Skill 25 hrs.; alignment, door 59.Identify electrical components of Study the construction &
gasket fitting, direct cool refrigerator. (05 hrs) working of direct cool
Professional
replace door switch. Refrigerator. Study the
Knowledge 60.Identify mechanical components of
07 hrs. direct cool refrigerator. (05 hrs) electrical components of
61.Installation of refrigerator. (02 hrs) refrigerator.
62.Checking door alignment, adjustment of Study the mechanical
door switch operation & replacing of components of refrigerator and
gaskets. (03 hrs) their types. Study the heat
exchanger, door gaskets, Heat
63.Tracing the mechanical components of
refrigerator. (03 hrs) Insulation materials. Care and
maintenance of refrigerator.
64.Check, Find Fault and test the electrical (07 hrs)
and other system components of
refrigerator. (07 hrs)

Professional Test compressor 65.Testing of compressor. (02 hrs) Importance of flushing in

Skill 25 hrs.; motor terminal, start 66.Identification of motor terminals. (02 hrs) evaporator and condenser, use
compressor Direct 67.Start of compressor with and without relay. of dry nitrogen for flushing,
Professional with relay & without necessity of replacing
Knowledge (03 hrs)
relay, technique of capillary
07 hrs. flushing, leak 68.Test performance of direct start refrigerator.
(02 hrs) and drier. Evacuation, leak
testing, replacing testing, gas charging method
capillary & filter drier, 69.Cleaning and flushing of evaporator and in refrigerator, Refrigerants
evacuation & gas condenser with dry nitrogen. (02 hrs) used in Refrigerators and its
charging. 70. Replacement of capillary tube and properties.Desiccant drying
drier. (02 hrs) agent. (07 hrs)
71.Installation of gauge manifold in the
system. (02 hrs)
72.Leak testing, evacuation and gas
charging in refrigerator. (05 hrs)
73.Check electrical wiring of refrigerator.
(05 hrs)

Professional Check components 74.Tracing electrical circuit of Frost Free Frost Free Refrigerator
Skill 50 hrs.; of frost free refrigerator. (07 hrs) Study the construction and
refrigerator 75.Checking, fault finding and testing of working of Frost Free (2 or 3
Professional door) Refrigerator parts
(electrical / electrical accessories like thermostat,
Knowledge particularly, the forced draft
mechanical), wiring timer, defrost heaters, bi-metal, air louvers
14 hrs. cooling, Air Duct circuit,
of frost free freeze & etc. and other system components. (10 hrs)
air distribution in temperature control in Freezer
76. Checking air distribution system. (03 hrs) & cabinet of Refrigerator, air
refrigerator sector.
eak detection, 77. Servicing of refrigerator. (03 hrs) flapper / louver used in
evacuators & gas 78. Testing the performance of refrigerator. (02 hrs) refrigerator section, automatic
charging. defrost system. Study of
Electrical accessories & their
functions (Timer, Heater,
Bimetal, Relay, OLP, T/S etc,.)
Refrigerator cabinet volume
calculation. (07 hrs)
79.Identify three and four door no frost Refrigerator (Inverter
refrigerator. (07 hrs) Technology)
80.Stripping of components.(07 hrs) Study the construction and its
81. Tracing electric circuit. (03 hrs) working of two and three door
82. Testing components. (03 hrs) frost free refrigerator. Care and
maintenance, installation
83. Leak testing, evacuation, gas charging. method. (07 hrs)
(05 hrs)

(xiv)
Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.01

Identify workshop and machineries

Objectives: At the end of this exercise you shall be able to
• visit various sections of ITI and familiar with the staff members
• draw the layout of R&ACTsection of ITI
• identify the various equipments located in R&ACTsection.

Requirements

Tools/Instruments
• Steel rule 300mm - 1 No. • Pencil HB - 1 No.
• Measuring tape 20m - 1 No. • Eraser - 1 No.
• Set square 300 & 450 - 1 set. • Papers - as reqd.

PROCEDURE

TASK 1: Visit various sections of ITI and familiar with different section and staff members.

Instructor will lead the new recruits to various 3 Take introduction about the major equipments of different
sections of ITI and explain about the training trade with respective instructor during visit and note
scheme. down.
4 Take brief knowledge about the scope and application
1 During the visit collect information like the designation of particular trade in industry.
of staff member and their name.
2 Identify the sections of ITI and list the trades in which
training is given.

TASK 2: Draw the layout of the R&ACT section of ITI.

1 Draw the plan of the R&ACTsection to a suitable scale 2 Draw the layout of lab as per the equipment located.
in a separate sheet of paper. (A4 size)

TASK 3: Identify the various equipments located and devices arranged in R&ACT section.

1 Identify the equipments and devices in R&ACTsection. 3 Keep the work room clean and tidy.
2 Identify the instruments and tools in the work floor and
list them.

1
Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.02

Demonstrate safety precautions and first aid

Objectives: At the end of this exercise you shall be able to
• identify the four basic categories and meaning of the safety sign
• read & record the meanings of road safety signs
• prepare the victim’s to receive artificial respiration
• resuscitate the victim by nelson's arm lift back pressure method, Schafer’s method, mouth -to- mouth method
• resuscitate the victim by mouth -to- nose method
• resuscitate a victim who is under cardiac arrest (CPR) cardio pulmonary.
• perform treatment for stopping or bleeding victims.
TASK 1: Identify the four basic categories and meaning of the safety signs
Table 1
Instructor may provide various safety signs
Fig No. Basic categories Meaning
chart categories and explain their categories
/ safety sign descriptions
and their meaning, description. As the trainee
to identify the sign and record in Table 1. 1
2
1 Identify the safety sign from chart
3
2 Record the name of the category in Table1. 4
3 Mention the meaning description of the safety 5
sign in Table 1
6
4 Get it checked by your instructor
7
8
9
10

TASK 2: Read and record the meaning of road safety signs.

Instructor will explain all the road safety sign 2 Get it checked by the instructor
and traffic police signals
Assumption - for easy manageability Instructor
1 Read the sign given in the chart and mention their kinds may arrange the trainees in group and ask
each group to perform one method of
and the meaning in the Table 2.
resuscitation.

Table 2
Fig No. Basic categories Meaning
/ safety sign descriptions

11
12
13
14
15
16
17
18
19
20

2
TASK 3: Prepare the victim’s to receive artificial respiration.

1 Loosen the tight clothing which may interfere with the 4 Start artificial respiration immediately without delay.
victim’s breathing. Do not waste too much time in loosening the clothes or
trying to open the tightly closed mouth.
2 Remove any foreign materials or false teeth in his mouth
and keep the victim’s mouth open. 5 Avoid violent operation to prevent injury to the internal
parts of the victim.
3 Bring the victim safety to the level ground, taking
necessary safety measures. 6 Word send for a doctor immediately.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.02 3

TASK 4: Resuscitate the victim by Nelson’s arm Lift back pressure method.

Nelson’s arm-lift back pressure method must 3 Synchronise the above movement of rocking backward
not be used in case there are injuries to the with your hands sliding downwards along the victim’s
chest and belly. arms and grasp his upper arm just above the elbows as
shown in Fig 3. Continue to rock backwards
1 Place the victim prone (that is face down) with his arms
folded with the palms one over the other and the head
resting on his cheek over the palms. kneel on one or
both knees near the victim’s hand. Place your hands on
the victim’s back beyond the line of the armpits, with
your fingers speared outward and downward, thumbs
just touching each other as in Fig 1.

4 As you rock back, gently raise and pull the vitim’s arms
towards you as shown in Fig 4 until you feel tension in
his shoulders. To complete the cycle lower the victim’s
arms and move your hands up to the initial position.

2 Gently rock forward keeping your arms straight until

they are nearly vertical, and steadily pressing the
victim’s back as shown in Fig 2 to force the air out of the
victim’s lungs.

5 Continue artificial respiration till the victim’s begins to

breathe naturally. please note, in some cases, it may
take hours.

4 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.02

6 When the victim revives, keep the victim warm with a 7 Keep him in the lying down position and do not let him
blanket, wrapped up with hot water bottles or warm expert himself.
bricks; stimulate circulation by stroking the insides of
the arms and legs towards the heart. Do not give him any stimulant until he is fully
conscious

TASK 5: Resuscitate the victim by Schafer’s method.

Do not use this method in case of injuries to

victim on the chest and belly

1 Lay the victim on his belly, one arm extended direct

forward, the other arm bent at the elbow and with the
face turned sideward and resting on the hand or forearm
as shown in Fig 5

4 After two seconds, swing forward again and repeat the

cycle twelve to fifteen times a minute.
5 Continue artificial respiration till the victim begins to
breathe naturally.

2 Kneel astride the victim, so that his thighs are between

your knees and with your fingers and thumbs positioned
as in Fig 5
3 With the arms held straight, swing forward slowly so
that the weight of your body is gradually brought to bear
upon the lower ribs of the victim to force the air out of
the victim’s lungs as shown in Fig 6

TASK 6: Resuscitate the victim by mouth -to- mouth method

1 Lay the victim flat on his back and place a roll of clothing
under his shoulders to ensure that his heads is thrown
well back (Fig 8)
2 Till the victim’s head back so that the chin points
straight upward (Fig 9)

4 Take a deep breath and place your mouth over the

victim's mouth as shown in Fig 11 making airtight
contact. Pinch the victim's nose shut with the thumb
3 Grasp the victim’s jaw as shown in Fig 10, and raise it and forefinger. If you dislike direct contact, place a
upward until the lower teeth are higher than the upper porous cloth between your mouth and the victim's. For
teeth; or place fingers on both sides of the jaw near the an infant, place your mouth over its mouth and nose.
ear lobes and pull upward. Maintain the jaw position (Fig11).
throughout the artificial respiration to prevent the tongue
from blocking the air passage.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.02 5

 5 Blow into the victim's mouth (gently in the case of an
infant) until his chest rises. Remove your mouth and
release the hold on the nose, to let him exhale, turning
your head to hear the out-rush of air. The first 8 to 10
breaths should be as rapid as the victim responds,
thereafter the rate should be slow down to about 12
times a minute (20 times for an infant)

If air cannot be blown in, check the position

of the victim's head and jaw and recheck the
mouth for obstructions, then try again more
forcefully. If the chest still does not rise, turn
the victim's face down and strike his back
sharply to dislodge obstructions.
Sometimes air enters the victim's stomach as
evidenced by a swelling stomach. Expel the
air by gently pressing the stomach during the
exhalation period.

TASK 7: Resuscitate the victim by Mouth-to-Nose method.

Use this method when the victim’s mouth will

not open or has a blockage you cannot clear.

1 Use the fingers of one hand to keep the victim’s lips

firmly shut seal your lips around the victim’s nostrils and
breathe into him. Check to see if the victim’s chest is
rising and falling (Fig12)
2 Repeat this exercise at the rate of 10-15 times per
minute till the victim responds
3 Continue this exercise till the arrival of the doctor.

TASK 8: Resuscitate a victim who is under cardiac arrest (CPR) cardio pulmonary.

In cases where the heart has stopped beating,

you must act immediately

1 Check quickly whether the victim is used cardiac arrest

Cardiac arrest could be ascertained by the

absence of the neck (Fig 13), blue colour
around lips and widely dilated pupil of the
eyes.

2 Lay the victim on his back on a firm surface

3 Kneel alongside facing the chest and locate the lower
part of the breast bone (Fig 14)
4 Place the palm of one hand on the centre of the lower
part of the breastbone keeping your fingers off the ribs.
Cover the palm with your other hand and lock your
fingers together as shown in (Fig 15)
5 Keeping your arms straight, press sharply down on
the lower part of the breastbone; then release the
pressure (Fig 16)

6 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.02

 8 Move back to victim’s mouth to give two breaths
(mouth-to-mouth resuscitation) (Fig 18)

9 Continue with another 15 compressions of the heart

following by further two breaths of mouth-to-mouth
resuscitation, and so on, check the pulse at frequent
intervals.
10 As soon as the heartbeat returns, stop the compression
immediately but continue with mouth -to-mouth
resuscitation until natural breathing is fully restored
11 Place the victim’s in the recovery position as shown in
Fig 19. Keep him warm and get medical help quickly.

6 Repeat step 5, fifteen times at the rate of at least once

per second
7 Check the cardiac pulse (Fig 17)

Others step
1 Send for a doctor immediately
2 Keep the victim warm with a blanket, wrapped up
with hot water bottles or warm bricks; stimulate
circulation by stroking the insides of the arms and
legs towards the heart.

TASK 9: Perform treatment for stopping bleeding victims.

1 Determine the location of the bleeding

2 Elevate the injured area above the heart if possible
3 Apply direct pressure to the bleeding area with sterile
cloth
4 Keep the pressure on for 5 seconds
5 Check to see if the bleeding has stopped if not apply
further pressure for 15 minutes
6 Clean the wound
7 Bandage the wound with pad of soft material (Fig 20)
8 Advice victim to take treatment from doctor.
Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.02 7
Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.03

Demonstrate - fire fighting

Objectives: At the end of this exercise you shall be able to
• demonstrate the ability of fire-fighting,
– as a leader of the group
– as a member of the fire-fighting team.
• general procedure to be adopted in the event of fire
• extinguisher the fire

Requirements
Equipment/Machines
• Fire extinguishers
- different types - 1 No. each

PROCEDURE

TASK 1: General procedure to be adopted in the event of fire.

1 Raise an alarm. Follow the method written below for – switch off fans/air circulators/exhaust fans. (Better
giving an alarm signals when fire breakes out: switch off the main)
– by raising your voice and shouting Fire! Fire! to call 3 If you are not involved in fighting the fire:
the attention of others
– leave calmly using the emergency exit.
– running towards fire alarm/bell to actuate it
– evacuate the premises
– other means
– assemble at a safe place along with the others
2 On receipt of the alarm signal:
– check if anyone has gone to inform about the fire
– stop working break to the concerned authority
– turn off all machinery and power – close the doors and windows, but do not lock or bolt
8
4 If you are involved in fire fighting: – judge the magnitude of the fire, ensure emergency
exit paths are clear of obstructions and then attempt
– take instructions/give instructions for an organised
to evacuate (Remove explosive materials,
way of fighting the fire
substances that can serve as a ready fuel for fire
If taking instructions: within the vicinity of the fire break)
– follow the instructions, and obey, if you can do so – fight out the fire with assistance to put it out, by
safely; do not risk getting trapped. naming the person responsible for each activity.
If giving instructions: 5 Report the fire accident and the measures taken to put
– assess the class of fire out the fire, to the authorities concerned

– send for sufficient assistance and inform the fire Reporting all fires however small helps in the
brigade investigation of the cause of the fire. It helps to
– locate locally available suitable means to put out the prevent the same kind of accident occurring
fire again.

TASK 2: Extinguisher the fire

1 Alert people surrounding by shouting fire, fire, fire when 3 Put Off electrical power supply
observe fire
Do not allow people to go nearer to the fire
2 Inform fire service or arrange to inform immediately open
emergency exist and ask them to go away
4 Analyze and identify the type of fire. Refer Table1.

Table 1

Class A Class B Class C Class D

Wood, paper, Cloth, Oil based fire (grease, Gas and liquefied gases Metals and electrical
Solid material gasoline oil) equipment task
Liquefiable solids

5 Assume the fire is B type 9 Pull the safety pin from the handle (Pin located at the
6 Select CO2 (carbon dioxide fire) extinguisher top of the extinguisher) (Fig2)

7 Locate and pick up CO2 fire extinguisher Check for its 10 Aim the extinguisher nozzle or hose at the base of the
expiry date. fire (this will remove the source of fuel fire )

8 Break the seal (Fig1) Keep yourself low.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.03 9

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.04

Demonstrate on health hazards, and personal safety

Objectives: At the end of this exercise you shall be able to
• demonstrate how to work at height using PPE'S
• identify personal protective equipments (PPE).

Requirements
Safety accessories
• Safety shoes - 1 Pair • Safety belt - 1 Set
• Safety goggles - 1 No • Safety ear plug - 1 Pair
• Safety helmet - 1 No • Safety jacket - 1 No

PROCEDURE

TASK 1: Demonstrate how to work at height using PPE's

1 Work at height is properly planned and organized Fig 1. 3 Choose required proper working tools and equipment
2 The risk from work at height are assessed and appropriate before start the work at height.
PPE's selected and used
Safety : Ensured hanging belt and other safety
measure are taken before going at height Fig 2

TASK 2: Identify the personal protective equipment (PPE)

1 Identify the PPE in the Table - 1 2 Mention the name of the PPE nature of Hazards and
type of protection

10
Identify the personal protective equipment and note in Table

Figure PPE Name of PPE Hazards Type of

protection

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.04 11

 Figure PPE Name of PPE Hazards Type of
protection

4.Get it checked the instructor

12 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.04

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.05

Identify general tools instruments & equipments with care and maintenance
Objectives: At the end of this exercise you shall be able to
• identify general work shop tools and mention the use
• identify workshop equipments and mention the use
• identify precision instruments and mention the use
• care & maintain of tools, equipments and instruments.

Requirements
Tools/Instruments Equipment/Machine
• General workshop tools - as per table • Workshop equipments - as per table
• Precision measuring Instruments - as per table

PROCEDURE

TASK 1: Identify the general workshop tools and write the name & use the Table -1

Table - 1

Figure Name Uses

13
 Figure Name Uses

14 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.05

 Figure Name Uses

TASK 2: Identify workshop equipment and mention the use in Table 2

Table - 2
Sl.No Figure Name Uses

Fig 1

Fig 2

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.05 15

Sl.No Figure Name Uses

Fig 3

Fig 4

TASK 3: Identify precision equipment and mention the use

Table - 3
Sl.No Figure Name Uses

Fig 1

Fig 2

Fig 3

16 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.05

 Sl.No Figure Name Uses

Fig 4

Fig 5

TASK 4: Care and Maintenance of Tools Instruments and equipments

1 Do not over tight in bench vice. 9 In Chisel, Avoid mushroom heads.

2 Do not use a hammer with a loose handle. 10 While drilling, Do not apply excess pressure on small
bits.
3 The face of the hammer must be free from oil, grease
and mushroom. 11 In the case of an electric drilling machine it must be
properly earthed and the insulation should be sound.
4 Do not use steel rule as a screw driver.
12 After measuring Vernier Caliper, keeping the box.
5 Do not use the file without the handle.
13 While measuring in micrometer, do not over tight.
6 Do not throw a file since the teeth get damaged.
14 All measuring Instruments after use should be cleaned
7 Do not use pliers as hammers.
of grease, oil, dust etc., using a banian cloth and store
8 The edge of a Chisel must be maintained as per the it in a pouch or in the container from the supplier.
required angle.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.05 17

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.06

Practice flat filing, marking, punching & sawing

Objectives: At the end of this exercise you shall be able to
• practice on flat filing and check the flatness
• mark parallel lines to the given dimension
• punch with centre punch & ball pein hammer
• fix the hacksaw blade & practice sawing.

Requirements
Tools/Instruments Equipment/ machine
• File flat Bastard double cut 300mm - 1 No • Bench vice 100mm - 1 No
• File flat second cut double cut 300mm - 1 No • Angle plate 150mm - 1 No
• Try square 150mm - 1 No • Surface plate 300 mm x 300mm - 1 No
• Ball pein hammer 200gms - 1 No • Anvil 300mm with stand 100 kg
• Steel Rule 300mm - 1 No
• Centre punch 100mm - 1 No Materials
• Dot punch 100mm - 1 No
• MS equal channel 75 x 40 x 155mm -1 piece
• Marking block with scale 150mm - 1 No
• Hacksaw blade with frame 300mm,24 TPI - 1 No

PROCEDURE
TASK 1: Practice on flat filing and check the flatness
1 Check the material size 155 x 75 x 40mm equal angle 2 Remove all the rust from all the surface by the edge of
MS channel.(Fig 1) file, clean by cotton waste.(Fig 2)
3 Hold file handle with thumb will be placed firmly to grip
the file, left leg will be in forward direction right leg will
300 mm from front leg. Also check the height of your
vice should be on the level of your elbow as in Fig 3.

18
4 Hold the job in bench vice grip firmly from width of the
channel.(Fig 4)

5 Place file on the job and start filing. Exert pressure on

file while moving forward direction. At return stroke
release the pressure. Shift to the next area and continue
in the same way complete the entire process and check
flatness with the help of try square blade. If light appear
surface is not flat. (Fig 5)

6 Open the job and start on (A) side filing as directed

previously. Check the squareness along with(B). (Fig 6
& Fig 7)

7 Finally we got the piece.(Fig 10)

• Open the job and start on (D) side filing as directed

previously. Check the squareness along with (A)
• Open the job and start on (C) side filing as directed
previously. Check the squareness along with (A,B & D).
• Open the job and start on (F) side filing as directed
previously. Check the squareness along with
(A,B,C & D). (Fig 8 & Fig 9)
Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.06 19
TASK 2: Mark parallel lines to the given dimension
1 Apply marking media on B surface allow it to dry (Fig11) 4 Place the job on anvil.(Fig 14)

5 Start punching over the line with the help of centre punch
and hammer on crossing point must dipped
2 Now place the marking block on surface plate and punch(Fig15)
placing steel rule with support angle plate and fix scriber
as per drawing length required. Tight the scribing block
nut and take away the steel rule. (Fig12)

3 Now places the MS channel on surface plate touching

C direction on surface plate face support of B will be
with angle plate hold the job with your left hand along
with the scriber point over the marking medias. Like
that mark the job as per drawing.(Fig 13 )

TASK 3: Punch with centre punch and ball pein hammer

1 Place the job on surface plate and place with support
of angle plate and mark on the side o f the channel as
figure. (Fig 16)
2 Take out the job and inspect.
3 Place the job on anvil and hammer (Fig 17)
4 Check the channel punch all the points are correct
(Fig 18)

20 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.06

TASK 4: Fix the hacksaw blade & practice sawing.

1 Fixing of hacksaw blade the teeth of the blade should

be away pointing from the handle. Fix the blade to the
frame in good tension.(Fig 19)

2 Set your thumb nail/vertically to the location of the

cut, and this location should be at least 10 mm from
the vice. Hold and press the hacksaw straight forward.
Do not use force when pulling it back. Apply cutting
compound occasionally while cutting. Use the full
length of the hacksaw blade. Make the last few cuts
while holding the piece to be cut with your left hand.
For this section use a fine grade blade. A minimum of
two or three teeth should be in contact with the work.
(Fig 20)
3 Open the vice, take out the job and remove the burrs.
(Fig 21)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.06 21

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.07

Practice: Drilling ,reaming tapping & dieing and check using precision
measuring instruments
Objectives: At the end of this exercise you shall be able to
• fix the drill, counter sinking tools & operate the drill
• fix the reamer on job and operate.
• fix the tap on job and operate
• fix the Die on job and operate
• measure with a vernier caliper
• measure with a depth gauge
• measure with a micro meter.

Requirement
Tools/ Instruments Equipment/ Machine
• Drill bit - 1 No • Machine vice 100 mm - 1 No
• Reamer - 1 No • Pillar type drill machine capacity 25mm - 1 No
• Counter sinking tool - 1 No • Drill chuck with key 12mm capacity - 1 No
• Tap set - 1 No
• Die set - 1 No Material
• Vernier Caliper • Ex No - 1-1-06 150 × 38 73mm for tapping
• Depth gauge • M.S. Round rod 10mm 150 mm length
• Micro meter

Note: Apply marking media and punch using centre punch Refer TASK - 2 of Ex No.1.1.06

TASK 1: Fix the drill, counter sinking tools & operate the drill.

1 Check the drill machine it is in proper working condition

fit drill chuck in drill machine and fit the drill bit required
tight with chuck key.(Fig1)

2 Hold the job with support wooden block on machine vice

start the machine and take the drill point the mark place
and feed drill as per chart mentioned complete operation
apply coolant at the time of operation.(Fig 2)
3 Fit countersinking drill and remove the bur of all drill
holes. Take out the job.(Fig 3)

22
TASK 2: Fix the reamer on job and operate
4 Now place the reamer maintaining 90° angle with job to 5 Start rotation on clock wise direction not take back
be reamed hole, now fit the reamer put handle provided neither finishing of the hole will be blend after complete
space on reamer.(Fig 4) reaming operation take out the reamer straight. (Fig 5)

Please refer, Tap drill size chart for selection of

drilling& tapping

TASK 3: Fix the tap on job and operate

1 Fit the job for further operation on vice. Hold the job on 3 With pressure start to rotate in clock wise direction after
vice with clamp sheet. Place first tap maintaining the rotating half turn back again rotate operation of direction,
90° angle with job and fix it.(Fig 6) like that complete the threading operation of first step,
next place second tap complete operation in the same
manner at time of thread cutting apply lubricate oil.(Fig8)
4 Finally we got the pieces like that (Fig 9)

2 Fit the tap handle provide space on tap, tight the handle.
(Fig 7)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.07 23

TASK 4: Fix the Die on job and operate

1 Fix the die in the diestock and place the leading side of - Check blank size
the die opposite to the step of the diestock . - Blank size - Thread size -0.1 x pitch of thread

Use false jaws for ensuring a good grip in the 4 Start the die square to the bolt centre line.(Fig 13)
vice. Project the blank above the vice- just the • Rotate the handle clock wise in a line at right angle to
required thread length only.
the rod is make one or two complete turns in a clock
wise direction
2 Place the leading side of the die on the chamfer of the
work.(Fig 11) • Apply lubricant at frequent intervals and complete
threading

3 Make sure that the die fully open by tightening the

centre screw of the die stock.(Fig 12)

24 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.07

TASK 5: Measuring by vernier caliper
1 Rest the job near the centre of the fixed jaw and move
4 For checking the parallelism of jaws hold them together
the sliding jaw with normal force.(Fig 1)
under very light pressure, and view the gap against a
light source.
5 While taking internal measurement hold the jaws
parallel to the axis of the slot be measured.
(Fig 4 and 5)

2 Do not give undue pressure while measuring as it will

make the jaws to spring and give wrong
measurements.(Fig.2)

3 Avoid parallel error while reading.(Fig 3)

Ensure all burrs are removed before taking

measurement.
Handle the vernier caliper very carefully. Do
not keep precision instruments with the cutting
tools.
Clean the instrument before and after use.

TASK 6: Measuring depth with vernier calipers

Measure with a vernier calipers 3 Before taking the measurement, clean the surface to
Vernier Calipers be measured and the end of the veriner calipers burrs if
any should also be removed.
1 Vernier calipers with depth bars can be used for
4 Accurate measurement is possible only when the end
measuring the depth of slots and the height of steps.
base of the vernier caliper can make a good seating on
2 This type of veriner calipers(Fig 1) is specially suitable both sides of the grooves. (Fig 2)
for measuring the depth of narrow slots.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.07 25

 7 While measuring, press the base of the vernier calipers
firmly on the surface, and then slowly bring down the
depth on the make contact.
8 When one side of the groove is used as datum the
measurement hold the caliper base firmly so that the
depth is perpendicular to the datum surface. (Fig 4)

5 When both side of a groove are used for measuring the

depth ensure that they are of the same level.
6 When both sides are not of the same level, use only
one side as datum.(Fig 3)

Excessive pressure on the depth bar will lift

the base of the vernier calipees from the datum
surface.
Soon after the measurement over, close the
jaws of the vernier calipers to pull the depth-
bar inside the slot. Being very thin the depth
bar can be damaged quickly.

TASK 7: Measuring with Micrometer

Observe the following aspects before taking the

measurements.
Clean the measuring faces of the micrometer and the
surface of the wok to be measured.
Check for the zero error.
In the case of a 0-25 mm outside micrometer, the zero of
the thimble should coincide with the datum line.(Fig 1)
If they do not coincide the instruments has an error.
The other sizes of the outside micrometer should be
checked for errors with the help of standard gauges
provided for this purpose.

26 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.07

If standard gauges are not available, slip gauges can be
used. (Fig 2)

Use the ratchet stop when the measuring faces touch

work piece. This will ensure uniform pressure needed for
The slip gauge may be of any size above the minimum consisitency while measuring accurate
range of the micrometer. Make sure the measuring on the job. Open the measured
faces will make the instrument completely until for pre
Note: The trainees are not expected to handle measurement.
slip gauges now.
Step required after taking measurements
Use the instruments only after making the necessary
correction. After use, clean the micrometer with a cloth and apply
thin film of oil.
Do not attempt to correct the errors, if any. The Store the micrometer always in its box (Fig 5)
instructor will do it for you.
Make sure the measuring faces are not in contact putting
Step required while taking measurements the measurement away.(Fig 5)
Holding of the micrometer for talking the measurement, if
the work piece.
Use both hands for talking the measurements, if the work
piece is held on the machine, workbench, surface plate,
etc.(Fig 3)

Hole the workpiece in one hand and the micrometer in the

other hand, if the workpiece is small(Fig 4)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.07 27

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.08

Cutting sheet by straight snip

Objectives: At the end of this exercise you shall be able to
• mark a straight line on the sheet
• cut sheet metal by a straight snip.

Requirement

Tools / Instruments Equipment / Machine

• Wooden mallet 500 gm - 1 No. • Bench vice 120mm - 1 No.
• Straight Snip 200mm - 1 No. • Tin man’s anvil - 1 No.
• Scriber 150 mm - 1 No. Material
• Try square 150 mm - 1 No.
• Smooth file single cut 200 mm - 1 No. • G.I Sheet 65 120 mm 22swh - 1 pieces for
• Wing compass 150 - 1 No. each trainees

PROCEDURE

TASK 1: Mark a straight line on the sheet

1 Mark off two ‘V’marks from the datum xx at a distance

as required by a measurement, using a steel rule and Scribe the line towards you with a proper
a scriber. Datum xx is a right angle to datum yy. (Fig 1) inclination of the scriber on the level edge of
the straight edge. (Fig 3)

3 The line AB is the parallel line to the datum xx. (Fig 4)

2 Set the straight edge in between the ‘V’ marks and

press with your fingers.(Fig 2)

Draw parallel lines as per dimension following the above

procedures

28
TASK 2: Cutting sheet metal by straight snip

Hold the sheet by one hand, and with the other hand, hold Caution
the snip handle at the end, and place the upper blade of the
Do not use the full length of the blade by a single stroke
snip on line by keeping a smaller opening angle.(Fig 1)
If you use the full length of the blade by a single stroke then
the cutting or shearing line will not be straight (Fig 5)

Maintain the gap in between the blades, less than 20°.(Fig2)

Keep less metal (sheet) as far as possible on the left hands

side at the time of cutting the sheet.(Fig 6)

If the blade gap is more than 20°,shears cannot

be gripped properly.(Fig 3)

Where stops are not fitted, care should be

taken not to palm of the hand between the
turned-in ends of the handles when closing the
cutting blades.(Fig 7)

Keep the blade perpendicular to the surface of the sheet

metal.Hold the snips straight.(Fig 4)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.08 29

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.09

Cutting sheet by bent snip

Objectives: At the end of this exercise you shall able to
• mark curved lines on a sheet using a wing compass
• cut along the marked outside and inside carved lines using straight snips and bent snips.

Requirement
Tools / Instruments Equipment / Machine
• Wooden mallet 500 gm -1 No. • Bench vice 120mm -1 No.
• Bent snip 200mm -1 No. • Tin man’s anvil -1 No.
• Scriber 150 mm -1 No.
Material
• Try square 150 mm -1 No.
• Smooth file single cut 200 mm -1 No. • G.I Sheet 65 x120 mm 22 SWG - 1 pieces
• Wing compass 150 -1 No. for each trainees

TASK 1: Mark curved lines on a sheet using a wing compass

• Check the size of the rectangular sheet as per sketch,
using a steel rule
• Level the sheet on a levelling plate using a mallet.
• Attach another sheet for marking the larger curve.
• Transfer the measurement from the steel rule to the
wing compass for the desired radius.
• Mark the first curved line on the sheet.
• Mark 10 curved lines equal distance of 6mm.

TASK 2: Cut along the marked outside and inside carved lines using straight snips and bent snips
• Cut on the marked curved lines by bent snips. First a rough cut can be made,(Fig 2)

Start cutting the curved line always from the For trimming a cylinder, keep the lower blade on the
nearest edge with the straight snips. outside of the cut.(Fig 3)

A bent snip can be used for cutting internal and external

curves.
For cutting holes bent snips are used.
First a rough cut is made. Then the hole is finished off (Fig1)

For circular cutting rotate the sheet while making continuous

cut.
30
Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.10

Bend fold and joints sheet metal

Objectives: At the end of this exercise you shall be able to
• bend and fold sheet metal as per marking
• make the locked grooved joint.

Requirement
Tools / Instruments Equipment / Machine
• Mallet wooden 500 gms -1 No • Tin man’s anvil -1 No
• Straight Snip 200 mm -1 No • Bench vice 120mm -1 No
• Steel Rule 300 mm -1 No
• Scriber 150 mm -1 No Material
• Try square 150 mm -1 No • G.I Sheet as required
• Smooth file single cut 200 mm -1 No

PROCEDURE
TASK 1: Bend and fold sheet metal as per marking
• Check the size of sheet as per sketch using a steel rule. • Cut the corners by straight snips.

• Level the sheet on the levelling plate using a mallet. • Make a single hemming on the four side of the tray
(Fig 1a)
• Develop the tray by the parallel line method
• Bend the four sides to 90° using a Tin man's anvil.
• Cut the sheet as per line by straight snips .

TASK 2: Make the locked grooved joint.

• Interlock the folds and press the joint on the four corners
(Fig 1b)

31
Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.11

Joining sheet metal by using rivet set and snap

Objective: At the end of this exercise you shall be able to
• measure, mark cut and layout the spacing for riveted lap joints
• mark straight lines of given dimension
• mark for marking holes with drilling machine
• drill holes in the sheet metal with drilling machine
• join the sheet metal using rivet with a rivet set
• identify the faults in riveted joints and their causes.

Requirements
Tools /Instruments
Equipment/Machines
• Steel rule 300mm - 1 No. • Hand drilling machine
• Scriber 200mm - 1 No.
• Centre punch 150mm - 1 No. Materials
• Rivet set - For No.14 • Sheet steel ISST 55 x 0.5 x 105 - 2 Nos.
Tin man's rivet. • No.14 Tinman's rivets - 10 Nos.
• Hammer 250gms - 1 No.

PROCEDURE

TASK 1: Joining sheet metal by using rivet set and snap

1 Check the dimension of the given sheet iron. 6 Insert the rivet in the hole, that is nearest to the centre
of span, resting the head of the rivet on the place.
2 Mark straight line for centre line of the rivet. (Fig 1)
7 Draw the material and the rivet together tightly by
3 Mark centres for drilling with centre punch.
placing the hole in the rivet set and striking the set one
4 Drill holes using the hand drilling machine. or two sharp blows with hammer.
5 Place together the two pieces of sheet metal on a 8 Place the cup shaped hole on the rivet and give the rivet
suitable solid plate. set one or two sharp blows with the hammer to head the
rivet.
9 Rivet alternately in each direction, beginning with the
nearest centre hole.
10 Insert the rivet in the holes made in the sheets.
11 Draw the rivet and the sheet together by striking one or
two sharp blows with a hammer.(Fig 2)
12 Perform heading the rivet with the cup shaped hole of
the rivet set and hammer.

32
In thin plates the holes for rivets are punched as shown in Finally, place the rivet snap on the rivet (as shown in Fig 7
Fig 3. and finish the work by giving a few blows with the hammer.

Fault in riveted joints

Pass the rivet through the punched hole in the sheet as
The following faults may be noticed in riveted joints.
shown in Fig 4.
Burrs between work pieces as shown in (Fig 8).

To set the rivet firmly in the sheet, use a rivet set. The rivet
head is to be supported with a dolly. A dolly is used to Punched holes in work pieces are not correctly aligned
prevent the rivet head from expanding when it is struck with (Fig 9)
the hammer.(Fig 5)

Rivet not set correctly with the rivet set.(Fig 10)

The shank is to be rounded by giving glancing blows with

the hammer (as shown in Fig 6) for firming the head.

Punched holes too large.(Fig 11)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.11 33

Rough rivet length too short.(Fig 12) Closed head displaced. (Fig 14)
The rivet set and rivet snap must be free from burrs.

Rough rivet length too long.(Fig 13)

34 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.11

Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.12

Joining sheet metal by soldering

Objectives: At the end of this exercise you shall be able to
• practice soldering on sheet metal.

Requirement
Tools / Instruments Material

• Soldering iron (copper hand iron) - 1 No • Ex. No -1-1-10 (refer)

• Soldering lead 60/40 lead/tin

TASK 1: Practice soldering on sheet metal.

Clean the area to be joined thoroughly. Place the sheet on a soldering bench. (Fig 4)

Where a lap joint is required on mild steel, both Apply the flux on the area to be joined. (Fig 4)
sides of the top lap should be cleaned and Heat the soldering iron until the flame is green. Keep the
tinned to assist heat transfer when soldering. tip of the copper bit upwards.

Heat the copper of the soldering iron until the flame is light Dip the point into the flux. This will remove the oxide film
green.Keep the edge of the copper bit upward.(Fig1) from the tinned faces.

Dip the edge of the bit in flux solder- acid. (Fig 2)

Apply the solder to the point (Fig 5)
Apply the bit to the work
Spread the solder evenly on the surfaces
Keep the tinned face of the bit flat, to obtain maximum,
heat transfer.
Apply more solder as required
Turn the sheet over and tin the other lap area in the same
manner.
Using a wet rag, clean off the excess flux.
The tip is tinned by rubbing it along the solder. (Fig 3)

35
Capital Goods and Manufacturing
R&ACT - Fitting & Sheet Metal Exercise 1.1.13

Prepare a box with sheet metal or funnel as per drawing

Objective: At the end of this exercise you shall be able to
• cut sheet metal as per dimension
• bend the sheet as per measurement given.

Requirement
Tools / Instruments Equipment / Machine
• Straight snip 200 mm - 1 No • Shearing machine - 1 No
• Mallet 500 mm - 1 No • Bench vice120mm - 1 No
• Scriber 150 mm - 1 No • Anvil 100kg - 1 No
• Steel Rule 300 mm - 1 No
Material
• Try square 150 mm - 1 No
• Smooth file single cut 200 mm - 1 No • As required according to diagram

Job Sequence

• Check the size of the raw material as per drawing using • Develop and layout the pattern for rectangular box by
a steel rule. parallel line method on sheet metal.
• Flatten the sheet metal on a Tin man's anvil using a • Cut the sheet metal pattern using a straight snip notch
wooden mallet. and clips the corners.

36
 Skill sequence

Developing and cutting

Objective: At the end of this exercise you shall be able to
• calculate the developed length and width
• cut the pattern with notches.
• develop the box or funnel as per dimension.

TASK 1: Calculate the developed length and width.

Developed length = Base length+2(side height+flange Draw lines for 100 mm height of the four sides of the
length + single hem allowance) rectangular box parallel to AB,BC,CD and DA as shown in
354 + 2 (100+10+6) = 586 mm. the Fig 3.
Developed width = Base width + 2(Side height+flange Draw lines for 10 mm flange and 6 mm single hemming
length + single hem allowance) allowance on the four sides parallel to FG,HI,JK,LE as
= 200+2(100+10+6) 432 mm. shown in Fig 4.
Mark and cut the sheet metal work pieces to the size of
586 432 mm maintaining squareness.
Draw the centre lines of the length and width XX and YY
(Fig1).

Draw the base length and width at the centre of the

workpiece. Mark lines at 177 mm on both sides of YY and
100 mm of both side of XX.(Fig 2)

TASK 2: Ccut the pattern with notches.

Draw lines for 12 mm lap for the riveted joint at the corners
of the rectangular box parallel to BH,CL,DL and AE as
shown in Fig 5.
Draw lines for 45° slant notches at points H,I,J,K,L,E,F and
G,A,B,C, and D.(Fig 5)
Cut the unwanted area shown in shadow using a straight
snip.(Fig 5)
Deburr the edges of the sheet metal pattern using a smooth
flat file.
Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.13 37
FUNNEL MAKING

38 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.13

TASK 3: develop the box or funnel as per dimension
• Develop and layout the pattern for the body of a
funnel frustum of a cons) on a plan drawing paper
using a geometry box (instrument box)

• Cut the layout pattern using scissors and paste it

on the given raw material using fevicol/gym.
• Cut the sheet metal on the outlines of the layout
pattern of the paper so pasted using a straight and
bend strips.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.13 39

40 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.1.13
Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.14

Demonstrate electrical safety precaution and first aid

Objectives: At the end of this exercise you shall be able to
• disconnecting a person (mock victim) from a live supply (simulated)
• artificial respiratory resuscitation
• resuscitation of a victim by the Holgen-Nelson method
• resuscitation of a victim by the Schafer’s method
• perform resuscitation of a victim by mouth to mouth method.

Requirements

Equipment/Machines Material
• A wall mounted/ pedestal bus-bar chamber controlled • Workshop coats,sacks, long hanfled wooden brush,
by an isolator - dummy - not connected to mains - length of timber, rubber mat, hot water bag.
an Electrical machine connected through an isolator-
(dummy - not connected to mains).

PROCEDURE

TASK 1: Disconnecting a person (mock victim) from a live supply (simulated).

1 Observe the person (mock victim) receiving an electric 2 Remove the victim safety from the ‘live’ equipment by
shock. Interpret the situation quickly. disconnecting the supply or using one of the items of
insulating material.

Do not run to switch off the supply that is far

away.
Do not touch the victim with bare hands until
the circuit is made dead or the victim is moved
away from the equipment.
Push or pull the victim form the point of contact
of the live equipment, without causing serious
injury to the victim.

3 Move the victim physically to nearby place.

4 Check for the victim’s natural breathing and
consciousness.
5 Take steps to apply respiratory resuscitation if the
victim is unconscious and not breathing.

TASK 2: Artificial respiratory resuscitation

1 If breathing has stopped, apply immediate artificial 5 Look for visible injury in the body and decide on the
respiration suitable method of artificial respiration.
2 Loosen the tight clothing of the victim. If not possible to 6 Have you observed ? (In this case you are told by the
loosen quickly, do not spend too much time in this, instructor)
activity.
7 In the case of injury /burns to chest and /or belly follow
3 Remove obstruction from the mouth, if any. the mouth to mouth method.
4 Send word for professional assistance.( If no other 8 In case the mouth is closed tightly. Use Schafer’s or
person is available, you stay with the victim and render Holden Nelson method.
help as best as you can.)
9 In the case of burn and injury in the back, follow
Nelson’s method.
41
10 Arrange the victim in the correct position for giving
Exercise extreme care to prevent injury to
artificial respiration. Follow the steps explained, given
internal organs.
under skill information for each method of artificial
respiration, until the victim breathes naturally or 11 Place the mock victim in the recovery position
professional help arrives.
12 Cover the victim with coat, sacks or improvise your own
All action should be taken immediately. method. It helps to keep the victim’s body warm.
Delay even by a few seconds may be dangerous.

TASK 3: Resuscitation of a victim by the Holgen-Nelson method.

Caution 4 As you rock back gently raise and pull the victim’s arms
towards you as in Fig 4 until you feel tension in his
- Remove the victim from content with the live equipment
shoulders. To complete the cycle lower, the victim’s
(Ref. related theory - Electrical safety )
arms and move your hands up to the initial position.
- Tight clothing which may interfere with the victim’s
breathing must be loosened.
- Remove any foreign materials or false teeth from his
mouth, and keep the mouth open.
- Do not delay artificial respiration for loosening cloths or
even if the mouth is closed tightly.

Nelson's arm-lift back pressure method must

not be used in case there are injuries to the
chest and belly.

1 Place the victim prone (that is , face down) with his arms
folded with the palms one over the other and the head
resting on his cheek over the palms. kneel on one or
both knees near the victim’s hand. Places your hands
on the victim’s back beyond the line of the armpits, with
your fingers spread outward and downward, thumbs
just touching each other as in Fig 1.

2 Gently rock forward keeping the arms straight until

theory are nearly vertical, and thus steadily pressing
the victim’s back as in Fig 2 to force the air out of the
victim’s lungs.
3 Synchronizing the above movement rock backwards,
slide your hands downwards along the victim’s arms
and grasp his upper arm just above the elbows are
shown in Fig 3. Continue to rock backwards.

42 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.14

Other steps
1 Send for a doctor immediately. 4 When the victim revives, keep him lying down and do not
2 Continue artificial respiration till the victim begins to let him exert himself.
breathe naturally. Please note in some cases it may 5 Do not give him any stimulate until he is fully conscious.
take hours.
3 Keep the victim warm with a blanket, wrapped up hot
water bottles or warm bricks; stimulate circulation by
stroking the insides of the arms and legs towards the
heart.

TASK 4: Resuscitation of a victim by the Schafer’s method

- Do not use this method in cases of injuries to victim on

the chest and belly
- Make the equipment dead by opening the switch and
release the victim.
- If the victim is aloft, measure must be taken to prevent
him from falling or to make him fall safe.
- Do not touch the victim with bare hands until you are
sure that he is free from electrical contant.
Caution
4 Now swing backward immediately removing all pressure
- Tight clothing which may interfere with the victim’s from the victim’s body as shown in Fig 3,and thereby
breathing must be loosened; all foreign matters, such allowing the lungs to fill with air.
as false teeth, tobacco, pan, etc., should be removed
from his mouth. Delay by even a few seconds may be
dangerous.
- Avoid violent operation to prevent injury to be internal
parts
1 Lay the victim on his belly, one arm extended directly
forward, the other arm bent at the elbow and with the
face turned sideward and resting on the hand or fore -
arm as shown in Fig 1.
5 After two seconds, swing forward again and repeat the
cycle twelve to fifteen times a minute.
Other steps
1 Send for a doctor immediately.
2 Keep the victim warm with a blanket, wrapped up hot
water bottles or warm bricks; stimulate circulation by
stroking the insides of the arms and legs towards the
heart.
3 Continue artificial respiration till the victim begins to
breathe naturally. Beware it may take hours even.
2 Kneel astride the victim, so that his thighs are between
your knees and with your fingers and thumbs positioned 4 When the victim revives, keep him lying down and do not
as in Fig 1 let him exert himself.
3 With the arms held straight swing forward slowly so that 5 Do not give him any stimulant until he is fully conscious.
the weight of your body is gradually brought to bear
upon the lower ribs of the victim to force the air out of the
victim’s lungs are shown in Fig 2.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.14 43

TASK 5: perform resuscitation of a victim by mouth to mouth method
Mouth-to-mouth method of artificial respiration 4 Take a deep breath and place your mouth over the
victim's mouth as shown in Fig 4 making airtight
– Free the victim from the live equipment before com-
contact. Pinch the victim's nose shut with the thumb
mencing artificial respiration.
and forefinger. If you dislike direct contact, place a
Caution porous cloth between your mouth and the victim's. For
an infant, place your mouth over its mouth and nose.
– Loosen tight clothing which may interfere with the
(Fig 4).
victim's breathing.
– Make sure that the airways (nose and mouth) are clear.
Remove loose dentures or other obstructions from the
mouth.
– Do not delay artificial respiration for loosening the
clothes. Delay even by a few seconds may be
dangerous.
1 Lay the victim flat on his back and place a roll of clothing
under his shoulders to ensure that his head is thrown
well back. (Fig 1) 5 Blow into the victim's mouth (gently in the case of an
infant) until his chest rises. Remove your mouth and
release the hold on the nose, to let him exhale, turning
your head to hear the out-rush of air. The first 8 to 10
breaths should be as rapid as the victim responds,
thereafter the rate should be slow down to about 12
times a minute (20 times for an infant).

If air cannot be blown in, check the position

of the victim's head and jaw and recheck the
2 Tilt the victim's head back so that the chin points mouth for obstructions, then try again more
straight upward. (Fig 2) forcefully. If the chest still does not rise, turn
the victim's face down and strike his back
sharply to dislodge obstructions.
Sometimes air enters the victim's stomach as
evidenced by a swelling stomach. Expel the
air by gently pressing the stomach during the
exhalation period.

Mouth to nose method: If the victim's mouth will not

open, or has a blockage you cannot clear, use the fingers
of one hand to keep the victim's lips firmly shut, seal
your lips around the victim's nostrils and breathe
3 Grasp the victim's jaw as shown in Fig 3, and raise into him. Check to see if the victim's chest is rising
it upward until the lower teeth are higher than the upper and falling. (Fig 5)
teeth; or place fingers on both sides of the jaw near the
ear lobes and pull upward. Maintain the jaw position
throughout the artificial respiration to prevent the
tongue from blocking the air passage.

44 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.14

Cardiac arrest: In cases where the heart has stopped
beating, you must act immediately.
You should check if :
• the carotid pulse in the neck can be felt. (Fig 6)

• Move back to the victim's mouth to give two breaths

• the casualty is blue around the lips. (mouth-to-mouth resuscitation). (Fig 4)
• the pupils of his eyes are widely dilated. • Continue with another 15 compressions of the heart,
followed by a further two breaths of mouth-to-mouth
Quick action is essential. resuscitation, and so on, checking for the pulse at
• Lay the victim on his back on a firm surface. frequent intervals.
• Kneel alongside, facing the chest and locate the lower • As soon as the heartbeat returns, stop the
part of the breastbone. (Fig 7). compressions immediately but continue with mouth-
to-mouth resuscitation until natural breathing is fully
restored.
• Place the victim in the recovery position. Keep him

• Place the palm of one hand on the centre of the lower

part of the breastbone, keeping your fingers off the warm and get medical help quickly. (Fig 10)
ribs. Cover the palm with your other hand and lock
your fingers together. (Fig 8) Other aids
1 Send for a doctor immediately.
2 Keep the victim warm with a blanket, wrapped up hot
water bottles or warm bricks; stimulate circulation by
stroking the insides of the arms and legs towards the
heart.
3 Continue artificial respiration till the victim begins to
breathe naturally. It may take hours.
4 When the victim revives, keep him lying down and do not
let him exert himself.
• Keeping your arms straight, press sharply down on 5 Do not give him any stimulant until he is fully conscious.
the lower part of the breastbone; then release the
pressure. (Fig 9)
• Repeat this 15 times at a rate of at least once per
second.
• Check the carotid pulse.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.14 45

Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.15

Identify, use and maintain electrical tools

Objectives : At the end of this exercise you shall be able to
• identify the tools when specification is given
• identify the tools for specific uses
• care and maintenance of tools.

Requirements

Tools/Instruments Equipment/Machines
• Trainee’s tool kit - 1 set • Electric bench grinder - 1 No.
• Triangular file bastard 150 mm - 1 No.
• Saw-tooth setter - 1 No. Materials
• Long round nose pliers 200mm - 1 No. • Lubricating oil - 100 ml.
• File flat 250 mm bastard - 1 No. • Cotton waste - as reqd.
• Rawl jumper and bit No.8 - 1 No. • Cotton cloth - 0.50 metre square.
• Grease - as reqd.
• Emery sheet 00 - 1 sheet.

Note: The instructor shall arrange for the necessary tool/equipment like saw-tooth setter , grinder etc.
from other sections and also arrange for the required materials from scrap for practising the functioning
of tools.

PROCEDURE

TASK 1: Identify the tools when specification is given.

Assumption - A set of trainee’s tool kit and specified tools

as given in this exercise are displayed on the workbench. Specification Sketch
Trainees are required to identify the tools from the
specification given below and draw the sketch of the tools. vi Flat file bastard 250 mm

1 Draw a neat sketch against each item given below. vii Bradawl 6 mm x 150 mm
square-pointed
In case of change in specification, rewrite the
correct specification of the items given to you. viii Gimlet 4 mm x 150 mm

ix Ratchet brace 6 mm
Specification Sketch
capacity
i Combination pliers with
x Raw l jumper holder with
pipe grip, side cutter and
bit No.8
insulated handle-size 200 mm.

ii Long round nose

pliers 200 mm.

iii Screwdriver 0.8 x 6 x 150mm

iv Firmer chisel 12 mm

v Wood rasp file 250 mm

46
TASK 2: Identifying tools for specific uses

Practise the use of each tool for different operations

as given below.
1 Combination pliers (Fig 1)

Pipe grip is serrated for gripping cylindrical objects.

Two joint cutters are provided for cutting or shearing off
wires. (Fig 2)

Side cutting edges are provided for cutting of soft wires. 5 Screwdriver
(Fig 3) It is used for slot head screws.
Use screwdrivers with tips correctly fitting into the screw
slot. (Fig 7)

2 Pliers-flat nose
It is used for bending and folding narrow strips of thin sheet
metal. (Fig 4)
6 Screwdriver-Phillips - headr (star)
It is used for star-headed screws.(Fig 8)

3 Pliers-diagonal cutting
It is used for shearing off wires in confined spaces and
cutting off wires close to the surface level.(Fig 5)
4 Pliers-round nose
It is used to shape loops in wires and to form curves in light
metal strips.(Fig 6)
Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.15 47
7 Neon tester
It is used for testing live terminals.(Fig 9)

8 Electrician's knife
It is used for skinning the insulation.(Fig 10)

9 Try-square
It is used for checking surfaces and squareness. (Fig 11)

10 Firmer chisel
It is used for chiselling wood.(Fig 12)
11 Ten on-saw
It is used for cutting battens.(Fig 13)
12 Plumb-bob
It is used for drawing vertical lines on walls.(Fig 14)
13 Centre punch
It is used for making punch marks on metals.(Fig 15)

48 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.15

14 Cold chisel
It is used for chipping metals.(Fig 16)

15 Hacksaw
It is used to saw metal pieces.(Fig 17)
16 Portable electric drilling machine
It is used for drilling holes in wood or metals. (Fig 18)

TASK 3: Care and maintenance of tools

Prevent rust formation Reshaping the screwdriver tip
1 Inspect all the tools; if rusted, use fine emery-paper to 8 Check the tips of the flat tipped screw drivers. If the tip
remove the rust. is blunt or disfigured report to the instructor.

While removing rust keep your hands clear off Observe how the screwdriver tip is ground to
sharp edges. Do not use emery paper on steel form the perfect cornered tip for effective usage.
rule or tape.
Sharpen and set the saw-teeth
2 Apply a thin coat of oil over the surface of the rusted
tools and clean with cotton cloth. 9 Check the teeth of the ten on-saw.
10 Report to your instructor, if the saw-teeth are blunt.
A hammer should not have even a trace of oil
on its striking surface.
Observe how the saw-teeth are filed to make
the saw-teeth sharp.
3 Check and lubricate the tools for easy movement of
jaws of pliers, blades of knife, jaws of wrench, pinchers,
11 Check the saw-teeth setting.
gears of the hand drilling machine.
4 Apply a drop of oil at the hinged/geared surfaces, if the The teeth for the ten on-saw should be off set
movement is found to be hard or sluggy. alternatively to enable the dust to be removed
while sawing.
5 Activate the jaws and gears till the muck/grim in the
surfaces comes off.
12 Report to the instructor, if the setting is not proper.
6 Apply a drop of oil again and clean the tools with cotton
13 Observe how the teeth are set by a saw-setter.
cloth.
Remove the mushrooms
7 Check the cold chisel and hammer striking face for
mushrooms. If found report to your instructor to enable
him to remove the mushroom through grinding.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.15 49

Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.16

Prepare simple twist joints of wires / cables

Objectives : At the end of this exercise you shall be able to
• mark the length of insulation to be removed (R)
• skin the insulation (R)
• prepare a straight twist joint in copper and aluminium
• prepare a rat tail joint in copper and aluminium.

Requirements
Tools/Instruments Materials
• Wireman’s tool kit - 1 set. • PVC insulated copper cable 1/1.12 - 2 mtr.
• Steel rule 300 mm - 1 No. • PVC insulated aluminium cable 1/1.40 - 1 mtr.
• Diagonal cutting pliers 150 mm - 1 No. • Cotton cloth 30 cm sq. - 1 No.
• Sandpaper ‘o’ (smooth) - 1 sheet.

PROCEDURE

TASK 1: Make a straight twist joint as shown in Fig 1

5 Clean the ends with the help of cotton cloth.

Use smooth sandpaper if necessary to clean

the conductor.

1 Collect 2 pieces of 1/1.12 PVC copper cable of 0.5 6 Place the conductors together about 50 mm from the
metre length from the scrap yard. ends. (Fig 4)

2 Straighten the cables.

3 Mark 80 mm length on one end of each piece of cable.

7 Twist them tightly around each other in the opposite

direction. (Fig 1)

Pliers can be used just to grip the crossed

conductors.
4 Use the knife at an angle of 20o as shown in Fig 2 and Each twist should contain about 6 turns.
remove the insulation from each conductor for a distance Each turn of a conductor should fit closely to the
of 80 mm. (Fig 3) adjacent turn.

8 Cut off the excess length of the conductor with side

cutters.
9 Press the sharp edge of the conductor end and smooth
it.

Soldering and insulating the joint by tape should

be done before putting the jointed cable in use.
Avoid Knicks in the conductor.
10 Show the joint to your instructor.

50
11 Cut off the joint after leaving 30 mm cable from the joint.
(Fig 5)

Repeat the steps 3 to 9 and make a few more

joints for practice, using the remaining cable.

TASK 2 : Make a rat tail joint as shown in Fig 6.

1 Collect 2 pieces of 1/1.2 mm PVC copper cable of 0.5

metre length

2 Straighten the cable.

3 Skin both the cable ends for 50 mm.
4 Clean the conductor ends with the help of cotton cloth.
5 Cross the bare wires at an angle of 90o at a distance of
45 mm from the cable end.
6 Tightly twist the ends as shown in Fig 7.
9 Press the ends of the wire with the help of combination
The twist on the wire should be uniform and pliers to avoid sharp ends, and cut the excess wire.
close.
10 Repeat the steps from No 3 to 8 of Task 2 for four more
7 Make at least 6 twists. (Fig 8) joints for practice, using the remaining cable.

8 Fold the remaining wire back on the twists. (Fig 9)

TASK 3 : Repeat the joints with PVC insulated aluminium cable of size 1/1.40.

1. Collect two pieces of 1/1.40 aluminium cable. 2. Repeat the steps from 2 to 9 in task 1 and 2 to 9 in task

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.16 51

Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.17

Prepare married joint

Objectives : At the end of this exercise you shall be able to
• prepare a married joint in multi-strand conductors.

Requirements

Tools/Instruments Materials

• Wireman’s hand tool kit - 1 set. • PVC insulated copper cable 7/0.914
• Diagonal cutting pliers 150 mm - 1 No. of 660 V grade - 1 metre.
• Steel rule 300 mm - 1 No. • PVC insulated copper cable 3/0.914
of 660 V grade - 1 metre.
• Cotton cloth 30 x 30 cm - 1 piece.
• Sandpaper (smooth) No.' 00' - 1 sheet.

PROCEDURE

TASK 1: Prepare a married joint in 7/0.914 stranded conductors as shown in (Fig 1).

1 Collect 2 pieces of PVC insulated copper cable 7/

0.914 of length 0.5 metre.
2 Mark both cables at 120 mm from the cable ends.
3 Remove the insulation for 120 mm on both the cables.

Care should be taken while removing the

insulation. Do not knick or shave the conductor.

4 Open the strands, clean the wires and re-twist the

strands in the original direction up to 50 mm from the
cable insulation. (Fig 2)

8 Hold one of the cables in one hand and twist the strands
of the other cable end over it - one by one, closely and
tightly. In doing so, each strand has to be twisted half
a turn at a time.

The direction to twist to form the shoulder,

should be the same as the cable’s original twist
direction.
5 Cut the centre strand of both cables close to the twist
(about 70 mm from the free end). 9 Remove the binding made at step 6.
6 Make a binding on the twisted part of both the cables as 10 Repeat the operation at step 8 on the other side with the
shown in (Fig 3). 2nd cable end.
7 Interlace the strands keeping the centres butt. (Fig 4) 11 Complete the joint as shown in Fig 1 by rounding off the
twisted strands with a mallet or pliers.

52
Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.18

Measure current, voltage, resistance, power, frequency and energy using

analog and digital meter
Objectives At the end of this exercise you shall be able to
• use voltmeter and check voltage
• use Ammeter and check current
• operate multimeter
• connect energy meter terminals to line and load
• determine the energy in single phase circuit by the indirect method (load remaining constant over a period).

Requirements

Tools/Instruments
• Cuttiing plier 150 mm - 1 No. • Watt meter, energy meter &
• Nose plier 150 mm - 1 No. frequency meter -1 No each.
• Screw driver set - 1 set . Materials
• Line tester 500 V - 1 No.
• Volmeter 0 -500 VAC - 1 No. • Wire pieces - as reqd.
• Ammeter - 0 - 30 A - 1 No. • Electrical clips - 2 Dozen.
• Multimeter Multirange - 1 No. • Switch 5 A - 4 Nos.
• Wire stripper - 1 No. • Lamp 200 W - 4 Nos.
• Lamp Holder 5A - 4 Nos.

PROCEDURE

TASK 1: Use voltmeter & Measure voltage

1 Take the required length wire & skin the ends. 2 Connect the lamp holder with phase &neutral wire
(prepare test lamp).
3 Connect volmeter parallel to the supply.
4 Connect Volmeter terminals with phase and neutral
connection.
5 Fix the 200W bulb & switch on the supply.
6 Check the voltage in volmeter & record.
7 Switch off the supply &remove the connections after
talking the readings.

TASK 2: Use Ammeter &measure current

1 Take the required length wire and connect 01 Hp motor
with phase &neutral.
2 Connect Ammeter 0-30 A series with the phase line (in
between the phase line).
3 Connect voltmeter parallel to the supply.
4 Switch on the supply and check the current drawn by
the motor in Ammeter.
5 Switch off the supply & remove connections after
taking the readings.

53
TASK 3: Operate mulitmeter
AC Voltage Measurements 2 Plug the red lead into the 10A (Top) Jack . Plug the
1 Turn the Range Selector Switch to 750 ACV setting, black lead into the COM (Bottom) Jack. Switch the
Always start with the highest range if the voltage is Multimeter.
unknown. 3 Carefully touch the exposed conductors with the tips of
2 Plug the red lead into the VΩ mA (Centre) Jack. Plug the probes to measure the amperage.
the black lead into the COM (Bottom) Jack. Switch the
Multimeter ON. (Fig 3) Note : Amperage is always tested in series with
the circuit under test.
Fig 3
DC VOLTS RANGE AC VOLTS RANGE 4 Read measurement. If the reading is less than .2
DC CURRENT
AMPs, switch the red lead to the VΩ mA (centre) Jack
RESISTANCE(ohms)
RANGE
and set the Range Selector Switch to the 200 mA
RANGE
setting.
SOCKET FOR
TESTING TRANSISTORS
10 Amp 5 When testing is complete, remove Test Leads and
store with multimeter.
VOLTS,CURRENT(mA),
RESISTANCE,CONTIUITY
AND DIODE TEST
common
Resistance Measurements
PROBE LEAD
SOCKET
Never measure resistance on a circuit with
3 Carefully touch the exposed conductors with the tips of voltage running thread it.
the probes to measure the voltage (not amperes).
1 Turn the Range Selector Switch to the 200 mA position.
4 Read measurements. If the voltage is less than 200
volts, set the Range Selector Switch to the lower range. 2 Plug the red Test Lead into the VΩ mA (Centre) Jack.
Plug the black Test Lead into the Com (Bottom) jack.
5 When testing is complete, remove Test Leads and store Switch the Multimeter ON. Short the Test Leads together.
with multimeter. The meter should read "0" Ohms.
DC Voltage Measurements 3 Touch the exposed conductors with the tips of the test
1 Turn the Range Selector Switch to 1000 DC setting. leads.
2 Follow the direction above under "AC Voltage 4 Read measurement. If the reading is "1", set the Range
Measurements", only use the DC setting instead. Selector Switch to the next higher Ohm (Ω) position.
DC Current Measurements
1 Turn the Range Selector Switch to the 10 A position
Always start with the highest range if the amperage is
unknown.

TASK 4: Measurement of frequency

1 Connect the frequency meter parallel to load 3 Measure frequency in "Hertz"

2 Switch on power supply .

TASK 5: Using digital multimeter

1 Turn the dial to HZ (Fig 4) Fig 4

2 Insert the black test lead into the COM jack. DC VOLTS RANGE AC VOLTS RANGE

3 Insert the red lead into V Ω jack. DC CURRENT

RANGE

4 Connect the black test lead first and red lead second to
RESISTANCE(ohms)
RANGE

power supply. SOCKET FOR Hz

TESTING TRANSISTORS
10 Amp
5 Read the frequency measurement in the display of VOLTS,CURRENT(mA),
RESISTANCE,CONTIUITY
digital meter. AND DIODE TEST
common

PROBE LEAD
SOCKET

N L

54 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.18

TASK 6: Measurement of power
1 Identify the wattmeter terminals.
2 Connect the wattmeter terminals in the circuit on
shown in in Fig 5.
3 Switch circuit with load.
4 Note the wattmeter reading

TASK 7: Measurement of power by indirect method.

1 Connect the ammeter series to load. 4 Measure Ampere and voltage
2 Connect the voltmeter parallel to load. 5 Calculate the power as power P = V I
3 Switch on the load.

TASK 8: Measurement of energy by the direct method

1 Identify the energy meter terminals - line and load, after

removing the terminal cover.

Always mount the meter vertically.

2 Associate the circuit diagram (inside) with the terminal

markings of the instrument.
3 Connect the energy meter terminals (line & load) in the
circuit as shown in Fig 1.
4 Note the meter constant from the name-plate of the
energy meter. (Fig 2)
5 Record the initial meter reading.

6 Switch ON the circuit with load.

7 Record the reading after 30 minutes.
8 Calculate the energy consumed which is the difference
between the current and previous reading.
9 Repeat the steps 5 to 8 for changed load condition.
10 Repeat step 9 at least 3 times.

TASK 9: Measurement of energy by the indirect method

1 Select a suitable range of voltmeter and ammeter. 3 Close the switch S of the circuit.
2 Connect the ammeter and the voltmeter to the line and 4 Start the stopwatch.
load as shown in Figure 3.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.18 55

5 Observe the readings of the voltmeter and ammeter.

Watch the instruments constantly. No change

in the reading should take place during the
period of measurement.

6 Record the reading and time in the tabulation form

(Table 1) after 30 seconds. Table 1
7 Calculate the energy with the given formula.
Voltage (V) Current (I) Time(s) Energy(Ws)
8 Repeat the steps 3 to 7 for 60 seconds and 90 seconds
time and record the values of the ammeter and the
voltmeter. Calculate the energy consumption.

TASK 10: Verify the calculated energy with the meter reading ( with disc rotation).

1 Connect the instruments as per circuit diagram in Table 2

Fig4.
Sl. Voltmeter Ammeter Rev. Time in Energy
2 Close the switch S. No. reading,V I counted, Seconds ws me ws cal
N t asured culated
3 Observe that the voltmeter and ammeter indicate
steadily while the bulb is glowing.
4 Watch the rotation of the disc in the energy meter.

10 Energy recorded

No.of Revolution s counted (N)

5 Record the meter constant (i.e. the number of revolutions Kwh
Meter constant
per KWH) from the dial mark on the meter.
N
i.e Energy = kwh
If the meter constant i.e. rev.per kwh is very Meter constant
high, say in the order of 1000 and above,
reduce the load suitably.
(kwh = 1000 x 3600 watt. second.)
6 When the red mark on the disc passes the window, 11 Calculate energy from the formula
start the stopwatch to count the time.
7 Start counting the number of revolutions of the energy i.e Energy =
V xIx t
= kwh
meter disc. 1000 x 3600

Watch there is no change in the readings of the

voltmeter and ammeter. 12 Compare the direct reading of energy with the indirectly
measured energy.
8 On completion of 1/10 of the meter constant or
13 Repeat the steps 10 to 12 for the following value of N.
equivalent to the whole number of revolutions, stop
the stopwatch and switch OFF the supply. N = 1/5 of meter constant
9 Record the number of revolutions in Table 2. Record N = 1/4 of meter constant
the time also in Table 2. N = 1/3 of meter constant
The value of N calculated from the meter constant is
rounded off to the next higher value.

56 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.18

Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.19

Test insulation and earth resistance using megger

Objectives At the end of this exercise you shall be able to
• measure the insulation resistance value between the windings
• measure the insulation resistance between each winding and body or frame
• measure the resistance of the earth continuity conductor (E.C.C).

Requirements

Tools/Instruments • Battery 6V, 60 AH - 1 No.

• M.I voltmeter 0- 50 V - 1 No.
• D.E spanner 5mm to 20mm - 1 Set. • M.I voltmeter 0-25 A - 1 No.
• Cutting plier 200mm - 1 No.
• Screw driver 200mm - 1 No. Equipment/Machines
• Megger 500 - 1 No. • AC 3- phase, 415V squirrel cage
• Ohm meter low range 0-10 ohm - 1 No. induction motor - as available
• Test lamp 230V,60W - 1 No.
• Earth tester with spikes and Material
connecting leads - 1 No. • Connecting cables 70/0.2 of length 40m - 1 No.
• Hammer straight pein - 1 No. • Connecting cables 70/0.2 of length 10m - 1 No.
• M.C voltmeter 0-10V - 1 No. • Testing prods - 1 pair.
• M.C ammeter 0-20A - 1 No.
• Calibrated rheostat 0.1 ohm, 10 amp - 1 No.

PROCEDURE

TASK 1: Measure the insulation resistance value between the windings.

1 Note the name -plate details and enter them in Table 1.

As a precautionary measure remove all the
Before starting the Megger test see that the links in the terminal plate and check the
supply is off fuse- carriers are removed and the continuity of each winding. End terminals of
motor is disconnected from the starter. the same winding should have continuity.

2 Identify the terminals of the given AC induction motor

from the markings.
Table 1
Name - Plate details

Manufacturer, Trade Mark.............................. Rated frequency ..................

Type, model or list number............................. Rated power.............. k.w/HP

Type of current............................................... Rating class...........................

Function........................... Insulation class......................

Fabrication or serial number......................... Rated current..................amps

Type of connection............... sep/shunt/ Rated speed...................r.p.m

series/compound

Rated voltage...........volts Protection class..............

57
3 Connect the test leads of the Megger as shown in Fig1 Recommended standard insulation resistance
to the terminals U1 and V1
R1 = in megohm... Eqn.1

Where
R1 = insulation resistance in megohm at 25°C
E = rated phase-to-phase voltage
P = Rated power in kW.
If the resistance is measured at a temperature different
from 25°C,the value shall be corrected to 25°C.

4 Rotate the Megger at its rated speed and note down the The equation 1 given here is used to calculate
readings in table 2. the insulation resistance as a standard value.
5 Repeat the steps 3 and 4 by connecting the Megger However the accepted insulation value should
terminals between U1 and W1 and also between V1 and not be less than 1 megohm.
W1. Record the findings in Table 2.

TASK 2: Measure the insulation resistance between each winding and body or frame
1 Connect the test leads of the Megger to the frame of the 2 Rotate the Megger at its rated speed and note down the
motor and terminals U1 as shown in Fig 2. readings in Table 2.
3 Repeat steps 1 and 2 for the other two windings (V1 and
W1)
4 Compare the measured value with the standard value.

The above test will not be valid until and unless

the following conditions are observed.

CONDITION 1
Check and ensure that the earth continuity conductor
(E.C.C) connected to the main earth electrode is in
perfect continuity, having a resistance of less than1
The Megger connection to the frame should be ohm.
done at the earthing stud of the frame. Before
connecting, remove the varnish, dust, dirt and CONDITION 2
grit thoroughly at the earthing stud. The resistance of the earth electrode should be less
than 5 ohm unless otherwise stated.

Table 2
Insulation resistance of 3 - phase Induction motor

SI.No Between terminals Insulation resistance Remarks

1 U1 and V1

2 U1 and W1

3 V1 and W1

4 U1 and frame

5 V1 and frame

6 W1 and frame

58 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.19

TASK 3: Measure the resistance of the earth continuity conductor (E.C.C)

1 Measure the resistance of the earth continuity conductor Write below your suggestion to have effective earth
(ECC) according to the method and enter the value in connection to isolate the circuit under earth fault by
Table 3. fuse or circuit breaker.

2 Measure the earth electrode resistance and enter the

value in Table 3.
3 Write the conclusion in the remarks column of table
indicating whether the fuse will blow in case of earth
fault in the above circuit, or suggest methods to be
adopted to have effective earth connection in the above
case.

Table 3

Insulation resistance of 3 phase induction motor

SI. Resistance Resistance Total earth Voltage Earth Fuse Remarks

No. E.C.C earth electrode Resistance between fault rating
RECC REE RE = phase and current of the
RECC +REE earth Ep IF =Ep/RE motor
circuits

1
2
3
4
5
6

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.19 59

Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.20

Connect star and delta connection on a three phase motor

Objectives : At the end of this exercise you shall be able to
• draw the star delta connection of motor winding through starter handle operation
• connect the manual star delta starter with 3 phase motor
• adjust the overload relay according to the motor current rating
• stop the 3 phase motor through the manual star delta starter
• measure line current and line voltage, phase current and phase voltage.

Requirements

Tools/Instruments
• Insulated cutting plier 200mm - 1 No. • Manual star -delta starter 16A,415V
• Screw driver 20mm,300mm - 1 No each. without overload relay and no volt coil - 1 No.
• Side cutter 150 mm - 1 No. Materials
• Wire stripper - 1 No.
• M.I ammeter 10 amp - 1 No. • Pre insulated standard aluminium
• M.I voltmeter -0- 500V - 1 No. cable 2.5 sq.mm 650V grade - 25 meter.
• Fuse wire 10 amps - as reqd.
Equipment/Machines • Black insulation tape - as reqd.
• 3 phase squirrel cage induction • ICTP switch 16A 415 V - 1 No.
motor 415 V 5HP - 1 No.

PROCEDURE

TASK 1: Connect star and delta connection on a three phase motor

1 Identify the parts of the star delta starter trace the
connection and study its operation Draw the traced out
circuit and get it approved by the instructor.

The layout diagram in the Fig -1. The schematic

diagram of the star delta starter in Fig -2 and
two types of practical circuits in Fig 3 and 4 are
all given for your guidance only.

2 Draw the complete connection diagram with the ICTP

switch., the given star delta starter and motor and get
it approved by your instructor.

60
3 Make the connection of the motor starter and the ICTP 6 Set the over load relay according to the full load current
switch as per the approved diagram. rating of the motor.
4 Connect three cables from supply L1,L2,&L3 to the 7 Switch 'ON' the main observe the voltmeter reading and
main switch an shown in Fig 3 & 4. move the handle to the star position positively and at the
same time observe the starting current& voltage and
5 Connect ammeter in series and voltmeter in parallel as
enter it in Table 1.
shown in Fig 3 & 4.

9 Note down the current & voltage taken by the motor in

running condition and enter the value of the current
Table1
10 Then stop the motor by pressing the stop button of the
starter.
11 Power and control wiring of 3 phase motor refer Fig no
5&6

8 Allow the motor to start race initially and let this sound
of the rotating shaft come to a steady state. Then move
the handle to the delta position positively

Table 1

SI.No Description VL in volts IL in amp Vph in volts Iph in amps

1 Start starting current

2 Delta Running current

Result :-

In Star :- The current and phase current are.....where as

line voltage =.........x phase voltage
In Delta :-The line voltage & phase voltage are.......where
as line current = ...........x phase current
Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.20 61
Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.2.21

Measure three-phase power and power factor

Objectives: At the end of this exercise you shall be able to
• select a proper range of a two-element 3-phase wattmeter and connect it in the circuit
• select suitable C.T. for the load and current coil range of wattmeters
• select suitable P.T. for the supply voltage and pressure coil range of wattmeters
• connect the current transformers with the 3-phase wattmeters
• connect the potential transformers with the 3-phase wattmeters
• measure and determine 3-phase power.

Requirements

Tools and Instruments • Insulated screwdriver 200mm - 1 No.

• 3-phase 2-element wattmeter 500/ -1 No. Equipment/Machines
250/125V/5A
• 3-phase 415V 50 Hz 10 HP
• 3-phase 3-element wattmeter 500/ -1 No.
induction motor - 1 No.
250/125V/5A
• 3-phase load 415V 50 Hz 5 kW - 1 No.
• Current transformer 20A/5A - 3 Nos.
• Power factor improving capacitor bank
• Potential transformer 440/110V - 1 No.
3-oase 240V, 1.5 KVAR - 1 set.
3-phase
• 3-phase lamp load 0-3KW - 1 No.
• Electrician tool kit - 1 No.
• Adjustable spanner - 1 No. Materials
• Single phase P.F. meter 250V/500V ; - 1 No.
• Wattmeter 250/500 V, 5A/10A - 2 Nos. • PVC insulated cable multi-strand
• Ammeter 0-5A/10A m.I - 1 No. 2.5 sq.mm 650V- grade - 15m.
• Voltmeter 0-300V/600V m.I - 1 No. • PVC insulated cable 23/0.2mm - 5m.
• Insulated combination pliers 200mm - 1 No. • ICTP Switch - 32A 500 V - 2 No.
• T.P.I.C. switch 16A, 500V - 2 No.

PROCEDURE

TASK 1: Measurement of power in 3-phase system using 2-element and 3-element wattmeter (Direct
connection)

1 Collect 2-element and 3-element wattmeters.

Voltage ranges Current ranges Multiplying factor
2 Note down the specification of the wattmeter in Table 1.

Table 1
Details of the wattmeter

Voltage ranges Volts

Current ranges amps
Full scale deflection (F.S.D) W/KW
The multiply factor is normally given in the
wattmeter.
Multiplying factor (M.F.) =
3 Connect the element wattmeter with load and supply as
shown in Fig.1.

62
 Select and connect suitable voltage and current 4 Switch 'ON' the main switch then, the load switch and
ranges in the case of a multi-range wattmeter. observe readings in the meters.
5 Note down the readings and record in Table 2.
6 Repeat the steps 1 to 5 for different loads and record the
readings in Table 2.
7 Calculate the power consumed in the circuit using the
formula
W = Wattmeter reading x Multiplication factor.

The trainees may also use a 3-phase 3-element

wattmeter as shown in Fig 2 instead of 2-
element 3-phase wattmeter or they can do the
experiment on both separately.

Table 2

SI.No Load Wattmeter Multiplication Total power = Remarks

reading (W) factor (M.F.) W x M.F.

1 3 x 100 W

2 6 x 1000 W

3 6 x 200 W

TASK 2: Measurement of 3-phase power using C.T.

1 Select the CT according to the current coil rating of the

wattmeter and load current.
2 Identify the terminal markings of the given wattmeter
and ascertain the same with respect to the
connection diagram given on the cover of the given
wattmeter.
3 Record the name-plate details of CT in a format as
shown in Table 1.
4 Connect the CTs, wattmeter and load as in Fig 2 or Fig
3 (according to availability of meter).
5 Switch ON the main and load switches and observe the
deflection of the meters. Keep the switch closed if
nothing is abnormal.
6 Note down the meter readings at different loads and
record in the Table 3. Switch OFF the circuit.
7 Vary the load and take two more readings.
8 Calculate the actual power consumed by the circuit
using the formula
W = Wattmeter reading x M.F. x CT ratio.
9 Switch ‘off’ the circuit.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.21 63

 Table 3

SI.No Load particulars CT ratio Wattmeter Multiplication Power Remarks

1 3 x 100 W

2 6 x 1000 W

3 6 x 200 W

TASK 3: Measurement of power in 3-phase system using CT & PT

1 Record the name-plate details of PT in a format as 4 Note down the meter readings at different loads and
shown in Table 1. record in Table 4.
2 Make connection of CTs, PTs wattmeter and load as 5 Switch off the supply and disconnect the circuits.
shown in Fig 5 or Fig 6. (According to availability of
6 Calculate the actual power using the formula W=
meters.)
Wattmeter x M.F. x CT ratio x PT ratio. reading.
3 Switch ON and observe the deflection of the meter.

Table 4

SI.No Load particulars CT ratio Wattmeter Multiplication Power p

reading (W) factor (M.F.) P=WxM.Fx CT Ratio

TASK 4: Connect a single phase P.F. meter in 3-phase balanced circuit - verify the P.F. with ammeter,
voltmeter and single wattmeter connections.

1 Collect the meters and the 3-phase lamp load. 2 Make necessary connections of the meters and load as
per circuit diagram - Fig 1.
The lamp load should have equal wattage in
all the three phases.

64 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.21

 Connect the current coils of wattmeter and P.F.
meter in series with load. 11 Observe the range of current coil in wattmeter and P.F.
meter connection.
3 Get the circuit approved by the instructor.
12 Keep the capacitor switch in OFF condition. Switch ON
4 Switch ‘ON’ the power supply momentarily and observe
the power supply and observe the deflection of the
all the meter deflections. Keep the switch closed if
meters.
nothing is abnormal.
5 Note down the meter readings and enter in Table 1. If P.F. meter shows leading P.F. for inductive
load, switch ‘off’ the supply and interchange
6 Switch ‘OFF’ the power supply. current coil connections of the P.F. meter.
7 Determine the power factor by using the formula,
13 Record the meter readings in Table 1 for the load
conditions shown in Table 1.
14 Switch ‘OFF’ the power supply.
Where W - Wattmeter reading (power in one phase) 15 Calculate the power factor in each case and compare
with the measured P.F.
EPH - Phase voltage
IPH - Phase current (Also Consider the multiplying factor of the wattmeter
equal to line current) which depends on the C.C. and P.C. range
selected. The reading of the wattmeter should
8 Compare the calculated power factor and power factor
be multiplied with the multiplying factor to get
meter reading and write your observation.
the actual power.
Observation:
16 Observe the P.F. in each load condition and write your
observations.
Observation:

9 Show the readings to your instructor for approval.

10 Disconnect the lamp load and connect the 3-phase
induction motor with P.F. improving capacitor as shown
in Fig 2.
Table 1

3-phase appa- P.F. Cal-

Ammeter Voltmeter rent power Wattmeter 3-phase culated value Mea- Re-
Load condition reading reading in volt reading power sured ma-
Amps. IPH Volts EPH ampere Watts W WX3 value rks
3 x EPH x IPH
Resistive load

Motor without load

Motor without load

but with capacitor

Motor with load

Motor with load and

with capacitor

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.2.21 65

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.22

Identify the electronic components, tools and instruments

Objectives: At the end of this exercise you shall be able to
• identify the passive components by visual inspection
• identify the active components by visual inspection
• identify the tools ans instruments and equipments.

Requirements
Tools and Instruments
• Multimeter/ohm meter - 1 No. • Standard wire gauge - 1 No.
• Combination plier - 1 No. • Multimeter - 1 No.
• Long Nose piler - 1 No. • CRO - 1 No.
• Diagonal cutter - 1 No. • Regulated power supply - 1 No.
• Neon tester - 1 No. • Function generator (up to 1 MHz) - 1 No.
• Teezer - 1 No. Materials
• Soldering iron - 1 No.
• Screw driver flat - 1 No. • Assorted active and passive
• Screw driver philip - 1 No. components like capacitors,
• Test lamp (series) - 1 No. Inductors ,Resisitor diodes asorted
• Test lamp(parallel) - 1 No. types etc - 5 Nos.each

PROCEDURE
TASK 1: Identify the types of resistors by pictorial representation

Electronic components like resistors, inductors 3 Get your result corrected by your instructor.
and capacitors few can be visually identified 4 Collect assorted size, shape and type of passive
and other can be identified by coding only. components from your instructor.

1 Identify the passive components referring to Fig 1. and 5 Divide the passive components into separate groups
write the type of passive component in table 1. as resistor, inductor and capacitor by their appearances
(or) code references.
2 Sketch the appropriate symbol against the corresponding
type of passive components in table 1.
TABLE 1
SI.No Fig Components Reasons for Symbols Remarks
Alphabets Identified as Identifications

1 A
2 B
3 C
4 D
5 E
6 F
7 G
8 H
9 I
10 J
11 K
12 L
13 M
14 N
15 O
16 P
66
TASK 2: Identify the active components

1 Look at the Fig 1. Identify the component from the

Assumption : Given components have their
pictorial representation. Give your response in Table 1.
code number, lead identification marks as
well as related data books are available TABLE 1
Sl. Figure number Component's name
No.

1 Fig 1 a
2 Fig 1 b
3 Fig 1 c
4 Fig 1 d
5 Fig 2 e

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.22 67

2 Write the figure Nos. that indicate the components 5 Identify the electronic components from the given circuit
given in Fig 2, in Table 2 diagram Nos 4,5 and write the names of the components
in the Table 3.

Table 2
Sl. Figure number Component's name
No.

1 Transistor
2 Diode bridge 6 Decode and name the semiconductor devices from
their letter designation given in Table No.4 with the help
3 Integrated circuit
of the data book.
4 Diode
Table 4
3 Match the names and pictorial representations of the Sl. Code No. of Component's name
active components shown in Fig 3. Record your No.
response in the space provided.
1 OA79
2 DR25
3 IN4007
4 AA119
5 BY127
6 BZ148
7 BC147
8 2N904
Table 3 9 BD115
Sl. Component indicating Component's 10 BFW10
No. symbol name 11 3N187
12 BTY87
1 A
13 2N2646
2 B
14 D3202Y
3 C
15 T2801B
4 D
16 CA741
5 E
17 CA723
6 F
7 G 7 Identify the leads by decoding the marking in the base
8 H diagram in the data book for the semiconductor devices.
9 I Draw a neat sketch against each item given
10 J below

4 Collect the electronic (ACTIVE) components from your Assumption :

instructor. Identify the components and record your A set of specified tools as given in this exercise are
response in your record book along with sketches of the displayed on this work bench. Trainees are required to
components. (Refer Fig 3 for guidance) identify the tools given in the exercise and the tool name is
allotted in column.

68 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.22

TASK 3: Identify the tools ans instruments and equipments.

Identify the tools, instruments & equipments

Figure Name the tools Figure Name the tools

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.22 69

 Figure Name the tools

70 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.22

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.23

Colour coding of resistor

Objectives : At the end of the this exercise you shall be able to
• identify different types of fixed value resistors by their appearance and measure the value using
ohmmeter.

Requirements

Materials/Components
• Ohm meter / multimeter - 1 No
• Assorted types & values of fixed value resistors - 20 Nos./batch.

PROCEDURE

TASK 1: Identify different types of fixed value resistors by their appearance and measure the value using
ohmmeter.

1 Take a colour coded resistor from the given lot and

identify the colours of bands starting from one end of the
resistor as shown in Fig 1. Record the colours of the
bands in Table 2 of record sheet.
2 Refer appendix D of this book and calculate the nominal,
minimum, maximum value of the resistor. Record
values in Table 2 of record sheet.
3 Repeat steps 1 & 2 for the remaining colour coded
resistors and get your work checked by your instructor.
4 Decode the resistor value by using colour code chart.
5 Measure the value of the resistor by using ohm meter Table - 20/2 (LE: 8.01)
6 Compare the calculate value with measured value. Tolerance
Temperature First Second More Less
Colour Coefficient Digit Digit Multiplier than than
Table - 20/1 (LE: 8.01) 10pf 10 pf
(%) (pf)
Coding scheme for ceramic capacitors
(A) (B) (C) (D) (E)
Black 0 0 0 1.0 ±20 ±2
Brown -30 1 1 10 ±1 ---
Red -80 2 2 100 ±2 ---
Orange -150 3 3 1000 ±3 ---
Yellow -220 4 4 10,000 ±4 ---
Green -330 5 5 ---- ±5 ±0.5
Blue -470 6 6 ---- ±6 ---
Violet -750 7 7 ---- ±7 ---
Gray +30 8 8 0.01 ±8 ±0.25
White +120 to 9 9 0.1 ±10 ±1
-750
Gold -- -- -- 0.7 ±5 --
Silver -- -- -- 0.01 ±10 --

NOTE: Capacitance values formed using colour code is always in PF

71
 Table - 21/1 (LE: 8.01) Table - 21/2 (LE: 8.01)
Coding scheme for moulded, tubular paper and
mica capacitors Colour First Second Multiplier Tole- Voltage
Digit Digit rance Rating
(Volts)

Black 0 0 1 ±20 100

Brown 1 1 10 ±1 200
Red 2 2 100 ±2 300
Orange 3 3 1000 ±3 400
Yellow 4 4 10,000 ±4 500
Green 5 5 1,00,000 ±5 600
Blue 6 6 1,000,000 ±6 700
Violet 7 7 10,000,000 ±7 800
Gray 8 8 100,000,000 ±8 900
White 9 9 1,000,000,000 ±9 1000
Gold -- -- 0.1 ±5 2000
Silver -- -- 0.01 ±10 --

72 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.23

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.24

Verify ohm's law

Objectives: At the end of this exercise you shall be able to
• connect the voltmeter in the circuit
• read the voltmeter
• connect the ammeter in the circuit
• test the circuit elements in series.

Requirements

Tools/Instruments
• Rheostat 20 oms - 3.7 A - 1 No.
• Ammeter(MC) 0 to 500mA - 1 No.
Materials
• Ammeter(MC) 0 to 1A - 1 No.
• Voltmeter(MC) 0-15 V - 1 No. • S.P switch 6A, 250 V - 1 No
• Resistor 10 ,20, 50 ohms, 2W - 1 No.
Equipment/Machines
• Connecting leads 14/0.2 mm - 1 No.
• 6 Volts battery 30 AH capacity OR - 1 No. • P.V.C insulsted copper wire
• DC variable power supply assorted length - 8 Nos.
• 0-30 V 2 ammperes - 1 No.

PROCEDURE

TASK 1: Relation between voltage, current and resistance : Voltage variable- resistance constant

1 Identify the voltmeter - from the dial marking 'V' 6 Close the switch keeping the potentiometer to the
2 Identify the ammeter -from the dial marking 'A' minimum value of output.

3 Identify the fixed and variable terminal of the rheostat. 7 Apply different voltages by varying the rheostat arm of
the potential divider in succession across the resistance.
4 Connect the circuit elements as shown in Fig 1.
8 Measure the, voltage and corresponding current from
the instruments.
9 Record the measured values in Table1.

To avoid parallel error:

Position your eye in line to the pointer and also
in front level of the instrument
Position your eye to coincide with the mirror
image of the pointer in instruments having anti
parallax mirror.

Conclusion
The proved relationship between the current that flows
through the resistance and the voltage applied across the
resistance, show that the current is

5 Ascertain the value of each major division and minor

division of the scales.

73
TASK 2: Relation between current and resistance : Voltage constant - resistance variable.

1 Connect the circuit elements as shown in Fig 2 with

0.1A ammeter.
2 Close the switch and measure the current and voltage.
3 Read and record values in the given Table 2.
4 Open the switch change the ammeter to 0- 500 mA and
repeat the steps 2 and 3 by replacing the 10- ohm
resistance successively by 20 and 50 ohms.
Conclusion
The proved relationship between the current and the
resistance value shows that current is

74 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.24

Capital Goods and Manufacturing
R&ACT - Electrical Exercise 1.3.25

Use voltmeter, ammeter and multimeter

Objectives At the end of this exercise you shall be able to
• use voltmeter and check voltage
• use ammeter and check current

PROCEDURE

TASK 1: Use voltmeter & Measure voltage

1 Take the required length wire & skin the ends.

2 Connect the lamp holder with phase &neutral wire
(prepare test lamp).
3 Connect volmeter parallel to the supply.
4 Connect Volmeter terminals with phase and neutral
connection.
5 Fix the 200W bulb & switch on the supply.
6 Check the voltage in volmeter & record.
7 Switch off the supply &remove the connections after
talking the readings.

TASK 2: Use Ammeter & measure current

1 Take the required length wire and connect 01 Hp motor

with phase &neutral.
2 Connect Ammeter 0-30 A series with the phase line (in
between the phase line).
3 Connect voltmeter parallel to the supply.
4 Switch on the supply and check the current drawn by
the motor in Ammeter.
5 Switch off the supply & remove connections after taking
the readings.

75
Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.26

Practice soldering and de-soldering

Objectives: At the end of this exercise you shall be able to
• clean and tin lugs
• solder wire on to lugs
• lay wires neatly between lugs
• desolder of wires using soldering iron
• desolder of using desoldering pump.

Requirements
Tools Equipments/Instruments Materials/Components
• Trainee kit - 1 No • Lug board
• Cleaning brush ,1/2 inch -1 No. • Single strand wire (hook -up wire) - 1 metre.
• Solder - 25 gms.
• Soldering flux - as reqd.
• De- soldering pump - 1No.

PROCEDURE

TASK 1: Clean, tin and solder lugs

1 Keep ready the soldering iron for soldering. 7 Insert and bend the tinned wire in lug 1 hole as shown
in Fig 2.(side entry method)
2 Check if the lugs of the lug board are bright/already
tinned. If not, scrap the outer face of the lugs, using knife
such that, the oxide layer/varnish is removed. Wipe the
lugs with a piece of dry cloth.
3 Apply a thin layer of flux on the outer face of the lug as
shown in Fig 1a.

8 As shown in Fig 3a, hold the bit of the soldering iron on

the inner face of the lug without touching the wire for 1
to 2 seconds. Apply solder at the outer face of the lug
as shown in Fig 3b. Once the solder melts and flows
over the tinned wire and lug as in Fig 3c, take away the
iron and solder from the lug.
4 To tin the lug, hold the bit of soldering iron at the inner
face of lug no.1 and wait a seconds. Hold the tip of
solder wire at the outer face of the lug as shown in Fig
1b. As the solder melts and flows on the lug, take out
the solder wire and iron from the lug.
Refer Fig 5 for lug numbers.
Allow a very small quantity of solder to flow over the lug.

Do not shake the board till the melted solder

dries up by itself.
Do not blow air to cool the solder on the lug.

5 Repeat steps 3 and 4 tin all the lugs on the lug board.
Get the tinned lugs checked by your instructor.
6 Skin one end of the given single strand wire to a length
of 1 cm. Tin the exposed conductor.

76
Allow the solder joint to cool normally 11 Skin the wire for 10 mm using a wire stripper and tin
skinned end.
If the joint cooled by blowing air, the joint will become a dry
solder joint and, hence, will be a weak joint. 12 Insert the tinned wire end into the hole of lug 11, be the
wire as done in step 8. Solder the wire as done step 9.
Shaking of wire/lug board before cooling result in dry solder
joint. 13 Follow steps 7 to 12 above to solder and bend the wire
to obtain a wiring as close as possible to that shown in
9 Get the soldered joint checked by your instructor.
Fig 5.
10 Take the wire along the path from, lug 1 to lug 11 as
shown in Fig 4. Cut the wire at a point 10 mm ahead of
lug 11.
Use flat nose piler to lay the wire.

14 Clean the soldered points using a brush to remove

excess flux.

Excess of flux may corrode the lugs.

15 Get your work checked by your instructor.

Do not desolder/ remove the soldered wires on

the lug board. This will be done as a separate
exercise.

Observation and Tabulation sheet

Instructors remarks on
[] Completed board in respect of,
[] Tinned of lugs on the lug - board
(i) Quality of soldering [ ]
V.Good Good Satisfactory Poor
(ii) Wire hamessing [ ]

(iii) Cleaning of solderd points [ ]

[] Soldering of wire on the lug

V.Good Good Satisfactory Poor

[] Bending of wires between solder points

V.Good Good Satsifactory Poor

TASK 2: Desoldering using a soldering iron and Nose plier

1 Keep the soldering iron ready for soldering This prevents excessive heat transfer to the wire thus
preventing melting of the wire insulation.
2 Wipe the tip of heated soldering iron on a rag, so as to
remove the solder sticking on the tip. 4 Hold the heated soldering iron tip on the soldered joint
at lug 1 as shown in fig 7 till the solder at the joint
3 Hold the exposed conductors of the wire with a sharp tip
carrying some of the melted solder with it as shown in
flat nose plier or tweezers as shown in Fig 6.
Fig 7.Remove the solder on the iron tip by wiping the bit
on a rag.
Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.26 77
 This makes the wire almost free for pulling it out from
the lug.
6 Hold the cleaned tip of the iron at the outer face of the
lug and pull the wire gently using a nose plier or
tweezers as shown in Fig 8.

5 Repeat step 4, till the joint and the hole are almost free
from solder.

7 Remove the residual solder sticking to lug 1 using

soldering iron such that the lug hole is clear of solder.
8 Get the desoldered point checked by your instructor.
9 Repeat steps 2 to 7 and desolder the wires at lugs 2 to
10 as in Fig 12

TASK 3: Desoldering using hand held desoldering pump.

1 Press the handle of the desoldering pump fully as
shown in Fig 9 till it makes a click sound, and release
the handle.

2 Hold the pump nozzle at lug no.11 of lug board as shown

in Fig 10a.
3 Hold the heated tip of the iron at the inner face of lug as
shown in fig 10b till the solder melts. With the pump
nozzle touching the melting solder at the joint press the
pump button.
The pump sucks the molten solder.
4 Take away the iron and pump from the lug. Check if the
solder at the joints is sucked off and the lug hole is clear.
If not repeat steps 1 to 3 till the hoel is almost clear.

78 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.26

5 Clean the tip of iron and hold at the outer face of the lug. 7 Repeat steps 1 to 5 desolder wires at lug no.11 to 101
Pull out the wire from the lug as shown in Fig 11 as in (Fig 12)
8 Get your work checked by your instructor.

ASSIGNMENT :
As a practice of soldering, solder back the
desoldered wires on the lug board as shown in
Fig 12. After getting it checked, desolder the
wires and get it checked.

Do not force the wire out as the wire may get

cut. if the wire is not coming out easily, repeat
steps 1 to 5

6 Get the desoldered point checked by your instructor.

Observation and Tabulation Sheet

[] Instructors remarks on [ ] Additional marks for the optional Lab

assignment, if done.
[] Desoldered wire from lug board :
[ ] Desoldered wire from lug board
(using soldering iron and nose player)
(using solderiing iron and desoldering pump)
V,Good Good Satisfactory Poor
V.Good Good Satisfactory Poor

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.26 79

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.27

Identify transistors, resistors, czapacitors, diodes, SCR, UJT, amplifier and

IC's

Refer exercise 1.2.22 - TASK 1 and TASK 2

80
Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.28

Construct and test full-wave rectifiers using diodes

Objectives : At the end of this exercise you shall be able to
• construct and test a full wave rectifier using two diodes.

Requirements

Tools/Equipments/Instruments
• Multi-strand wire, Red, Blue - as reqd.
• Trainees kit - 1 No.
• Mains cord with 2-pin plug - 1 No.
• CRO, 20 MHz, dual trace - 1 No/ batch.
• Resistors 470 1/2,w - 1 No.
Materials/Components • Nuts, bolts and washers - as reqd.
• Hook-up wires (red and black) - as reqd.
• Tag board code: 109-02-TB (soldered
• Semiconductor diode, 1N 4007 - 2 Nos.
with diode and resistor at - 1 No.
or Equivalent
• BASE BOARD (Wooden) - 1 No.
• Step-down transformer, - 1 No.
240V: 12-0-12V, 24VA

PROCEDURE

TASK 1: Construct and test a Full wave rectifier using two diodes.

1 Construct a full wave rectifier as shown in Fig 1. Check 2 Power-on the circuit. Measure and record the AC input
the components before soldering in the circuit. VS(rms) to the rectifier across the center-tap and any one
end of the transformer.

81
3 Calculate and record the expected DC voltage across 6 Using CRO measure and record the following;
load RL using the formula given below;
– Peak value of VS
In a full wave rectifier, Vdc = 0.9 x VS(rms),
– Frequency of VS
where, VS(rms) is the voltage across the centre-tap and
– Peak value of pulsating Vdc
any one end terminal of the secondary.
– Frequency of pulsating Vdc
4 Measure and record the rectified output Vdc across RL.
7 Get the waveforms and recorded readings checked by
5 Find and record the difference in the calculated and
youth instructor. Switch of Mains supply and CRO.
measured values of output DC voltage.
8 Fill the recorded datas in Table 1

Table 1

Transformer specification

1 Rated primary voltage :

2 Rated secondary voltage :

3 Rated secondary current

or VA rating transformer :

Readings of two-diode full-wave rectifier

V Calculated Measured Difference Peak value Frequency Peak value Frequency

s(rms)
V volts V volts of 2 & 3 of V of V of pulsating V of pulsating V
dc dc s s dc dc

1 2 3 4 5 6 7 8

82 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.28

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.29

Construct and test a bridge rectifier

Objectives: At the end of this exercise you shall be able to
• construct the bridge rectifier
• determine the output DC voltage
• measure voltage levels
• measure the waveform parameters using CRO.

Requirements

Tools/Equipments/Instruments
• Trainees kit - 1 No. • Hook-up wires (red and black) - as reqd.
• CRO 20 MHz, dual trace - 1 No./batch. Semiconductor diode,
1N 4007 or Equv., - 2 Nos.
Materials/Components
• Resistor 470 ohms, 1/2 w - 1 No.
• Tag board mounted with transformer
and wired fullwave rectifier(2 diode) - 1 No.

PROCEDURE

TASK 1: Construct and test a Bridge rectifier

1 Measure the primary and secondary output voltages/ 3 Get the wired circuit checked by your instructor.
currents of transformer. Record values in record sheet.
4 Power-on the wired circuit. Measure and record the AC
2 Modify the two diode full wave rectifier wired in exercise input VS(rms) to the rectifier in record sheet.
1.2.27 to construct a bridge rectifier as shown in Fig 1.
Test the two new diodes to be used before assembling.

83
5 Calculate and record the expected output DC voltage 8 Using a CRO measure and record the peak ac input
Vdc across load RL using the formula, voltage to the rectifier, peak value of pulsating DC
voltage and ripple frequency.
In a bridge rectifier, Vdc = 0.9 V s(rms)
9 Show the waveforms and recorded reading to your
Where, Vs(rms) is the AC input to rectifier(refer Fig 1)
instructor.
6 Measure and record the output DC voltage Vdc across
10 Change the value of the load resistor RL 9 from 470 ohms
the load RL in record sheet.
to 220 ohms and repeat steps 6,8 and 9.
7 Record the difference in the calculated and measured
11 Switch- off mains supply and CRO.
values.
12 Get it checked by your instructor

Observation and Tabulation sheet

Transformer specification

1 Rated primary voltage :

2 Rated secondary voltage :

3 Rated secondary current

or VA rating transformer :

II Readings of Bridge rectifier with Load resistance of 470 Ohms.

Table 1

V Calculated Measured Difference Peak value Frequency Peak value Frequency

s(rms)
V volts V volts of 2 & 3 of V of V of pulsating V of pulsating V
dc dc s s dc dc

1 2 3 4 5 6 7 8

III Readings of Bridge rectifier with Load resistance of 220 Ohms.

Table 2

V Calculated Measured Difference Peak value Frequency Peak value Frequency

s(rms)
V volts V volts of 2 & 3 of V of V of pulsating V of pulsating V
dc dc s s dc dc

1 2 3 4 5 6 7 8

84 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.29

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.30

Construct and test series voltage regulator circuit

Objectives At the end of this exercise you shall be able to
• construct a given simple series regulator circuit
• measure output voltage and current
• test the regulator and find its percentage regulation and ripple rejection

Requirements

Tools/Equipments/Instruments 220 Ω - 1 No.

• Trainees kit - 1 No. 330 Ω - 1 No.
• Unregulated dc power • Capacitor, 10μF, 25 V - 1 No.
supply,17VDC - 1 No. • LED, Red colour - 1 No.
• CRO, 20 MHz - 1 No/batch. • Hook up wires (Red and Black) each - 3 Mts.
• Rosin core solder - 30 gms.
Materials/Components • Series regulator wired in Task-1 - 1 No.
• Tag board - 1 No. • Transistor, BC147 or equivalent - 1 No.
• Transistor SL100 or equivalent - 1 No. • Zener diode, 9.1V, 1/4W - 1 No.
• Zener diode, 12V, 1/4W - 1 No. • Resistors1.5 k Ω, 1/4 W - 1 No.
• Resistors, carbon, 1/4W, 10% 3.3 k Ω, 1/4 W - 1 No.
180 Ω - 1 No. 820 Ω, 1/4 W - 1 No.
1K Ω - 1 No. 330 Ω, 1/4 W - 1 No.

PROCEDURE

TASK 1: Construct and test a simple series regular circuit

1 Refer data book and record the required details of the

given transistor(SL 100 or equivalent) in Table 1 of
record Sheet.

2 Test to confirm good working condition of the given

transistor and other circuit components.

3 Solder the components on the given Tag board as per

the schematic diagram and layout shown in Fig 1 and
2 respectively. Get the wired circuit checked by your
instructor.

Note that the tag board is already wired with

bridge rectifier with filter in earlier exercises.

4 Connect an unregulated dc voltage of 17V to the input 8 Measure and record the following voltage levels in
terminals (2 & 3) of the wired series regulator board. record Sheet.
5 Get the interconnections made checked by your in- a) Voltage across zener, VZ
structor.
b) VCE of the transistor Q1
6 Switch-on the ac mains supply to the unregulated dc
c) VBE of the transistor Q1.
supply.

7 Measure and record the input voltage and output voltage

of the series regulator.

85
9 Using a CRO, measure and record the peak - peak
Do not use RL of value lower than 180 Ω, this
ripple voltage at the input and output of the regulator.
will load the regulator beyond is designed
10 Switch off mains supply. Replace the 220Ω load resistor load current which will damage the pass
RL by a 180 Ω resistor. transistor.

With RL = 180 Ω, the load current will increase 11 With increased load current, repeat steps 7, 8 and 9.
from the earlier 55mA to 66mA. This results in
12 Get your work and recorded readings checked by your
a total load of 10.3mA through LED, plus, 66mA
instructor.
through RL (10.3mA + 66mA = 76.3mA). By doing
this, you are still in safe loading the regulator
because the regulator was designed for a load
of <100mA. (Refer lesson 13.01 step 3, note)

86 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.30

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.31

Construct and test power supply using fixed voltage regulator ICS
Objectives At the end of this exercise you shall be able to
• construct and test a +12 volts regulator using a 7812 three-pin regulator.

Requirements

Tools/Equipments/Instruments
(b) Component list for project power supply
• Trainees kit - 1 No each. • Diodes type 1N5408 - 2 Nos.
• Rheostat 100 Ω, 50W - 1 No./batch. • Capacitor 10 KpF, disc - 4 Nos.
• CRO, 20MHz - 1 No./batch. • Capacitor 4700 μF, 25 V - 1 No.
• DC ammeter, 0-1A - 1 No./batch. • Capacitor 1000 μF, 25 V - 3 Nos.
Materials/Components • Three-pin voltage regulator
μA 7812 or equivalent - 1 No.
(a) Component list for Tag board power supply • Resistor 56 Ω, 1/2 W - 2 Nos.
• Tag board Code No. - 1 No. • Project power supply PCB - 1 No.
• Three-pin voltage regulator • Terminal strip, 2 pin - 1 No.
μA7812 or equivalent - 1 No. • 240:12V 60 VA step-down
• Heat sink for 7812 - 1 No. transformer - 1 No.
(use suitable heat ) • Plastic spacers, 20 mm - 4 Nos.
• Zener diode 6.1 V, 1/4 W - 1 No. • Screws
• Capacitor 270nf, disc - 1 No. 3mm X 25 mm - 4 Nos.
• 10μf, 25 V, electrolytic - 1 No. 4 mm X 10 mm - 2 Nos.
• Preset/Potentiometer, 470W - 1 No. 3 mm X 15 mm - 1 No.
• Red LED - 1 No. • Banana sockets
• Resistor 820 Ω,1/4 W and 1KΩ,1/4W - 1 each. Red - 3 Nos.
• Hook up wires (red and black colour) - 1 Mtr. Yellow - 2 Nos.
• Rosin cored solder - 10 cms Black - 3 Nos.
• Wire sleeve (R,Y,G) each - 2 cm

PROCEDURE

TASK 1: Construct and test a +12 V fixed voltage regulator

1 From the type code marked on the given 3 pin regulator

IC, identify and record the IC’s specifications in record
sheet.
2 Identify the terminals of 7812 and put sleeves to the
terminals using colour coding scheme given below;
Input - Yellow/Orange sleeve.
Common - Green/Black sleeve.
Output - Red sleeve.
3 Get the work done in steps 1 and 2 checked by your
instructor. 6 Get the neatness and correctness of your wiring checked
by your instructor.
4 Fix the heat sink on IC 7812 as demonstrated by your
instructor. Refer Fig 2 for the position of heat sink on the 7 Apply 16 to 20 volts unregulated dc voltage to the input
tag board. of the wired 12V regulator. Record the unregulated input
voltage and no-load output voltage of the regulator in
5 Construct the voltage regulator circuit referring to the record sheet.
schematic and layout diagram shown in Fig 1 and
Fig2.

87
 The unregulated dc voltage to the regulator
should not be more than 24 volts; otherwise the
IC may get damaged.

The unregulated dc voltage to the regulator should be at

least 15 volts, otherwise the regulator may not work
satisfactorily.
8 Using loading rheostat, load the regulator in steps of
200 mA up to 800mA and at each step measure and
record,
– Regulated dc output voltage
– Input and output ripple.

Loading is limited to 80% of its rated maximum

of 1A. This is because the heat sink used with
7812 may not be very effective in taking away
the heat. 10 Get your work checked by your instructor.
9 From the recorded readings, calculate the
– Output voltage regulation at each step of loading.
– Ripple rejection at each step of loading.

88 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.31

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.32

Identify and test SCR

Objectives At end of this exercise you shall be able to
• identify the specifications of SCR referring to data book
• identify the anode, cathode, gate pins of the given SCR
• conduct quick-test to find the condition of the given SCR.

Requirements

Materials/Components
• Assorted type of SCRs - 20 Nos.
• Multimeter - 1 No
• International SCR data book - 1 No

PROCEDURE

TASK 1: Identify SCR type and leads referring to data manual

1 Pick any one SCR from the assorted lot. Enter the
picked SCR label number and its Code/type number In some power SCRs, the metal case itself will
(printed on the SCR) in Table 1 of record sheet. act as anode. In such a case mark ‘A’ on the
case using a pencil or put a RED colour dot
2 Draw a pencil sketch of the SCR pin diagram. Identify using colour marker pen.
and record the Anode, Cathode and Gate pins of each
SCR referring to the data manual. 5 Get your work checked by your instructor.
3 Put sleeves of suitable length to the identified pins of the 6 Repeat steps 1 to 5 for at least five different types of
SCR using the colour scheme given below: SCRs from the assorted lot.
Gate Pin : BLUE sleeve
Anode : RED sleeve
Cathode : YELLOW sleeve

TASK 2 : QUICK test SCRs using an ohm meter

1 Pick anyone SCR used in Task 1 whose terminals are 4 From the recorded readings, record your conclusion
identified. about the working condition of the SCR.

2 Identify and mark the internal battery polarity at the 5 For the picked SCR carryout the following steps to
terminals of the ohmmeter/multimeter (in ohms range) check the gating effect of SCRs;
to be used for Quick-testing SCRs. Select Rx100
range. – Set multimeter to low resistance range (Rx1 or
Rx10).
3 Test the picked SCR following the table below and
record the measured resistances in Table 2. – Connect positive lead of multimeter to the anode and
the negative lead to the cathode. Measure and
– Between Anode - Cathode record resistance.
Irrespective of polarity – Short anode and gate of SCR using a piece of wire.
– Between Gate - Cathode Measure and record resistance between Anode and
Cathode.
(i) Forward biased
– Disconnect the shorted anode-gate, measure and
(ii) Reverse biased
record resistance between Anode and Cathode.
– Between Gate - Anode
Irrespective of polarity
89
6 From the recorded readings in step 5 and from the 7 Repeat steps 1, 3 to 6 for at least two more SCRs.
knowledge acquired about working of SCR in lesson
8 Get your work checked by your instructor.
1.038 conclude the condition (GOOD/ OPEN/
SHORTED) of the SCR under test.

Table 1

Label No. Code No/ Measured resistance between Conclusion

SCR type A&K G&K G&A
number Forward Reverse Forward Reverse Forward Reverse

a) Resistance between anode and cathode before shorting the anode with gate ______________.
b) Resistance between anode and cathode with anode to gate shorted ______________.
c) Resistance between anode and cathode after removing the short between anode and cathode ______________.
d) Condition of SCR after testing with jig ______________.

90 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.32

Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.33

Construct and test an electronic timer using UJT and SCR

Objectives: At the end of this exercise you shall be able to
• build a timer and test the circuit.

Requirements

Tools/Equipments/Instruments • Capacitor 100 μ F, 25V - 1 No.

• Trainees tool kit - 1 No. • UJT 2N2646 - 1 No.
• Zener 18V - 1/2 watt - 1 No.
Materials/Components • Wire wound resistor 56Ω - 2w - 1 No.
• General Purpose PCB (4x8) cm - 1 No. • Carbon resistor, 1 MΩ - 1/2 W - 1 No.
• SCR C106 or equivalent - 1 No. • Lamp 24V/0.3A screw type with holder - 1 No.
• Diode IN4007 - 1 No. • Wires - as reqd.
• UJT 2N2646 - 1 No. • Push button switch - 1 No.
• Carbon resistor - 1/4 watt 47Ω - 1 No. • Solder and soldering paste - as reqd.
150 Ω, 1/4 watt - 1 No. • Stop clock - 1 No.
1 MΩ 1/2 w - 1 No. • POT 1MΩ - 1 No.
• Potentiometer 1 M - 1 No.
• Capacitor 10 μ F , 25V - 1 No.

PROCEDURE

TASK 1: Build a timer and test the circuit.

1 Refer to the circuit diagram shown in (Fig 1) assemble 6 Record the time taken by the circuit (time delay) to
the electronic timer in the general purpose. (PCB). switch on the lamp from the time the circuit is energised
using stop watch in Table 1.
2 Get your wired circuit checked by the instructor.
7 Turn the potentiometer R2 to minimum, middle and
maximum position and repeat steps 5 & 6 for each
position and enter the result in Table 1.
8 Change the position of Switch S1 to position 2.
9 Repeat steps 4 to 7. Enter the results in Table 1.
10 Write the conclusion by
a) When the SCR is turned on the lamp will ________.
b) To turn the SCR ‘on’ the UJT has to produce a pulse
at the __________ of the SCR.
c) The UJT can produce a pulse wave form depending
on the time required to change the ________.
d) The changing time of capacitor is more when the
POT resistor value is ________.
3 Keep the switch S1 in position 1. (POS1)
e) The charging time of capacitor is more when the
4 Keep R2 in minimum position. value of resistors R1 and R2 are fixed but the value of
5 Energise the circuit with the rated voltage. ________ is more.

TABLE 1

Position of Delay time in sec for Delay time in sec for position 2
potentiometer positions 1 with 10 μF capacitor with 100 mF capacitor

One extreme end

Another extreme end
Approximate middle position

91
Capital Goods and Manufacturing
R&ACT - Electronics Exercise 1.3.34

Apply OP - AMP photo transistor and test performance

Objectives : At the end of this exercise you shall be able to
• identify the manufacturing company of IC under test
• identify the type package of the given OP AMP and timer ICs
• identify the pin numbers of ICs under test
• to use IC tester for testing the given ICs
• identify the electrical characteristics of each IC.

Requirements

Tools/Equipments/Instruments Materials/Components
• Analog/Universal IC Tester with • Assorted Analog ICs Such as Op. Amp and timer
operating manual - 1 No/ batch ICs(IC 741,LM 324,555,556)
• International Op-Amp Data book - 1 No/ batch • GP PCB - 1 No./batch.
• International Timer Data book - 1 No/ batch • IC base (88,16 pins) - 1 No./batch.
• Semiconductor Data book - 1 No/ batch • Bread board - 1 No./batch.

Note: Keep a minimum 20 nomber assorted labelled ICs on a table at two places and instruct the trainees
pick one IC at a time to carry out the testing work.
Instructor should demonstrate the operation of IC tester available in the laboratory. A typical IC tester is
shown in Fig .1

PROCEDURE

TASK 1: Identify diode package, diode terminals and find its specifications
1 Pick any one of the labelled IC from the assorted lot and - GBP of the IC
record its product code/ lable number printed on the
- Slew rate of the IC
body.
- Any other parameter applicable to this IC
2 Refer the international data book for OP-Amp / timer
(which ever applicable) and record the following - Typical applications.
specification of the given IC in Table 1. 3 Count the number of the pins in the given IC. Make a
- Type of package rough sketch of the IC. Identify and record the pin
numbers.
- Manufacturing name
4 Referring the data book identify the specification of ICs
- Number of OP- Amps/timer in the IC
from the product code and sketch the input-output
- Rated maximum dc supply voltage characteristics diagram .
- Open - loop gain AVOL 5 Repeat the exercise for at least four different ICs having
different product code.
- Minimum output current Iout (min)
6 Get the work checked by the instructor.

Table 1

SI No. IC No./ Package Manufacturer VDc AVOL Iout (min)

GBP Slew rate Application
Product
code /
Lable No.

92
TASK 2: To test the given OP AMP and timer ICs with Analog Universal IC Tester.

1 With the help of your instructor and operating manual of Observation

tester be familiar with operation of analog /universal IC
1 Result for the testing the OP Amp IC
tester available in laboratory.
2 Result for testing timer IC.
2 Note down the features and characteristics of the tester
to know which ICs may be tested with your tester. No detailed procedure for using IC tester is
3 Keep the IC to be tested in the zip/socket of the tester given here as the IC tester used in different
properly. settings and specifications.
4 Switch on the power switch of IC tester and see the
Table 2
result.
5 Match the result with what is given in the data book & IC No Mode of test Condition of IC
operation manual of the IC tester.
6 Find out whether the given IC is ok or not also if the IC
is heated in a few seconds, it may be defective.
7 Repeat the exercise for at least 10 Op-Amp and 10
Timer IC to show the difference between good and
defective one and record in Table 2.
8 Get the work checked by the instructor.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.3.34 93

Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.35

Identify gas welding equipment and accessories

Objectives: At the end of this exercise you shall be able to
• identify the gas welding equipments
• identify the gas welding accessories
• identify the gas welding safety accessories.

PROCEDURE
TASK 1: Identify gas welding equipment

TASK 2: Identify the gas welding accessories

94
TASK 3: Gas welding safety accessories

Table 1
Fig 9

Gas welding EQU Accessories Safety accessories

Identify complete accessories of gas welding (oxy-

Acetylene) & record in a table.
• Check with your instructor.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.35 95

Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.36

Demonstrate safety precaution in handling of Oxy- Acetylene of cylinder,

regulator
Objectives: At the end of this exercise you shall be able to
• storage and handle of cylinder
• test the gas leakages
• wear personnel protective equipments
• operate the cylinder, Regulator and light the torch
• care and maintain gas welding set.

PROCEDURE
TASK 1: Storage and Handling of cylinder

1 Stand opposite side of valve opening while cracking

(flushing) the cylinder valve (Fig 1).

2 Securely chain equipement to prevent falling.

3 Store away from flammable and combustible
4 Store extra gas and oxygen cylinders separately.
5 Roll cylinder on bottom edges to move - Do not drag.
(Fig 2)
6 Close cylinder valves before moving.
7 Protective caps or regulators should be kept in place.
8 Store in an upright position(Fig 3)
9 Allow very little movement when transporting.

TASK 2: Test the gas leakages

1 Use a spark lighter to ignite the flame.(Fig 4) 4 Protect hoses and cylinder from sparks, flames and
2 Inspect hoses for leaks and worn places. hot metal.

3 Replace bad hoses. 5 Inspect equipment for leaks at all connection using
approved leak-test solution.(Fig 5 a & b)

96
TASK 3: Wear Personnel Protective Equipment

1 Infrared radiation is a cause of retinal burning and • Shirts should have long sleeves
cataracts. Protect your eyes with safety goggles. • Trousers should be straight -legged and covering
2 Protect your body from welding and arc flash with shoes when arc welding.
protective clothing. Such as : • Fire resistance cape or shoulder covers are needed
• Woollen clothing for overhead work.
• Flame-proof apron • Check protective clothing equipment before each
use to make sure it is in good condition.
• Gloves
• Keep clothes free of grease and oil.
• Properly fitted clothing that is not frayed or worn

TASK 4: Operate the cylinder, Regulator and light the torch.

1 Stand to the side (away form the regulators) when 5 Close the acetylene torch valve first when shutting off
opening cylinder valves. the torch (a “pop” might occur as the oxygen “blows
out” the flame but this eliminate the possibility of the
2 Open cylinder valves very slowly to avoid sudden high
flame burning up the acetylene line).
pressure from exploding the regulators.
6 When finished ,close cylinder valves, bleed the lines
3 Only open the acetylene cylinder valve 1/4 - 3/4 turn;
to take pressure off regulators, neatly coil hoses and
leave wrench in place so the cylinder can be quickly
replace equipment.
closed in an emergency.
7 Have a fire extinguisher easily accessible at the
4 Open and light acetylene first, then open and adjust
welding site.
oxygen to a flame.

TASK 5: Care and maintenance of Gas welding set

1 Proper ventilation 2 Proper infrastructure

• Be sure there is adequate ventilation available when • The room or welding area contains at least 10,000
welding in confined areas or where there as barriers cubic feet for each welder.
to air movement. Natural drafts fans and positioning of
the head can help keep fumes away from the welder’s • Ceiling height is not less than 16 feet.
face. • Cross ventilation is not blocked by partitions,
equipment or other structural barriers.
• Welding is not done in a confined space.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.36 97

3 Safety concern
• Proper personal protective equipment is important.
• Acetylene is very flammable.
• Inspect all equipment before welding.
• If ventilation is not suffcient, then the welding area
should be equipped with mechanical ventilation
equipment .
• Always have a fire extinguisher ready for immediate
use.
• Do not put oil or any lubricant in threaded surface.(Fig6)

98 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.36

Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.37

Setting up Air - LPG, can type O2 - LPG and O2 - C2 H2 using portable flame set.
Objectives: At the end of this exercise you shall be able to:
• set up AIR - LPG brazing set (Single torch)
• set up OXY- LPG welding set
• set up an oxy - acetylene welding plant
• set gas pressure according to the nozzle size
• ignite, adjust and extinguish oxy-acetylene flame
• split the oxy-acetylene plant for stopping work.

Requirements

Tools/Instruments • Oxygen rubber hose - asreqd

length mts.
• Weld man Torch - 1 No • Acetylene rubber hose - as reqd
• Weld man gas Tin - 1 No. lengthmts.
• Commercial O2 Cylinder - 1 No. • Eye goggle - 1 No.
• Commercial LPG Cylinder - 1 No. • Spark lighter - 1 No.
• Oxygen Regulator - 1 No. • Safety apparel - 1 Set
• LPG Regulator - 1 No . • Spark lighter - 1 No.
• Hose pipe (Red & Black) - 2 Nos.
• Torch with Nozzles - 1 Set. Equipment/Machines
• Back fire arrestor - 2 Nos. • Cylinder trolley - 1 No.
• Hose clamps 1/2 - 4 Nos. • Oxy-acetylene welding brazing set - 1 No.
• Oxygen gas regulator - 1 set
• Acetylene gas regulator - 1 set Materials
• Cylinder key - 1 No. • Cylinder with oxygen - 1 No.
• Welding/brazing torch - 1 No. • Cylinder with acetylene - 1 No.

PROCEDURE

TASK 1: Setting up AIR - LPG single torch

1 Take the Butane fuel tin & open the sealed cap. Fig 1.
Fig 2

Fig 1

3 Place the torch on top of the tin valve.

2 Hold the Butane fuel tin vertical position facing the 4 Make sure torch seated properly in the slot provided
valve up. Fig 2. in the fuel tin.
5 Gently press the torch & rotate the torch clock wise.
6 Check torch seated firmly & there is no leak.

99
7 Use Soap Solution & Check the leakage
Fig 3
8 Open the Valve & Ignite the flame.
9 Adjust the neutral flame by varying the valve & flow of
fuel Quantity (Fig 3)
10 Close the valve & shut the flame after work is over.

Note : Do not store butane tin above 50°C temp.

Keep flammable materials away from work.
Make sure proper ventilations available.
Do not bend gas tin horizontal during brazing
since liquid comes out .

TASK 2: Set OXY- LPG Gas welding set

1 Crack the oxygen cylinder valve once. • Black colour for oxygen
• Red/Maroon hose for LPG.
Fig 1
4 Fix back fire arrestor / Non return valve before
connecting hose pipe. Fig 3.

Fig 3

2 Fix the regulator to the Oxygen & LPG Cylinder.

3 Attach rubber hoses to regulators(Fig 2)

Fig 2
5 Attach blow pipe to the other end of the hose.
6 Tighten the rubber hose with the clamp
7 Open the cylinder valve and adjust the pressure in the
regulators.(Fig 4)
8 Check the leakage in all connections using soap
water.(Fig 5)
9 Open the valve of both cylinder slowly.
10 Ignite the flame & adjust neutral flame.

100 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.37
 Fig 4 Fig 5

TASK 3: Set up an oxy-acetylene welding plant

1 Wear safety apparel.

2 Keep the cylinders in a trolley and secure them in
position using a chain.

Crack the cylinder valves before fixing the

regulators.

4 Fix the regulators on the cylinders. Ensure the pressure

adjusting screws are released.
5 Attach the rubber hoses with gas regulators. Fit the
black coloured hoses for oxygen, and the maroon
coloured hoses for acetylene lines.
6 Attach the blowpipe with rubber hoses.
7 Acetylene connections have left hand threads while
the oxygen connections have right hand threads.
8 Open the cylinder and adjust the pressure in the
regulators.
9 Check for leaks in all connections (use soap water).

Skill Sequence
Attaching gas regulators
Objectives: This shall help you to.
• crack gas cylinder valves
• attach gas regulators with cylinder valves.

Chaining gas cylinders: The cylinder may be chained to Attaching of gas regulators with cylinder valves:
a cylinder trolley or to a wall or fixed in cylinder stands to Acetylene regulators should be attached with acetylene
keep in an upright position for safe handling. (Fig 1). cylinders and the oxygen regulators with the oxygen
cylinders. (Fig 3)
Cracking the gas cylinder valves: For the safety of gas
regulators, the cylinder valve sockets are cleaned by
opening and closing the cylinder valves quickly. (Fig 2)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.37 101
 Acetylene connections have left hand threads
while oxygen connections have right hand
threads.

All thread connections should be first tightened by hand

and then tightened with a spanner.

Use spanners of the correct size.

Never apply any kind of lubricant on the threads.
Before opening the cylinder valves, the
pressure-adjusting screws of both the
regulators must be released.

Attaching blow pipe

Objectives: This shall help you to
• Attach blowpipes with regulators of an oxy-acetylene plant.

Attaching rubber hose: Acetylene hose connections

have left hand threads.
Oxygen hose connections have right hand threads.
Acetylene hose-pipes are of maroon colour. Oxygen
hose-pipes are black in colour. The colours are meant to
identify the gases easily.
Attach one end of the acetylene hose-pipe with the
acetylene regulator outlet, and the oxygen hose-pipe
with the oxygen regulator outlet. (Fig 1)
Before fitting the holes make sure that the hose-pipes
Connect the threads by hand first and finally tighten with
the correct size spanner.
Never apply undue force.

The connections should be dry-tight.

Ensure the hose connection with the non-return valve is

attached with the blowpipe.

102 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.37
Never use wire to grip the hose-pipe and hose
connections.
Always use a proper size hose clip.
Attaching blowpipe: Blowpipes have different threaded
inlet connections.
Attach the other end of the acetylene rubber hose having
the hose connection with the non-return valve to the
blowpipe inlet connection marked ‘A’. (Fig 2)

Connect the oxygen rubber hose pipe with the blowpipe.

Attach the other end of the acetylene rubber hose having
Connect the oxygen rubber hose pipe with the blowpipe
the hose connection with the non-return valve to the
connector marked ‘O’.
blowpipe inlet connection marked ‘A’. (Fig 2)
See the complete plant setting. (Fig 3)

Adjusting gas pressure

Objectives: This shall help you to
• adjust the gas pressure according to the nozzle size
• test leakage in the connections.
The gas pressure for both oxygen and acetylene has to Read the pressure settings on the working pressure
be adjusted at the regulators according to the nozzle gauge of the gas regulators. (Fig1)
size.
While opening the cylinder valves, always stand aside of
The nozzle size is selected according to the job material the regulators. Do not open the valves suddenly.
and thickness. (SeeTable I for mild steel).
Testing leakage
Open the valves of both the cylinders slowly by one turn
1 The leakage of gas must be tested in all connections.
and set the pressure on both the regulators at 0.2 kg/cm2
for small size nozzles, by tightening the pressure adjusting
screws. (Fig 1)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.37 103
2 Apply soap water for acetylene connections and fresh 3 Never use a match or a flame light while conducting
water for oxygen connections. (Fig 2) leakage tests.

Table 1

Nozzle sizes for welding mild steel

Plate thickness (mm) 0.8 1.2 1.6 2.4 3.2 4.0 5.0 6.5 10.0 13.0 16.2 19.0 25.0 over
25
Nozzle size 1 2 3 5 7 10 13 18 25 35 45 60 70 80

Flame setting.
1 Wear safety apparel.
2 Open the gas cylinders and adjust the gas pressures
on the regulators.
3 Open the control valve of the acetylene gas in the
blowpipe.
4 Ignite the flame by using a spark lighter.

Avoid using any other source of fire.

5 Adjust the acetylene flow till the black smoke goes

away.
6 Open the oxygen gas till a proper round inner cone is
established without any sound in the flame. This is
known as a neutral flame. Flame extinguishing and stopping work
7 Adjust the oxidizing flame by increasing the oxygen 10 Extinguish the flame by closing the acetylene valve
gas. (with sharp inner cone and little hissing sound) first and then the oxygen valve.
8 Set the neutral flame again and adjust the carburizing 11 Dip the blowpipe nozzle in water to cool down by
flame by increasing the acetylene gas with the soft opening a little oxygen gas.
inner cone covered with an outer feather without any
sound. 12 Close the cylinder valves and release all the pressure
from the line.
9 Repeat the setting of the flames till you manage to set
the flame without any backfire or flash-back.

Lighting, setting, extinguishing oxy-acetylene flame and shutting the plant

Objectives: This shall help you to
• ignite, set and extinguish an oxy-acetylene flame for gas welding correctly
• shut the oxy-acetylene plant for stopping work.

Flame lighting
While setting the pressure on the regulator,
keep the blow pipe control valve open the
Ensure that safety apron, gloves and goggles accurate setting.
are worn. (Fig 1)
Open the acetylene control valve 1/4 turn of the blow pipe
Set the pressure of oxygen and acetylene at 0.2 kgs/cm and ignite with the help of the spark-lighter. Adjust the
for a small size nozzle. (No 3) acetylene flow till the black smoke goes away.(Fig 2)

104 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.37
 The gas mixture from the blowpipe consists of
oxygen and acetylene in equal volumes.

To adjust the oxidising flame, add more oxygen.

The white cone will become short and sharp.
The flame will produce a hissing sound and will have a
short length. (Fig 5)

To adjust a carburising flame, adjust the flame to neutral

and then add acetylene.
The white cone will become long, surrounded by a
feather-like portion.
The flame will burn quietly and have more length. (Fig 6)

Avoid back fire or flash-back of blow pipe.

Observe the flame and add oxygen by opening the
oxygen control valve of the blowpipe. (Fig 3) Extinguishing the flame: To extinguish the flame, close
the acetylene valve (blowpipe) first and then the oxygen
valve.
Shutting off the plant: At the end of the work, shut off the
plant as stated below.
Close the acetylene cylinder valve.
Open the blowpipe acetylene valve and release all
pressure.
Flame adjustment: To adjust the neutral flame, add Release the acetylene regulator pressure adjusting screw.
sufficient oxygen to make the white cone clear and round.
(Fig 4) Close the blowpipe acetylene valve.
Repeat the above four steps for shutting off oxygen also.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.37 105
Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.38

Oxy- Acetylene gas cutting , brazing & welding on sheet metal.

Objectives: At the end of this exercise, you shall be able to
• straight cutting by hand on thin sheet
• brazing of copper tubing
• welding of copper sheet.

Requirements

Tools/Instruments Equipment/machines

• Safety apparel - 1 set • Oxy-acetylene welding set - 1 set

• Spark lighter - 1 No. Materials/Components
• M.S. Plate (work piece) - 1 No.

PROCEDURE
TASK 1: Straight cutting by hand on thin sheet
1 Wear complete safety apparel.
2 Set the gas welding with a cutting blow piece.
3 Attach the correct cutting nozzle according to the
thickness of the metal.
4 Adjust the gas pressure of acetylene and cutting
oxygen according to the thickness of the metal and
the cutting nozzle.
5 Clean the surface to be cut.
6 Punch a straight line.(Fig 1)

11 Move the cutting blowpipe towards the other end,

following the punched line.(Fig 3)

7 Adjust proper cutting flame.

8 Hold the cutting blowpipe at 90° to the cut line and
plate surface.(Fig 2) While gas cutting ensure straight travel of the
cutting blowpipe without side-to-side
9 Heat at one end of the plate on the punch line up to movement and correct nozzle position with the
cherry red heat. plate surface till the cutting oxygen valve is
fully open.
Keep a distance of about 5mm between the
workpiece and the nozzle. 12 Maintain a correct speed and distance of the nozzle.
10 Release the cutting oxygen and observe the cutting 13 Close the cutting oxygen and shut off the flame on the
action. completion of the cut.
106
14 Clean the cut and inspect for its accuracy. Acetylene pressure should be 0.5 kgf/cm2
15 Repeat the exercise till a good and smooth cut is Set the cutting nozzle in the blowpipe correctly.
achieved.
Adjust the neutral flame for pre-heating.

TABLE 1
Data for cutting

Diameter of Thickness of Cutting

cutting oxygen steel plate oxygen
orifice nozzle pressure
(mm) (mm) (Kgf/cm2)
(1) (2) (3)
0.8 3-6 1.0-1.4
1.2 6-19 1.4-2.1
1.6 19-100 2.1-4.2
2.0 100-150 4.2-4.6
2.4 150-200 4.6-4.9
2.8 200-250 4.9-5.5
3.2 250-300 5.5-5.6

TASK 2: Brazing of copper tubes

1 Make sure that the pipe enters the swage properly. It

must be an easy fit.
2 Apply a small amount of flux to the surface to be
joined.
3 Heat the joint with blow torch.
4 Heat the joint up to dull red, put the filler rod (Brazing
rod). It will starts to melt
5 The molten filler rod will be drawn in to the joint and fill
the space b/w end of the other.
6 When the complete ring a brazing material can be
seen at the end of the swage remove the blow torch.
7 Allow the joint to cool.
• Do not over heat the joint.
• Do not leave the brazing rod in the flame.
• Do not remove pipe untill the brazing
material is hardened.

Job Sequence

Welding of copper sheet (Butt joint)

• Tack-weld for every 40 to 50mm length of the join
• Prepare the copper sheet as per dimensions.
• Check the alignment of the joint.
• Clean the edges of the sheets and debar.
• Select nozzle No.7 and phosphor bronze filler rod.
• Set the sheets as a square butt joint.
• Select the correct bronze flux and set soft oxidising
• Follow necessary safety precaution. flame.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.38 107
• Heat the edges of the joint to dull red colour. • Clean the joint and inspect the weld.
• Braze weld the joint using leftward technique.

Skill Sequence
Welding of copper sheet (Butt joint)
Objectives: This shall help you to.
• weld copper sheet (butt joint)

Ensure a de-oxidised copper sheet of correct size since Hold the blowpipe over the ends of the joint at an angle
commercial copper will develop cracks during welding. of 60° - 70° and the filler rod at 30° - 40° and then tack–
weld. The filler rod is coated with flux by heating and
Clean the edges and surfaces free from oil, grease and
dipping into the powder flux.
dirt using pickling/solvent.
Hold the blowpipe and filler rod at the angles given for
Ensure the joint surfaces are free from surface oxides.
tack welding. Slight weaving of the blow pipe ensures
Use emery sheet, wire brush or wire wool for cleaning the
proper fusion of both edges.
surface.
Commence at one end and continue with a slight weaving
Set the sheets as butt joint with correct alignment and a
motion, adding the filler rod at regular intervals until the
root gap of 2.5mm.
seam is completed.
Select a phosphor bronze filler rod.
Ensure uniform root penetration.
Select the bronze flux. (Borax flux)
Terminate the weld, keeping the reinforcement up to full
Set a soft oxidising flame, which will help in controlling the section and after closing the crater.
evaporation of zinc and tin from the weld metal.
Remove the flux residue.
Preheat the plates until the surface oxides just begin to
form. The deposit should be of uniform size, bright
in appearance and free from porosity.
Tack weld for every 50mm length of the joint to take care
of the higher thermal expansion of copper.
Clean the bead and inspect for weld defects and bead
size, profile and appearance.

108 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.38
Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.39
Demonstrate care & safety of welding tools and equipments and back fire
arrestor
Objectives: At the end of this exercise, you shall be able to
• care and safety of welding tools & equipments
• check for back fire.

Requirements

Tools/Instrtuments
• Oxygen gas regulator - 1 set • Eye goggle - 1 No.
• Acetylene gas regulator - 1 set • Spark lighter - 1 No.
• Cylinder key - 1 No. Equipment/Machines
• Welding/brazing torch - 1 No.
• Oxygen rubber hose - as reqd • Cylinder trolley - 1 No.
length mts. Materials
• Acetylene rubber hose - as reqd
• Cylinder with oxygen - 1 No.
length mts.
• Cylinder with acetylene - 1 No.

PROCEDURE

TASK 1: Care & safety of welding tools and equipment

Refer (Task 5 of Exercise 1.4.36)

TASK 2: Check for back fire

1 Attach the back fire arrester in the oxygen and

acetylene cylinder lines (Fig 1)
2 Fix one back fire arrester in the low pressure side of
the regulator near the cylinder.
3 Fix another back fire arrester near the torch.
Safety :
1 In case back fire or explosion of the gas pipe
immediately close both cylinder valves.
2 Rectify the causes before procedure further to avoid
back fire.

109
Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.40

Set- oxy acetylene plant, use two stage regulator adjusting &flame and gas
pressure
Objectives: At the end of this exercise, you shall be able to
• chaining gas cylinders
• crack gas cylinder valves
• attaching of gas regulators with cylinder valves
• attach blowpipes with regulators of an oxy-acetylene plant
• adjust the gas pressure according to the nozzle size
• test leakage in the connections
• testing leakage
• flame setting
• ignite, set and extinguish an oxy-acetylene flame for gas welding correctly
• shut the oxy-acetylene plant for stopping work.

Refer Exercise 1.4.37 - TASK 3: Page No: 101 to 105

110
Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.41

Perform brazing between copper to copper and copper to MS, copper to

aluminium pipes
Objectives: At the end of this exercise, you shall be able to
• joint cu to cu pipe
• joint cu to M.S pipe
• joint cu to aluminium pipe.

Requirements
Material
Tools/Instruments
• Copper pipe 6mm 200mm each - 10 Nos.
• Oxy- acetylene set with Nozzle - 6 Nos
• Copper pros rod - as reqd.
• Welding screen - 1 set
• Steel pipe 6mm 200mm each - 10 Nos.
• Welding mask - 1 No.
• Aluminium pipe 6mm 200mm each - 10 Nos.
• Hand gloves - 1 No.
• Silver braze rod - as reqd.
• Alumina, Borax flux - as reqd.
• Fire brick - as reqd.

PROCEDURE
TASK 1: Joint cu to cu pipe (fig 1)
1 Prepare copper surface clean inner and outer diameter.
2 Place the tube on fire brick.
3 Set flame neutral
4 Heat up joint till red colour.
5 Touch copper prosperous filler rod surrounding the
joint
6 Molten metal should fill up gape by capillary action

TASK 2 : Joint cu to M.S pipe (Fig 2)

1 Prepare copper pipe surface clean inner and M.S
outer diameter.
2 Place the tube on fire brick
3 Set neutral flame.
4 Heat up joint till red colour.
5 Apply flux on joint and over filler rod.
6 Touch silver braze filler rod surrounding the joint
7 Molten metal should fill up gap reheated for uniform
joint.

TASK 3 : Joint cu to aluminium pipe

1 Prepare copper pipe surface clean inner or outer 5 Place aluminium pipe on the mouth of pipe and press it
diameter as required 6 Apply flux on joint and over filler rod
2 Set flame neutral 7 Touch silver braze filler rod surrounding joint.
3 Heat up copper tube 8 Molten metal should fill up gap reheated for uniform
4 Heat up joint till red shining appear joint.

111
Capital Goods and Manufacturing
R&ACT - Welding Exercise 1.4.42

Prepare square butt joint on and lap joint on M.S sheet

Objectives: At the end of this exercise you shall be able to
• prepare the job to the given size as per drawing
• file the edges of the plate to square without burr
• set the job as a square butt joint with proper root gap and tack weld them
• weld the square butt joint in flat position using leftward technique in one run
• clean and inspect the butt weld for root penetration and surface uniformity
• set and tack the job to form a lap fillet joint with recommended overlap
• weld lap fillet joint using correct size filler rod and nozzle in flat position
• clean and inspect the weldments of the lap fillet for weld defects.

Requirement

Tools /Instruments Material

• Oxy acetylene gas welding set • Cylinder with oxygen - 1 No
with different nozzles - 1 set • Cylinder with acetylene - 1 No
• Cylinder key - 1 No • Filler rod - as reqd
• Eye goggle - 1 No • M.S plate 2mm (work piece) - 4 Nos
• Spark lighter - 1 No • Flux surface - as reqd

Job Sequence

112
1 Prepare the job pieces as per drawing. 7 Start the weld at the right end of the job.
2 File the edges to square and ensure thorough cleaning 8 Keep the blow pipe nozzle at an angle of 60°- 70°
of the joining edges. towards right the nozzle at an angle of 60° - 70°
towards right.
3 Set the job pieces on the welding table to form a
square butt joint with a root gap of 2 mm. 9 Filler rod at an angle of 30° - 40° to the line of weld.
4 Set the gas welding plant, fix nozzle No.7 and set the 10 Maintain a uniform speed of the blowpipe with slight
gas pressure of 0.15 kg/cm2 for both gases. circular motion.
5 Select C.C.M.S. filler rod 3 mm ø for tacking and 11 Clean the welded joint and remove distortion.
welding.
6 Tack the pieces at both ends and at centre, using 1.6
mm ø filler rod with 2mm root gap at right end and
3mm root gap at the left end.

Skill Sequence

To make a butt joint

Objectives: This shall help you to.
• make a butt joint.

Sequence of operation Ensure that the

1 Marking 5 Tacking – distance between the tack-welds is 75 mm.
2 Cutting 6 Welding – length of the tack-weld is 6 mm.
3 Filing 7 Cleaning Tack welds should be on the back side of the joint to be
welded and in line with the joint.
4 Setting 8 Finishing
Check the alignment after tacking, and reset, if the
Preparation: Prepare the job pieces of size 150 x 50 x sheets are out of alignment. (Fig.2)
2.0 mm by shearing and then by filing.
Setting and tacking: Set the prepared job pieces on the
welding table with a root gap of 2mm at the right end and
3mm at the left end and in alignment. (Fig.1)

Welding: Keep free space under the joint for complete

penetration.(Fig.3)

The root gap is increasing from right end to the left end
because the gap will get closed as the weld proceeds Start the weld at the right end of the joint. (Fig.4)
towards the left end, due to expansion of the base metal. Weld a well fused uniform bead with complete penetration
Tack-weld the joint at equal intervals to hold them together, using leftward technique. (Fig.4)
maintaining the alignment.(Fig.1)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.42 113
Manipulate the blowpipe to maintain necessary motion to
the blow pipe and the filler rod and the recommended
angle of blowpipe and the filler rod.

Maintain uniform travel speed and feed to the flame and

the filler rod.

Maintain a keyhole which is a clear indication that the

melting is taking place upto the bottom of the root of the
joint ensuring better root penetration.(Fig.5)

Clean the deposited bead using wire brush. Safety precautions followed in Gas welding
Inspect the quality of weld by: 1 Gas welding plant can be set and check all leakages,
using soap water.
– checking the finish of the job
2 Adjust Gas pressure according to thickness of metal
– checking the alignment (remove distortion if required) and Nozzle.
– checking the uniformity of width and height of the weld 3 Wear Hand gloves, Apron shoes, gas welding goggle
bead in size (Fig.6) during welding.

– checking the uniformity of the ripples, fusion and 4 While igniting Blow pipe use spark lighter.
complete penetration (Fig.7) 5 Always cylinder must be upright position with an
trolley.
– checking that the weld is free from faults such as
porosity, undercut, lack of fusion, unfilled crater etc. 6 Cylinder, must be opended by cylinder key only.
7 After welding job must be cleaned by using wire brush.
8 Submit job for evaluation.

114 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.42
Job Sequence
1 Prepare the job as per drawing and clean the edges. 6 Start welding, using leftward technique with the
correct angle of the blowpipe and (3mm ø) filler rod.
2 Set the job on the welding table to form a lap joint.
7 Maintain correct travel speed, manipulation of
3 Set the gas welding plant, fix nozzle No.7 and set a blowpipe and filler rod to produce uniform weld
pressure of 0.15 kg/cm2 for both gases. bead.
4 Select a C.C.M.S filler rod 1.6 mm ø for tacking and 3.00 8 Stop at the left end, after filling the crater and
mm ø for welding and set the neautral flame. complete the weld.
5 Tack the pieces at both ends and also in the centre 9 Clean the welded joint with a wire brush.
using a 1.6 mm ø filler rod.

Sequence of operation Refer Ex.No 1.4.42

Skill Sequence
To make a lap joint
Objectives: This shall help you to.
• make a lap joint.

Set and tack the job pieces in correct alignment with proper Place the tack welds at correct locations. (Fig.2)
overlapping of pieces. (Fig.1)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.42 115
Weld a uniform, well penetrated, correct size fillet lap
weld in flat position by
– proper positioning of the joint (Fig.2)

Clean the weldment and inspect for: (Fig 5)

– uniform weld size and shape of whole length
(reinforcement and contour) of the joint.
– equal leg length
– proper angle of the blowpipe and filler rod (Figs.3 &4) – no undercut at the toe of weld
– proper manipulation of the blowpipe and filler rod – no fusing of the top plate edge to undersize
– using leftward welding technique. – smooth ripple appearance
– proper crater filling.

Avoid movement of blow pipe flame nearer to

the edge of the top plate. This will avoid edge
of the plate melted off defect.

– maintaining uniform travel speed and feed. Safety precautions to be followed in gas welding
refer EX.No.1.4.36 - TASK 5.

116 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.4.42
Capital Goods and Manufacturing
R&ACT - Refrigeration System Exercise 1.5.43

Identify & use of general hand tools, instruments and equipment used in
refrigeration work shop
Refer with Exercise 1.1.05
TASK : 1, TASK : 2, TASK : 3.

117
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.44

Identify special tools , instruments and equipment used in refrigeration work

shop
Objectives : At the end of this exercise you shall be able to
• identify the special tools with their function
• identify the Instruments used in refrigeration work
• identify the Equipment used in refrigeration work.

Requirements
Tools/Instruments
• Pressure gauge - 2 Nos.
• Flaring tool with yoke - 1 No.
• Thermometer - 1 No.
• Tube cutter with reamer - 1 No.
• Leak detector - 2 Nos.
• Pipe bender - 1 No.
• Gauge manifold - 1 No.
• Swaging tool - 1 No.
• Tong tester - 1 No.
• Pinching tool - 1 No.
• Vacuum pump - 1 No.
• Ratchet wrench - 2 Nos.

PROCEDURE

TASK 1: Identify the main parts of refrigeration tools with their function

1 Refer the diagram and Identify the parts of the label in • Identify the main part of Tube cutter with Reamer
Fig 1.
1 Refer the diagram and Identify the parts of the label in
2 Record the name of parts and functions in the given
Fig 2.
Table 1.
2 Record the name of parts and functions in the given
Table 2.

Table
Table
Label Name of the part Function
Label Name of the part Function
1
1
2
2
3
3
4
4

118
• Identify the main part of Pipe bender
1 Refer the diagram Fig 3 & 4 and Identify the parts of
the label.
2 Record the name of parts and functions in the given
Table 3.

Table

Label Name of the part Function

1
2
3
Table
4
Label Name of the part Function 5
1
• Identify the main part of Pinching tool
2
3 1 Refer the Fig 7 and Identify the parts of the label.
4 2 Record the name of parts and function in the given
5 table.
Table
6
7 Label Name of the part Function

1
• Identify the main part of Swaging tool
2
1 Refer the diagram and Identify the parts of the label in 3
Fig 5 & 6. 4
2 Record the name of parts and function in the given 5
table.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.44 119
• Identify the main part of Ratchet wrench

1 Refer the Fig 8 and Identify the parts of the label. TABLE
2 Record the name of part in given table. Label Name of the part Function
1
2
3
4

TASK 2: Identify the instruments used in refrigeration work

1 Refer the diagram 9 & 10 and Identify the parts of the • Identify the main part of Thermometer
label. 1 Refer the Fig 11 & 12 and Identify the parts of the
2 Record the name of parts and functions in the given label.
table. 2 Record the name of parts and function in the given
table.

Table
Label Name of the part Function
1
2
3

120 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.44
 Table
Label Name of the part Function
1
2
3
4 Table
5 Label Name of the part Function
6
1
• Identify the main part of leak detector 2
1 Refer the Fig 13 and Identify the parts of the label.
2 Record the name of parts and function in the given 1 Refer the Fig 15 and Identify the parts of the label.
table. 2 Record the name of parts and function in the given
table.

Table
Label Name of the part Function
1
2
3

1 Refer the Fig 14 and Identify the parts of the label.

2 Record the name of parts and function in the given
table.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.44 121
 Table Table
Label Name of the part Function Label Name of the part Function of the part
1
1
2 2
3 3
4
4
5
6
1 Refer the Fig 16 and Identify the parts of the label.
7
2 Record the name of parts and function in the given 8
table. 9

1 Refer Fig 17 and identify the parts of the label.

Table

Label Name of the part Function of the part

1
2
3
4

• Identify the main part of tachometer

1 Refer the diagram and Identify the parts of the label

given in Fig 18.
2 Record the name of part in the given table.

122 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.44
 Table

Label Name of the part Specification Function

1
2
3
4

TASK 3: Identify the equipments in refrigeration work

• Identify the main part of vacuum pump • Identify the main part of air composer

1 Refer the diagram and identify the parts of the label 1 Refer the diagram and identify the parts of label given
shown in Fig 19 in Fig 20.
2 Record the name of part and function in the given 2 Record the name of part in the given in table.
table.

Table

Label Name of the part Specification Function

1
2
3
4
Table 5

Label Name of the part Specification Function

1
2
3

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.44 123
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.45

Identify the components of vapour compression system and vapour absorption

system
Objectives: At the end of this exercise you shall be able to
• identify the system and trace out the cycle
• identify the components of v.c system
• identify the vapour absorption refrigeration cycle.

Requirement
Tool/Instruments
• Vapour compression system • Vapour absorption system - 1 No.
(Refrigerator) -1 No.

PROCEDURE

TASK 1: Identify the system of vapour compression and trace out the cycle.

Sl.No. Identify components in the system

1
2
3
4
5
6
7
8
9
10
11
12
13

TASK 2: Identify the components of V.C system.

124
 Record Sheet
Sl.No. Components Name Functions

1
2
3
4
5

TASK 3: Identify the vapour absorption system and the cycle

Record Sheet
4
Sl.No. Components Name Functions
5
1 6
2 7
3 8
9

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.45 125
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.46

Unroll, cut and bend on soft copper tubes

Objectives: At the end of this exercise you shall be able to
• unroll copper tubing from the roll
• measure mark and cut the copper tube the given size
• bend the copper tube

Requirement
Tool/Instruments • Triangular file150mm - 1 No
• Mallet or plastic hammer - 1 No • Nylon or rubber hammer - 1 No
• Tube cutter (0.25mm) - 1 No
Materials
• Reaming tool - 1 No
• Copper tube φ 6mm - 1 coil
• Spring bender (6mm) - 1 No
• Lever type bender (6mm) - 1 No • Cotton waste as reqd.
• Metal tape or steel rule - 1 No • A small quantity of oil as reqd.
• Copper tube two pieces (6mm OD) - 2 Nos.

PROCEDURE

TASK 1: Unroll the copper tube

1 Place the tube on the flat clean surface.

2 Unroll tube to the required length (Fig 1).

3 If any bend in the tube straighten the tube with light

blows from mallet or plastic hammer.

TASK 2: Measure mark and cut the copper tube the given size

Observation Table
1 Carefully measure the length of pipe needs and mark
Sl.No. Parameter Remarks the outside (where you are going to cut with the edge
of a file.
1 Straightness of the Excellent/Very good/
tube Good/Average 2 Place the pipe between the bottom rollers and the top
cutting wheel.
2 Safe handling of the Excellent/Very good/
3 Position the pipe so that the cutting wheel is in line with
tube Good/Average
the mark that you made with the file.(Fig 3).
3 Unrolling other sizes Excellent/Very good/ 4 Tighten the hand screw until the cutting wheel just
of tube Good/Average touches the outside of the pipe.

Note : Repeat it for various sizes of tubes

126
 10 Hold the open end of the pipe to be reamed down (so
that pieces of copper will not get inside the pipe). Turn
the reaming tool until all rough edges have been
removed from the inside of the pipe. (Fig 6)

5 Turn the pipe cutter slowly around the pipe so that the
cutting wheel cuts gradually into the outside.
6 Turn the hand screw to increase the pressure of the
cutting wheel and then turn the cutter around the pipe
again. (See Fig 4).

7 Continue the cutting by gradually increasing the

pressure of the cutting wheel. Work slowly and
carefully. Do not use too much pressure or you may
damage the pipe. Observation Table
8 When the cut is complete seal the open end and roll
the pipe back into a coil. Sl.No. Parameter Remarks

9 To remove all rough edges from the end of the pipe, 1 Angle of the bend 1 Correct/ not correct
use the reaming tool. (Fig 5)
2 Angle of the bend 2 Correct/ not correct

Note : Repeat the same procedure for various

sizes of tubes.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.46 127
TASK 3: Bend the copper tube

1 Refrigeration pipe is soft and can be bent by hand. 5 Do not make a sharp bend in the pipe. If the pipe
Because it is soft it can be easily damaged when diameter is 1/4 inch (6 mm), the sharpest bend that
bending. you can make without risk of damaging the pipe is 1
2 If the pipe is hard and will not bend easily, it must be inch (2.5mm) radius (see drawing).(Fig 9) Not less
annealed before use. than 5 times of its diameter.

3 Push a bending spring onto the outside of the pipe

(see drawing). This helps the pipe to bend evenly.

6 Pipe that cracks, splits, wrinkles or flattens during

bending must not be used.
7 Bend the pipe so that it fits onto the connection easily
(see drawing).

4 Bend the pipe a little at a time using your thumbs (see

drawing).(Fig 8) Do not try to complete the bend with Observation Table
one movement. This will cause the pipe to buckle.
Sl.No. Parameter Remarks

1 Length of the tube cut Excellent/good/

average
2 Cleaned edges of the Excellent/god/
tubes average

Note : Repeat the exercises for various sizes of

tubes.

128 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.46
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.47

Swage and make a brazed joint on copper tubing

Objectives: At the end of this exercise you shall be able to
• swage a copper tube (6mm)
• make a brazed joint.

Requirement

Tools /Instruments Materials

• Mallet or plastic hammer -1 No. • Brazing rod as reqd.

• Metal tape or steel rule -1 No. • Brazing flux as reqd.
• Triangular file 150mm -1 No. • Kerosene
• Flaring block -1 No. ( if blow lamp used) as reqd.
• Swaging tool set -1 No. • Gas with cylinder
• Ball pane hammer 225 gms -1 No . (for welding) as reqd.
• Blow lamp or Gas welding set -1 No . • Match box -1 No.
• Stove pin - 1 No.

PROCEDURE

TASK 1: Swage the end of the tube

1 To join two pieces of tube of the same size together one will be 1/4 inch (6mm) + 1/8 inch (3 mm) = 3/8 inch (9
must be made larger so that the other fits inside (Fig 1) mm), as shown (Fig 4).

2 Making the end of a tube larger is called swaging

3 The tool used for swaging is shown in the drawings
(Fig 2)&(Fig 3). Examine the pipe swaging tool and
compare it with the drawings. Make sure that you
understand how it works before starting to swage the
end of a pipe

6 Tighten the nuts at each end of the swaging block

7 Choose a punch of the right size to swage out the end
of the tube so that another piece fits inside. Oil the
4 Place the tube in the tool. Make sure that you have punch. Fit the clamp and punch onto the swaging
choosen the correct size hole to fit the tube. block. Twist the handle and Force the punch into the
tube.
5 Position the tube so that the end is “the outside
diameter of the tube plus 1/8 inch (3 mm) above the 8 The punch will open out the end of the tube.(Fig 5)
top of the swaging block . For 1/4 inch (6 mm) pipe this
129
TASK 2: Braze a swaged joint
1 Make sure that the tube enters the swage properly. It 6 Wait until the joint is dull red. When the brazing rod
must be an “easy” fit. If it is a tight fit there will not be starts to melt the joint is at the right temperature. This
sufficient space for the brazing material. If it is a loose temperature is found by touching the brazing rod onto
fit the joint will be weak.(Fig 6) the joint from time to time while heating. Do not
overheat the joint. Do not leave the brazing rod in the
flame. The brazing rod must be melted by the heat of
the joint and not by the flame.(Fig 9)

2 Mix a little flux powder with spirit (or water) to make a

stiff paste.
3 Apply a small amount of flux to the surfaces to be
joined. Only a small quantity is necessary. Too much
will contaminate the system.(Fig 7)

7 When the right temperature has been reached touch

the joint with the brazing rod at several points
8 Molten brazing rod will be drawn into the joint and fill
the space between the outside of one pipe and the
swaged end of the other. When a complete ring of
brazing material can be seen at the end of the swage
remove the blow torch.
9 Allow the joint to cool. Do not move either pipe until
the brazing material has hardened.
Note : If “self-fluxing” brazing rods are being Observation Table
used this stage of the work is not necessary
Sl.No. Parameter Remarks
4 Push the end of one pipe into the swage of the
other as far as possible. Turn the pipes to spread 1 Testing the swaging Excellent/Good/
the flux.(Fig 8) Average
5 Heat the joint with the blow torch. Use a flame of the 2 Testing the brazed joint Firm/ Blow holes
right size.
3 Time taken Slow/Medium/
Fast
4 Materials waste Less/Very less/
No waste
Note : Repeat the same exercise for various
sizes of tube and test the improvement.

130 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.47
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.48

Make flare joints and test them with flare fittings

Objectives: At the end of this exercise you shall be able to
• make flaring at the end of the tube
• join the flare fittings
• test the flared and brazed joints.

Requirement
Tool/Instruments • Cylinder with pressure - 1 no
• Flaring block with yoke - 1 set Materials
• Adjustable wrench 200mm - 1 no
• Valve key 6mm • Copper tubes 6mm - as reqd.
(cylinder valve opener) - 1 no • Flare nut 6mm size - as reqd.
• Pressure gauge with adapter - 1 no • Union 6mm - as reqd.
• Flat file smooth 200mm - 1 no • Soap solution with stirrer - as reqd.
• A small quantity of oil - as reqd.

PROCEDURE

TASK 1: Make flare on copper tubes

1 Refrigerator pipes are sometimes jointed to fittings by
making a flared connection
2 The end of the pipe is opened out to form a cone
(Fig1).

3 Always place the special flare nut on the pipe first

before flaring.
4 Examine the tube flaring tool. Make sure that you
understand how it works before starting to flare the
end of a pipe.
5 Make sure that the end of the tube is free of rough
edges before flaring
6 Place the tube in the tool (Fig 2). Make sure that you
have:
a Place the flare nut in to the tube.
b Chose the correct size hole in the flaring tool to fit
the pipe; (there are 5 holes to fit different sizes of
pipe.)
7 If the pipe is 1/4 inch ( 6 mm) in diameter, position the
tube so that the end is at least 2 mm above the top of
the flaring block (Fig 3). (This distance is calculated 8 Tighten the nuts at each end of the flaring block (see
as “pipe diameter divided by 3”; in this case, 6 mm drawing).
divided by 3 = 2mm).
9 Fit the yoke to the flaring block (Fig 4)
131
10 Oil the cone and slowly screw it into the end of the
pipe
11 The end of the tube will be formed into a flare.
12 Remove the flared tube from the block.
13 Examine the flare. If it has cracked, the cone was
screwed down too quickly.
14 Make sure that the flare is the correct size. It should
just fit inside the flare nut. If it is too loose, cut off the
flare and start again at instruction 5.
At instruction 7, use 3 mm instead of 2 mm. Repeat
until the flare is the correct size for the flare nut - not
too loose and not too tight.
Observation Table - 1

Sl.No. Skills Remarks

1 Checking Flaring Cracked/uneven/too
small/too long/
correct
2 Number of attempts One/two/three
Note : Repeat the steps to the various sizes of
copper tube

TASK 2: Join with flare fittings

1 Push back the flare nut and place the flared tube on Observation Table - 2
the fitting, then tighten the nut using adjustable wrench
or suitable double end spanner. Sl.No. Skills Remarks
2 Tighten the one end of the tube to the dry nitrogen 1 Selection of correct fittings Correct/
cylinder with the flare nut.Always use safety valve with notcorrect
double stage pressure regulator while wring dry
nitrogen. 2 Joining method Excellent/
good/fair
3 Connect a pressure gauge at the other end of the tube
with flare nut. 3 Time taken Less/very
less/more
Note :
– Do not give more pressure while tightening
since this will spoil flare.
– Make sure that they should not be loose in
the tube.

TASK 3: Test the leak in fittings

Observation Table - 3
1 After joined the tube firmly, open the cylinder valve
with help of valve key or ratchet.
Sl.No. Skills Remarks
2 The pressure will be shown in the pressure gauge.
3 Then close the cylinder valve. Major leaks will make 1 Selection of tools excellent/
noise and that needs the nut to be tightened. good/average
4 If there is no leak, the pressure in the pressure gauge 2 Detecting leak and excellent/
will remain constant. arresting good/average
5 If it decreases, check the joints with soap solution
foam. Leak will bubble, then tight the joints. If it stands
still then there is no leak.

132 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.48
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.49

Pinch off copper tubing

Objectives: At the end of this exercise you shall be able to
• pinch off copper tubings, braze the end of the tube and test for leaks
• pinch off the copper tube using pinching tool.

Requirement

Tool/Instruments
• Steel rule - 1 no.
• Tube cutter with reamer - 1 no.
• Small triangular file - 1 no. Materials
• Pinch off tool - 1 no. • Soft tubing 1/4",3/8",1/2" - 1 Roll each
• Double end spanner set - 1 no. • Clean cloth - as reqd.

PROCEDURE

TASK 1: Pinch Off the copper tube using pinching tool

1 Unroll 1/4" soft copper tubing so that a 3" piece may 17 Take a part turn on one screw and then an equal
be cut. amount on the other.
2 Measure 3" piece long tube using the steel ruler and 18 The tightening process must carry on until the two
mark it by nicking the face with a triangular file. blocks are evenly seated.
3 Cut the copper tube by placing the tubing in ‘V-guide’ 19 The tube is then pinched shut.
of the cutter.
4 Tighten the thumb screw until considerable pressure
is applied.
5 Revolve cutter slowly around the tubing.
6 Seal the end of the tubing coil after cutting off the
required piece.
7 Ream and file the edges of the tubing.
8 Repeat with other sizes using 3/8" and 1/2" tubes
(steps 1 to 7).
9 Place copper tube in the pinch off section of the tool
apply even pressure by turning screws equally by
hand. (Figs 1 & 2)
10 Take a part turn on one screw and then an equal
amount on the other.
11 The tightening process must carry on until the two
blocks are evenly seated.
12 The tube is then pinched shut.
13 Seal the end of the tubing coil after cutting off the
required piece.
14 Ream and file the edges of the tubing.
15 Repeat with other sizes using 3/8" and 1/2" tubes
(steps 1 to 7)
16 Place copper tube in the pinch off section of the tool
apply even pressure by turning screws equally by
hand. (Figs 1 & 2)

133
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.50

Connect the copper tubes with lokring fitting

Objectives: At the end of this exercise you shall be able to
• connect two copper tubes with lokring
• connect capillary tube by lokring fitting.

Requirement
Tool/Instruments Materials
• Tube cutter - 1 No. • Sand paper - as reqd.
• Tube caliper - 1 No. • Lock prep
• Lokring hand tool - 1 No. (adhesive) - 1 No.
• Digital micrometer • Lokring
caliper - 1 No. various sizes - 1 Set.
• Lokring tool kit - 1 No. • Copper tubes - as reqd.

PROCEDURE
TASK 1: Connect two copper tubes with lokring.
1 Select the correct lokring size and materials(size are
available range from 1.6mm to 35mm.) Fig 2

2 Check the size of the tubing with tube calipers( for

accurate measuring use digital micrometer caliper if
available)
3 Set the tube & lokring fitting in horizontal line(see
Fig1)
Fig 1

Fig 3

4 Use the lokring hand tool compress the fitting over the
joint (for hand lokring see Fig 2)
5 Apply the sealant lokprep on the tube outer space and
rotate the tubes.
7 After completing lokring fitting clean the lokring and
6 Now compress fully till the lokring have tight close.(see
joints with a dry cloth.
Fig 3)

TASK 2: Connect capillary tube by lokring fitting

1 Use the tube cutter to separate the tubing if necessary 7 Insert other end with copper tube and refer steps in
2 Clean the capillary tube end with sand paper. task 1 to complete the lokring connection.

3 Pass the capillary tube all the way in till it reaches the 8 After completion of joint wipe the joints with dry cloth.
other end of lokring connector.
Fig 4
4 Apply a single drop of lokprep while partially inserted
in the lokring .
5 Rotate the fitting 360° to spread the sealant evenly
around the tubing.
6 Place a slight bend into the capillary tube (sec fig 4)

134
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.51

Brazing of cu to cu, cu to steel cu to braze using Air - LPG

Objectives: At the end of this exercise you shall be able to
• set gas pressure according to the nozzle size
• ignite, adjust and extinguish LPG air flame
• braze the swaged copper tube joint.

Requirements

Tools/Instruments Materials
• Safety apparel - 1 set • Filler rod - as reqd.
• Spark lighter - 1 No. • Flux suitable - as reqd.
• Copper tubes length size - as reqd.
Equipment/machines
• LPG cane attached with nozzle
and control valve - 1 set

PROCEDURE
TASK 1: Set the gas pressure according to the nozzle size.

Remove the oxides and other impurities from 3 Select 1.6mm dia silver brazing filler rod and suitable
the surface to be joined. flux in the form of paste.
4 Take the LPG cane open the valve slightly.
1 Wear safety goggles grouses and apron.
Air will be sucked through the side of nozzle
2 Keep the copper tube swaged connection in position
(for oxygen)
easy to braze.

TASK 2: Ignite, adjust and extinguish LPG-air flame

2 Adjust the control valve of the LPG cane and set a soft
1 Ignite the flame by using a spark lighter.
neutral flame.

TASK 3: Braze the swaged copper tube joint

The flux should be applied after cleaning of the 4 Move the LPG cane flame (oxy-air)and filler rod along
tube swaged joint and kept ready before the joint to complete the brazing operation. Finally
brazing. close the control valve (put off flame)of LPG cane.
Note : If the joint is not properly wetted it indicates that
1 Heat both the tube by the joint area evenly.
the metals (tube) have not been heated to the required
2 Dip the silver brazing rod in the flux (paste) and apply brazing temperature.
the filler rod to the joint area as you pointing the flame
5 Cool the job (by natural air) and clean the flux residue
on the connection.(Fig 1)
thoroughly from the joint.
3 Carefully watch for proper melting and flow of the filler
metal into the minute gap (capillary action)of the joint 6 Inspect for any surface defects.
(i.e. wetting of the joint) 7 Get it checked by your instructor.

135
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.52

Brazing of cu to cu, cu to steel and cu to brass using Oxy LPG set

Objectives: At the end of this exercise you shall be able to
• set oxy - LPG gas welding set
• braze copper to copper
• braze copper to steel
• braze copper to brass.

Requirements : Ex.No : 1.5.53 except equipment - Type Oxy LPG welding set.

Refer Exercise 1.4.41 - TASK 1, TASK 2, and Exercise 1.5.53 TASK 3

136
Capital Goods and Manufacturing
R&ACT - Basic Refrigeration Exercise 1.5.53

Brazing of cu to cu, cu to steel, cu to braze using Oxy- acetylene

Objectives: At the end of this exercise you shall be able to
• braze a swaged copper tube joint
• braze copper with MS tube
• braze copper to brass tube.

Requirement
Tool/Instruments
Materials
• Gas welding set - 1 no.
• Sand paper materials - as reqd.
• Tube cutter - 1 no. • Brazing flux - as reqd.
• Wire brush - 1 no. • Brazing rods (silver & copper) - as reqd.
• Cylinder key - 1 no. • Ms tube & Brass tube - as reqd.
• Clean cloth - as reqd.
Equipments
• 6 mm copper tube (as required) - as reqd.
• oxy-acetylene welding set - 1 set.

PROCEDURE

TASK 1: Braze a swaged copper tube joint (Refer Ex: 1.5.47 - Task 2)

TASK 2: Braze copper with Ms tube cut the copper tube

1 Place the tube in V-guide of cutter. 9 Light the oxy-acetylene torch using the spark lighter
2 Tighten the thumb screw until considerable pressure 10 Heat the connection at safe distance from the joint
is applied until the water vaporizes
3 Revolve the cutter slowly around the tube so that the 11 Continue heating until the flux turns milky and finally
sharp cutting wheel feeds gradually on the tubings to turns clean (Fig 2)
apply pressure thumb screw till tube is completely cut
4 Ream and file the edges of the tubing
5 Use sand paper to clean the outer surface of the tube
and clean inside by wire brush
6 Make a paste of silver brazing flux by mixing it with
little bit of water and apply a thin coat of flux to outside
of the fitting
7 Insert the pipe into MS pipe and see that the fit is not
too easy (Fig 1)

12 Apply the silver solder to both edges of the MS tube

until the solder flows on both pipes
13 Remove silver solder rod and allow the joint to cool

8 Clamp the pipe in the flaring block and mount the

block in the vice

137
TASK 3: Braze the copper to brass tube

1 Soften the end of copper tube to be bell-mouthed by

heating.(Fig.3)

2 Dip the heated end in water and remove the oxides

(Fig 4)

3 Use a mandrel to form the bell mouth

7 keep the tack welded pipe assembly vertically and
4 Insert the mandrel and drive into the softened end of heat it until the colour of the tube starts changing.
the tube by hammering.(Fig.5 )
8 Make a thin run on the line formed by the outer
circumference at the bottom end of the brass tube and
the inner circumference at the bottom of the bell
mouth of copper tube (i.e tip of the bell mouth).
9 Make the first deposit starting from the tack weld 1 and
ending at the midpoint of the tack welds 2 and 3
covering half the circumference of the bell mouth.
(Fig.8)
10 Clean the deposit.
11 Make the second deposit starting from the commence
mint point of deposit 1 and ending at the finishing point
of the deposit 1 which will cover the remaining half
circumference of the bell mouth.
12 Ensure the deposit 2 merges with the deposit 1 at both
5 Remove any unevenness of the bell mouth.(Fig.6) ends (i.e. terminal points) properly by withdrawing the
filler rod and manipulating the flame over these merging
6 Insert the brass tube into the bell mouth and tack it at points.
3 points.(Fig.7)

138 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.53
 13 Ensure that the weld deposit is of the correct profile
and it completely covers and bonds (without over
spilling the outer edge of the bell contour.
14 Clean the bead and the joint and remove the flux
residue thoroughly.
15 Inspect the weld deposit for uniform size and weld
defects like porosity, etc.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.5.53 139
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.54

Identify the electrical and mechanical components of refrigerator

Objectives: At the end of this exercise you shall be able to
• identify the electrical parts /components of refrigerator
• identify the mechanical components of refrigerator.

Requirement

Tool/Instruments • Multimeter - 1 No.

• Screw driver - 1 No. Materials
• Line tester - 1 No.
• Combination insulated handle plier - 1 No. • Cotton waste/ cloth
• Series test lamp - 1 No. • Loose wire

PROCEDURE

TASK 1: Identify the Electrical parts ( Fig 1 to 7)

1 Disconnect the connection & identify the electrical 3 Clean the motor and spare part.
components
4 Identify the components.
2 Keep it on work bench.
Fig 3

Fig 4

140
 Table 1
Figure No Name of the part
1
2
3
4
5
6
7

TASK 2: Identify the Mechanical parts

Fig 1 Fig 4

Fig 2

Table 2
Fig 3
Figure No Name of the part
1
2
3
4
5

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.54 141
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.55

Check and replace electrical components in refrigerator

Objectives: At the end of this unit you shall be able to
• check and test current coil relay
• check and test overload protector
• identification of compressor winding terminal pins with ohmmeter
• check short circuit in compressor
• check the condition of a door switch
• check Thermostat & check capacitor.

Requirement
Tool/Instruments • OLP - 1 No.
• Screw driver 10mm tip 200mm length - 1 No. • FHP compressor - 1 No.
• Cutting plier 200mm length - 1 No. • 2 m 1 sq.mm lead wire as reqd.
(Insulated) • 2 m wire with crocodile clip as reqd.
• Phillips screw driver set - 1 No. • Test board fitted with
• Ohmmeter - 1 No. voltmeter & ammeter - 1 No.
• Thermostat - 1 No.
Materials • Capacitor - 1 No.
• Current coil relay - 1 No.

PROCEDURE
TASK 1: Test the current coil relay

1 Check continuity between the 4 & 5 with help of

ohmmeter. (Fig 1)
2 If the continuity is OK between 1 and 2. Coil continuity
of current coil relay is OK. Normal condition 4 & 5
continuing will be there.
3 Check continuity between 5 & 6. Normal condition
(when not in use) 5 & 6 open. If there is no continuity
between 5 & 6 relay is OK.
4 Keep the relay up side down. Check continuity
between 5 & 6. If the continuity is there. Relay is OK.
5 Bring to its original position.Check continuity between
2 & 3. If there is no continuity. Relay found OK.
6 Check plunger movement and observe sound. Keep
the relay upside down. Plunger moves up and you
can hear the sound. Bring to normal position. Plunger
comes down. You can hear sound. If there is no
sound, relay is defective. Relay plunger operating is
not OK.

TASK 2: Check and the overload protector

Refer TASK 1: Figure

1 Check continuity between 1 & 3 3 If there is no continuity Overload is defective

2 If the continuity OK between 4 & 5,continuity of bimetal 4 Check any rust formation in disc.If rust formation is
contacts OK. there, not advisable to use. (Fig 1)

142
TASK 3: Identification of compressor winding

Terminal pins with Ohmmeter of fraction horse power 3 Record in the record sheet table no.1
hematic compression.
4 Measure the resistance between A & B (40 ohms)
Before carrying out the exercise remember the
5 Record in the record sheet table
following
6 Measure the resistance between C & B (60 ohms)
– Running winding resistance always less than
starting winding 7 Record in the record sheet
– Starting winding resistance always higher than 8 Identified ‘A’ terminal pin become common terminal
running winding
9 Identified ‘B’ terminal pin become starting winding
– Resistance of run and starting winding sum of
10 Identified ‘C’ terminal pin run winding
starting winding resistance and running winding
resistance
Resistance value slightly vary from
1 Set the ohmmeter as per the (Fig 2) manufacturer to manufacturer. Instructor must
have compressor manufacturer specification.
2 Measure the resistance between A and C (20 Ohms)

TASK 4: Check short circuit in compressor.

1 Select ohmmeter scale (R x 10000) (Fig 3)

2 Place ‘A’ probe to compressor terminal
3 Place ‘B’ probe to metal casing of compressor
4 Check continuity. If continuity is there compressor
grounded.(Fig 3)
5 If there is no continuity compressor not grounded.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.55 143
TASK 5: Check the condition of a door switch

1 Switch ‘ON’ the refrigerator 6 Check the continuity in switch by multimeter or by test
lamp is ON and OFF position. (Fig 5)
2 Open the refrigerator door and check the condition of
cabinet bulb. It should glow.
3 If it is not, check the bulb. (Fig 4)

4 If the bulb is fused, replace the bulb on refrigerator and

check. 7 Check bulb holder wires.
5 Still the bulb not glows then switch off the refrigerator 8 If switch found defective, replace it and connect wires.
and remove the door switch and disconnect the wires.

Note : Mark all connections which are being

disconnected.

TASK 6: Check the condition of a thermostat.

1 Switch ON the Refrigerator.
2 If it is not run check thermostat.
3 Remove the thermostat and its wires.
4 Test thermostat continuity in ‘OFF and ON’ position by
multimeter or test lamp. (Fig 6)

TASK 7: Check capacitor.

Caution: do not place fingers across the 5 Press the charging switch (B) for one or two seconds.
terminals of a capacitor. It may be charged and (Fig 7B)
gives a shock. Short it with a insulated wire
6 Put off the circuit plug (E).
before handling.
7 With the switch open at (B) touch the shorting
1 Remove the capacitor for test. switch (C). If the capacitor is good, the switch will
spark. (Fig 7C)
2 Connect the capacitor in capacitor test circuit. (Fig 7A)
8 If it does not spark in the first time, try it two or three
3 Check the fuse (D) in the circuit as shown. times before replacing the capacitor to the unit.
4 Switch ON the circuit plug (E)

144 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.55
Note : If the capacitor is good it will spark as in
(Fig 7C).
If the capacitor is shorted or grounded the fuse
(D) will blow as in view. (Fig 7D).
If the capacitor does not take a charge, it will
not spark. This indicates an open circuit. (Fig
7A). The capacitor is connected to the terminals
of the tester.
Caution: The capacitor should be put in a
protective case while testing it because a
shorted capacitor may explode when put in a
circuit.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.55 145
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.56

Test leak, evacuation and gas charging in refrigerators

Objectives: At the end of this exercise you shall be able to
• flare and make additional charging tube in compressor
• braze compressor charging tube with additional flared copper tube
• connect compressor charging tube with gauge manifold and nitrogen cylinder
• charge nitrogen gas into the system
• test leak with soap solution
• braze the leak spots.

Requirements

Tools/Instruments Materials
• Nitrogen cylinder and • Soap solution concentrate - 1 bottle/100ml
2 stage pressure regulator - 1 Set • Clean and pure water - 500 ml.
• Charging hose - 1 No. • Sponge - 1 piece/0.25 ft3
• Combination plier - 1 No. • Fine emery sheet - 2 nos
• Cylinder key - 1 No. • Copper tube
• Dry bulb thermometer soft annealed type
(stem-alcohol type) 0-100°C - 1 No. - 1/4" OD (6 mm) - 15 cm
• Gauge manifold with LP/HP gauges - 1 Set • Flare nut brass
• Painting brush 1" (25 mm) - 1 No. 1/4" (6 mm) - 1 No.
• Double ended spanner • Flare union brass
Nos. 6/7 to 20/22 - 1 Set 1/4" (6 mm) - 1 No.
• Adjustable spanner 6" ( 15 cm) - 1 No. • Brazing rod copper to
• Flaring block with yoke - 1 Set copper 30 cm - 2 Nos.
• Brazing torch with hoses and • Flare dummy nut
oxygen and LPG cylinders - 1 Set brass (6 mm) 1/4" - 1 No.
• Plastic/ metal mug.
Equipments
1 ltr water volume - 1 No.
• Conventional Refrigerator - 1 No. • Dry nitrogen gas
• Frost free refrigerator - 1 No. • Oxygen gas
• Vacuum pump 2 stage • LPG gas

PROCEDURE

Conventional refrigerator (Fig.1)

TASK 1: Flare and make additional charging tube in compressor

1 Make sure that there is no gas in the system through 3 Insert the flare nut (6 mm) through the copper tube (6
the charging tube of compressor (it should be open) mm) at non flared end
2 Take the copper tube 6 mm (soft) 1/4 “ OD : Flare one 4 Insert (15 mm) the non flared end of copper tube (6
end with flaring block and yoke. mm) into the compressor process tube.

TASK 2: Braze compressor charging tube with additional flared copper tube

1 Take the gas welding brazing set 5 Take the flame to the point of compressor charging
2 Open the valve of oxygen cylinder and regulate tube with additional copper tube (6 mm)
pressure 6 Braze the point with brazing rod (copper - copper)
3 Open the valve of LPG cylinder and regulate pressure 7 Allow the point to cool down.
4 Light up the brazing torch and set the flame (neutral
type)

146
TASK 3: Connect compressor charging tube with gauge manifold and dry nitrogen gas cylinder

1 Connect flare nut of additional charging tube with 4 Connect the intermediate port of gauge manifold with
flare union 6mm. another charging hose.
2 Connect the other end of flare union with charging 5 Connect the other end of charging hose with outlet
hose. part of nitrogen cylinder.
3 Connect the other end of charging hose with HP(High
pressure) port of gauge manifold.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56 147
TASK 4: Charge dry nitrogen gas into the system

1 Make sure that all thread/ screw points are in tight fit 10 If the pressure not reached 150 psig, again allow
position nitrogen flow into the system through reopening the
2 If not, make the joints tighten by using cutting plier (to knob of manifold.
tighten charging hose), double ended spanner and 11 When the pressure reaches 150 psig, close the valve
adjustable spanner (to tighten flare nuts, flare unions) of nitrogen cylinder; close the regulator knob
3 Open the nitrogen cylinder valve using valve key 12 Close the knob of gauge manifold
4 Regulate the pressure to 50 psig. in the pressure 13 Take the dry bulb thermometer and find the
regulator temperature of ambient air
5 Open the knob of HP(High Pressure) port of gauge 14 Note down the time
manifold by turning the knob gently in anti clockwise
direction 15 Tabulate the readings in the tabular column which is
given at the end of this exercise
6 Observe the nitrogen gas flowing into the system
through, notice the reading in the HP gauge of manifold 16 Remove the charging hose II which inter connects
gauge manifold and nitrogen cylinder
7 Allow the nitrogen flow for 15 - 20 seconds
17 Close the intermediate port of manifold by dummy nut
8 Close the knob of gauge manifold by turning it gently brass 6 mm.
clockwise direction
9 Observe the reading in the pressure gauge (HP)
manifold

TASK 5: Test leak with soap solution

1 Take a plastic / metal mug filled with pure water 500 10 If any bubbles present in the joint, add more soap
ml. solution on the joint and find where it is coming from
exactly
2 Add 25 ml of soap solution concentrate into the water
11 If the leak at screwed/threaded joints (flare nuts,
3 Stir mixture well and make lather by a paint brush.
charging hose adapters) make it tight fit and arrest
4 If the lather is not sufficient, add some more soap the leak by using double ended spanner or adjustable
solution into the mixture. spanner or cutting plier.
5 Soak the sponge into the soap solution mixture 12 If the leak at brazed joints (copper tube), confirm the
leak and note down to carryout repairs
6 Take few quantity of soap solution mixture by the
brush and apply the solution on the points. 13 If there is no leak in screwed/brazed joints leave the
system as it is to hold the pressure for next 24 hrs.
Swaged joints charging hose adapters, flare nuts etc.,
brazed joints. Places where copper tubes are joined 14 After 24 hours note down the reading - pressure,
together. ambient - temperature and time
7 Take the sponge with solution and lather; place it 15 Compare the reading of pressure with previous days
under the joints. reading
8 Carefully watch any nitrogen bubbles are coming 16 If there is no difference between two readings or
from the system through the soap solution mixture there is 5 to 10 psig difference between two reading
- The system has no leak.
9 If no bubbles present, it indicates there is no leak

Record sheet

S.No. Date Time Ambient Test pressure Remarks

temp
D.M.Year Hrs.min °C psig/bar Joints leak
tested

148 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56
TASK 6: Braze the leak spots
1 Leaks if any in brazed joints mark the spots. 6 Stop the welding torch, let the brazing joint cool.
2 Let out nitrogen pressure from the system. 7 Pressurerise the system with dry nitrogen.
3 Clean the leak spots with emery papers. 8 Check leak with soap water on all brazed joints.
4 Light the brazing torch, use goggles. 9 If there is no leak, vent the nitrogen pressure.
5 Heat top and bottom joints of leakage pipes when it
get red hot apply flux and apply copper rod.

Evacuate hermetic system in refrigerator

Objectives : At the end of this exercise you shall be able to
• fix angle valve on compressor process tube
• connect the system with vacuum pump
• handle and operate vacuum pump
• dehydrate the system
• evacuate the system by low side and both high & low sides.

Requirements
Tools/Instruments/Equipment Equipments
• Heating kit - Infrared lamp type • Refrigerator conventional/frost free - 1 No.
or hot air gas - 1 set • Vacuum pump 2 stage - 1 No.
• Charging hose - 1/4"(6mm) flame - 2 Nos.
• Gauge manifold with LP/HP gauges - 1 No. Materials
• Cutting plier - 1 No. • Angle valve Brass - 1/4" (6 mm) flare x
• Online tester 230V - 16A - 1 No. 1/4" (6 mm) flare - 1 No.
• Double ended spanner 6/7 to 20/22 - 1 set • Clean cotton waste - as reqd.
• Adjustable spanner - 1 No.
• Ratchet wrench or ratchet key - 1 No.

TASK 1: Fix angle valve on compressor process tube. Figs (1 & 2)

Note : This practical exercise to be done after

leak testing of the unit /appliance. Ensure that
the unit/appliance is already leak tested.

1 Fix the angle valve inlet port to the compressor

process (additional) tube flare nut.
2 Tighten the joint ‘angle valve - flare nut’ by using a
suitable double ended spanner and adjustable spanner
3 Make sure that the angle valve is closed.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56 149
TASK 2: Connect the system with vacuum pump

1 Connect one end of charging hose (I) to the outlet of 3 Connect one end of charging hose (II) to intermediate
angle valve. Tighten the joint with a cutting plier port of gauge manifold.
2 Connect the other end of charging hose (I) to LP(low 4 Connect the other end of charging hose (II) to inlet port
pressure) port of gauge manifold of the vacuum pump

150 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56
5 Close the HP(High pressure) port of gauge manifold 7 Make sure that the HP/LP knobs of gauge manifold
with a brass flare dummy nut (6 mm) are closed.
6 Tighten the screwed/threaded joints by using cutting
plier (for charging hoses), suitable double ended
spanners (for flare nuts, dummy nuts etc).

TASK 3: Handle and operate vacuum pump

1 Ensure that the power(electrical) supply available to 5 Open the angle valve by turning the stem to
the vacuum pump by using a online tester. anticlockwise direction with ratchet key/wrench.
2 Connect the electrical power line of the vacuum pump 6 Observe the pressure reading available on the LP
to the power source (test board/switch board) gauge of manifold. The pressure gets reducing.
3 Switch on the vacuum pump 7 Leave the system as it is for 2 hours without any
interruption.
4 Open the valve knob (LP port) of gauge manifold

TASK 4: Dehydrate the system

1 Take the heating kit (Infrared lamp) and switch it ON. 5 Keep and maintain the distance between the heating
kit and surface of system (15cm) always.
2 Make sure that the system is getting vacuum and the
pump is functioning 6 Continue the process for 15-30 minutes.
3 Heat all over areas of the system with infrared lamp
4 Apply heat uniformly to all areas - Refrigerant tubes,
condenser coil, evaporator coil (if it is exposed), liquid
line drier/filter.

TASK 5: Evacuate the system

1 Notice and observe the pressure reading on the LP 3 Close the LP knob of gauge manifold
gauge of the manifold, it should be 100 microns or 4 Switch off vacuum pump and disconnect the power
below (equivalent 30 in of Hg) supply
2 Close the angle valve by turning its stem to clockwise 5 Disconnect charging hose (I) from angle valve
direction with ratchet key/wrench after 3 hours from
the time of vacuum pump started. 6 Close the outlet of angle valve with dummy nut (6 mm)
tighten the nut with a suitable size double ended
Caution: spanner
Whenever operating (opening /closing) angle 7 Disconnect charging hoses (I & II) from gauge manifold
valves fixed on pipe lines, needs extra care. and vacuum pump.
(Fig3).
Hand shut off valve can also be used instead of
Over tightening (closing) over loosening angle valve at compressor process tube.
(opening) of valve stems strictly to be avoided
as it damages the valve internally.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56 151
Charge refrigerant in refrigerator
Objectives: At the end of this exercise, you shall be able to
• charge refrigerant in hermetic (refrigeration) system of a conventional refrigerator
• charge refrigerant in hermetic (refrigeration) system of a frost free refrigerator.

Requirements
Tools, Instruments & Equipments
• Weighing scale/platform - 1 No. • Gas lighter - 1 No.
• Gauge manifold with LP and • Tong tester or clamp on meter - 1 No.
HP gauges - 1 set • Soap solution with sponge - Req Qty.
• Charging hose - 3 Nos. • Halide torch/Electronic leak detector - 1 No.
• Cutting plier - 1 No. • Eye goggles - 1 set
• Adjustable spanner - 1 No. • Tube cutter - 1 No.
• Double ended spanners Materials & components
(size 6/7 to 20/22) - 1 set
• Ratchet key/wrench - 1 No. • Brazing rod copper to copper - 1 No.
• Brazing torch with hoses - 1 set • Refrigerant cylinder with required
and oxygen & LPG cylinders refrigerant 250 gms - 2 Nos.
• Warm water 50°C with bucket - 2 lts
• Cylinder key - 1 No.
• Clean cotton waste - Req. Qty.
• Pinch off tool - 1 No.

Note: Method 1 : Using charging cylinder

1 This practical exercise to be started immediately Note:
(within 2 hours) after evacuating the unit/appliance.
1 Wear eye goggles and hand gloves
2 Before starting the exercise make sure that the unit
appliance is already vacuum to the required (30 in Hg) 2 Get charging cylinder filled with correct refrigerant
level. and not less than required quantity (pre determined)

3 It is assumed that the unit/appliance which is going to 3 This method is mostly followed in charging refrigerant
get charged is under/holding vacuum. in new/fresh system/appliance. (See Fig 1)

TASK 1: Connect system to charging cylinder (Fig 1)

1 Connect one end of charging hose (1) to the valve of 4 Ensure that the charging cylinder valve, LP and HP
charging cylinder and connect other end to valve knobs of gauge manifold and compressor angle
intermediate port of gauge manifold. valves are closed.
2 Connect an end of charging hose (II) to the angle 5 Tighten the ends of charging hoses using a cutting
valve of compressor and connect other end to low plier.
pressure (LP) port of gauge manifold.
3 Close the high pressure (HP) port of gauge manifold
with a flare dummy nut (6 mm) and tighten it using a
suitable double ended spanner.

TASK 2: Purge air in the charging hoses

1 Open the charging cylinder valve gently/slowly by 4 Open (2-3 turns) the LP knob of gauge manifold and
turning the knob 1/2 to1 turn to anticlockwise direction observe the reading on the LP gauge.
2 Purge the charging hose (I) by loosening its end at the 5 Purge the charging hose (II) by loosening its end at
intermediate port of gauge manifold using a cutting the angle valve using a cutting plier.
plier.
6 Observe the refrigerant escape then immediately
3 Observe the refrigerant is escaping out at intermediate tighten the end of charging hose II to arrest the
port of manifold in form of snow, then immediately refrigerant flowing out.
tighten the end of charging hose I and ensure that the
escape/release of refrigerant is arrested. Construction
MRAC - Refrigeration System -Ex- 1.4.56A

152 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56
TASK 3: Charge refrigerant into the system.

1 Note down the level of refrigerant in the charging 5 Leave the system as it is for 3-5 min or till all refrigerant
cylinder and record it in the tab column. /required quantity of refrigerant to settle into the
2 Open the stem of angle valve (at compressor process system.
line) by slowly turning the stem to anti clockwise 6 Close the valve of charging cylinder after ensuring the
direction using ratchet key / wrench. refrigerant is transferred into the system.
3 Observe the refrigerant flow in the charging tube of 7 Close the LP knob of gauge manifold by turning the
the compressor by touching it with hand/finger. ensure knob to clockwise direction using hand.
the refrigerant flow by feeling the charging line is cold.
8 Close the angle valve by turning its stem carefully to
4 Observe the refrigerant flow/ transfer by watching the clockwise direction using ratchet key and adjustable
level in the charging cylinder. spanner.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56 153
9 Observe and record the reading on the charging Method II
cylinder to calculate the amount of refrigerant is
Using refrigerant service cylinder
charged.
Note : Wear goggles and hand gloves
10 Disconnect charging hose-II from the angel valve.
Get the service cylinder filled with correct refrigerant and
Note:
not less than the required quantity.
To increase the flow of refrigerant into the system or to
This method is most commonly followed in the trade.
fasten the charging process, keep the level of charging
cylinder above than the compressor. This method is useful for spot charging.
To improve the charging process, heat the refrigerant
cylinder by wiping it with warm water cloth.

TASK 4: Connect system to service cylinder (Fig 2)

1 Connect an end of charging hose I to the valve of 4 Ensure that the service cylinder valve, LP and HP
service cylinder and connect the other end to the valve knobs of manifold and compressor angle valve
intermediate port of gauge manifold. are closed.
2 Connect one end of charging hose II to the angle 5 Tighten the ends of charging hoses using a cutting
valve of the compressor and connect other end of the plier.
low pressure (LP) port of gauge manifold.
3 Close the high pressure (HP) port of gauge manifold
with a flare dummy nut (6mm) and tighten it using a
suitable double ended spanner.

TASK 5: Purge air in the charging hoses

1 Open the service cylinder valve by slowly turning its 4 Open (2-3 turns) the LP knob of gauge manifold and
stem 1/2 to 1 turn to antic lock wise direction using a observe the reading on the LP gauge.
ratchet key/wrench.
5 Purge the charging hose (II) by lessening its end the
2 Purge the charging hose (I) by loosening its end at angle valve using a cutting pillar.
the intermediate port of gauge manifold using a 6 Observe the refrigerant escape then immediately
cutting plier. tighten the end of charging hose II to arrest the
3 Observe the refrigerant is escaping out at the inter- refrigerant flowing out.
mediate port of manifold in the form of snow, then
immediately tighten the end of charging hose I and
ensure that the escape/release of refrigerant is
averted.

TASK 6: Charge refrigerant into the system.

1 Open the angle valve stem (a compressor process 7 Test the electrical power supply available to the
line) by slowly turning it to anti clockwise direction appliance is in operating limits (180-230 volts) using a
using a ratchet key/wrench. multimeter.
2 Observe the refrigerant flow in the charging tube of Note :
the compressor by touching it with hand/finger. Ensure
1 It is always advisable using a suitable capacity voltage
the refrigerant flow by feeling charging line is cold.
stabilizer (0.5 KVA/500 W) with time delay (3 min.) and
3 Observe the refrigerant flow also in LP gauge of high and low voltage cut off for any home/commercial
manifold, the pressure is increasing from vacuum appliance to save the life of compressor.
level -30 in Hg to above 0 psig onwards.
2 Switch ON the appliance and ensure that the
4 Observe the hissing noise into the compressor during compressor is working by touching the dome by hand,
the pressure increasing from vacuum to above 0 feel mild vibration and sound.
level. It indicates the vacuum is braked.
3 Set the thermostat knob to maximum position by
5 Allow the refrigerant flow till it reaches 30 to 50 psig turning the knob to clockwise direction by hand.
in the LP gauge of manifold. Then immediately close
4 Observe the reading on the LP gauge and ensure it is
the angle valve.
‘0’ or above ‘0’ psig.
6 Ensure that the wiring of the system/appliance is
ready for switch ON using wiring diagram.

154 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56
Note :
1 After switching ON the compressor/ appliance the low 3 Pre-charge additional quantity of refrigerant then
pressure must be positive level or it should be more switch ON the appliance.
than atmospheric level to avoid atmospheric air sucked
by the compressor through minute leak joints/spots if 4 The appliance being charged is to be kept in normal
any. temperature (32°C ± 2°C) and it should be away from
any heating/cooling appliances like gas welding flame,
2 If the pressure on the LP gauge shows below ‘0’ level blow lamp flame, sun rays/light, any other heaters,
then immediately switch OFF the appliances. ceiling/table/pedestal fans.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56 155
5 Open more the angle valve to allow the refrigerant 15 Close the cylinder valve using valve key/ratchet key.
sucked by the compressor.
16 Disconnect the charging hose from the angle valve.
6 Open the refrigerator/appliance door and observe the
17 Disconnect the charging hoses I and II from service
hissing noise in the evaporator/freezer which indicates
cylinder and gauge manifold.
the refrigerant flow.
18 Close the cylinder valve with a dummy nut with a
7 Observe the cooling effect in the evaporator by touching
suitable double ended spanner.
its surface by hand and feel the cold then close the
door. 19 Test the cylinder (at valve seating, gland, dummy nut)
for any leaks with soap solution.
8 Observe the chillness (moisture formation) on the
suction line and hotness (above atmospheric temp.) 20 Measure the weight of cylinder with a weighing scale/
on the liquid line, feeling by the hand platform and record the value.
9 Allow the refrigerant flow till it gets saturation by 21 Let the appliance to work for 1 hour.
watching the suction tube of compressor gets frost Note:
formation.
1 It is advisable to keep the evaporator of the appliance
10 Stop the refrigerant flow to the appliance by closing with constant load during charging process.
the angle valve.
2 The load should not be very HIGH or LOW to its
11 Observe the reading on the LP gauge it may be 5 to 7 cooling capacity otherwise there will be a problem
psig. when setting the suction pressure.
12 Charge additional quantity of refrigerant if frost
3 If the appliance / system newly made it is better to
formation disappears on the suction line by opening
measure ‘discharge Pressure (HP)’ of the system by
the angle valve again.
having proper provision (at filter/drier) at liquid line.
13 Measure current drawn by the compressor using a
4 Confirm the values in the pressure temperature chart
clamp/tong tester and record the reading.
of a particular refrigerant (eg. R134a or other
14 Complete the charging if the low pressure reached to refrigerant).
its boiling point (5 - 8 psig) by closing the angle valve.
5 Common task for both methods.

TASK 7: Pinch the system

Note:
1 Pinching may require either on low side or high side. 8 Remove the angle valve by loosening it from the flare
Some times it requires at both sides suction/process nut using a adjustable spanner and a suitable size
line and liquid line. double ended spanner.
2 System to be in working condition when pinching at 9 Cut the copper tube between the flare nut and pinching
low side and system to be kept ‘off’ position when point using a tube cutter.
pinching at high side.
10 Test leak (refrigerant) at open end of copper tube-
3 Use of proper tools like pinching block or pinch off tool beyond the pinching point by applying thin film of soap
hand held type must be compulsory to carry out solution into the open end.
‘pinching process’ using cutting/nose pliers as pinching
tools to be strictly avoided as it may not serve the 11 Arrest leak if found by extra tightening of pinching
purpose block or double crimping the hand held pinching tool.

4 Wear eye goggles and hand gloves whenever 12 Light up the brazing torch and heat the open end of
necessary. copper tube (charging tube) till it becomes dark orange
colour then fill the open end with a silver brazing rod
5 Ensure that the compressor is working. immediately.
6 Pinch the line between compressor process tube and Note:
flare nut of angle valve using a pinching tool.
1 Silver rod must be put on the brazing spot only after
7 Hold the pinching tool tightly on the process line. the material reaching its melting point.

156 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56
2 The partial part of flame will turn to green colour due 6 Ensure that there is no any blow holes in the brazed
to presence of refrigerant gas in the brazing spot. spot.
3 When the pinching spot is completely filled the green 7 Test leak at the brazed spot/pinched spot by applying
flame will disappear. a thin layer of soap solution on to it.
4 At any cause the pinching tool should not be dis- 8 Re-braze the spot if found any leak.
turbed/shacked before the process gets over.
9 Remove the pinching tool from the charging/process
5 Light off the torch when the brazing spot is completely tube very carefully.
filled with silver rod.

Record sheet

Name of appliance :

Capacity :

Date :

Sl. Time Pressure Temp. Voltage Current Cylinder Net Rem

No. Hrs/min psig kg/cm2 °C Weight(Kg) Refg.
charge
Low High Ambient Volts Amps Before After (Kg)
side side charge charge

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.56 157
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.57

Check the wiring circuit of refrigerator

Objective: At the end of this exercise you shall be able to
• check the condition of a door switch and cabinet lamp with holder
• check the condition of a thermostat
• check the condition of relay and OLP
• check compressor winding
• check electrical wiring for RSIR operation.

Requirements

Tools/Instruments Equipments
• Trainees kit - 1 No. • A complete system of RSIR
• Line tester - 1 No. circuit,CSIR circuite - 1 No each.
• Test cords -5m
Materials
• Test lamp with holder - 1 No.
• Soldering iron - 1 No. • Soldering wire and flux as reqd.
• Multimeter - 1 No. • Clips - 5 Nos.
• Wire each colour R,B,G - 5 mts
• Insulation tape - 1 Roll

PROCEDURE

TASK 1: Check the condition of a door switch

1 Switch ‘ON’ the refrigerator 6 Check the continuity in switch by multimeter or by test
2 Open the refrigerator door and check the condition of lamp is ON and OFF position. (Fig 2)
cabinet bulb. It should glow. 7 Check bulb holder wires and terminals, if it is faulty
3 If it is not, check the bulb. (Fig 1) replace them.

4 If the bulb is fused, replace the bulb on refrigerator and

check.
5 Still the bulb not glows then switch off the refrigerator
and remove the door switch and disconnect the wires.

Note : Mark all connections which are being

disconnected. 8 If switch found defective, replace it and connect wires.

158
TASK 2: Check the condition of a thermostat.
1 Switch ON the Refrigerator.
2 If it is not run check thermostat.
3 Remove the thermostat and its wires.
4 Test thermostat continuity in ‘OFF and ON’ position by
multimeter or test lamp. (Fig 3)
5 If it is not working replace it.

TASK 3: Check the condition of a relay and OLP.

1 Disconnect the relay and OLP from the unit. 10 If there is no continuity, the OLP is faulty otherwise it
is good.
2 Remove the wires from relay and OLP
3 Set multimeter knob to resistance.
4 Connect one probe to relay contact 1 and other to S.
5 If there is continuity between them the contacts have
stuck or been welded together. (Fig 4)
6 Replace the relay.
7 Test the continuity of the current relay coil between 1
and M.
8 If there is no continuity means, the coil is open circuit.
Replace the relay.

9 Test the OLP continuity between the terminal 1 and 3

TASK 4: Check compressor winding (Refer Exercise. 1.6.55 - TASK 3 and TASK 4)

TASK 5: Check electrical wiring (RSIR operation).

1 Check wiring as per diagram in Fig (5).

Caution: Do not fail to put insulation tape on

connections where it is found necessary.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.57 159
TASK 6: Check electrical wiring.
1 Switch ‘ON the UNIT.
2 If it does not start, check the electrical circuit as per
(Fig 1) circuit diagram.
3 If the wiring circuit is good, check the other parts of
electrical circuit.

TASK 7 Check capacitor (Refer Ex. 1.6.55 - TASK 7)

Caution: The capacitor should be put in a

protective case while testing it because a
shorted capacitor may explode when put in a
circuit.

TASK 3: Check relay (Refer Ex. No.1.6.55 - TASK 1)

TASK 4: Check compressor (Refer Ex. No.1.6.55 TASK 3 and TASK 4)

TASK 5: Check OLP (Refer Ex. No.1.6.55 TASK 2)

160 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.57
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.58

Install and inspect a new domestic refrigerator

Objectives: At the end of this exercise you shall be able to
• uncrate/unpack the refrigerator unit
• select the location of the unit
• position the unit
• test the electrical power supply
• connect the voltage stabilizer to the unit
• start the refrigerator unit
• test the performance of the unit.

Requirements
Tools/Instruments • Clamp meter -0- 10 amps -1 No.
• Spirit level meter - 1 No. Equipments
• Multimeter - 1 No.
• Online tester - 1 No. • Domestic refrigerator -1 No.
• Combination plier - 1 No. Materials
• Wire stripper - 1 No.
• Soap solution - 50 ml
• Screw driver 6" 150mm - 1 No.
• Clean water - 2 lit.
• Adjustable spanner 150mm - 1 No.
• PVC insulation tape 12 mm width - 1 Roll
• Thermometer (stem/digital type)
• Voltage stabilizer 0.5 KVA - 1 No.
–5 to +50oC - 1 No.
• Clean cloth/sponge - 1 piece

PROCEDURE

TASK 1: Uncrate/unpack the refrigerator unit.

1 Place the unit in upright position on a flat even surface 5 Watch carefully the outer surface of unit. The outer
carefully. body should be clean and glossy and without any
scratches, dents etc.
2 Cut the packing tape/rope using wire stripper/small
knife. 6 Remove the base packing (wood) by unscrewing the
bolts and nuts using a suitable double ended spanner/
3 Remove the outer cover/crate by lifting it from bottom
adjustable spanner.
to top very carefully.
Note: Keep safe the unit inclined position while
Caution; Beware of condenser coil, if it is
removing the base bolts
backside. If any damage occurred on it may
leads to gas leak.
7 Keep the unit away from packing materials
4 Remove extra packing materials, if it is there.

TASK 2: Select the location.

Note: Normally ‘unit location’ will be decided 3 Ensure that there is no any heat emitting/radiating
before the unit is arrived to the place. So that units (gas stoves, heaters, sunlight etc.) nearby the
proper wiring and plug point will be made location.
accordingly. 4 Ensure that the floor level should be strong and flat
even surface using spirit level.
1 Ensure that the location has sufficient air ventilation.
2 Ensure that electrical power point available near the
unit.

161
TASK 3: Position the refrigerator unit.

1 Place the unit on the selected location. 3 Keep one foot or more space between the wall surface
and both sides of the unit, if the condenser is built in
2 Keep one foot or more space between the wall surface (Internal type)
and rear side of the unit, if condenser is in back side
(external type). 4 Keep sufficient space in front side for opening the
door fully.

TASK 4: Test the electrical power supply.

1 Test the availability of electrical power using online 3 Ensure the rated/measured voltage is in operating
tester by inserting its tips into the socket range of compressor of the unit (180-260 volts).

2 Measure the voltage rate using a multimeter/ tong 4 Use voltage stabilizer if the voltage is out of range or
tester/voltmeter by inserting the probes (phase and fluctuating.
neutral) into the socket. 5 Ensure proper earthing is made in the socket.

TASK 5: Connect voltage stabilizer.

4 Insert the 3 pin plug of the stabiliser into the socket.

Note : It is always advisable use voltage
stabilizer (correct capacity) not only in the 5 Switch ‘ON’ the socket
places of low voltage or fluctuating. Use it
6 Ensure the LED bulb (for MAIN ON) glows (If provided)
everywhere with every units to save the
compressor from sudden voltage fluctuations 7 Observe the voltage limits of input and output by
and maintain constant voltage to the pressing the selector switch.
compressor.
Note: Normally the voltage stabilizers for
1 Unpack the voltage stabilizer refrigerators/air conditioners are available with
time delay (3 min) start. So the output voltage
2 Notice the outer surface of stabilizer for any defects
may come after 3 minutes from the time it is
like sheetmetal bulge, scratches etc.
switched ‘ON’.
3 Make sure that the pointer of the voltmeter of stabilizer
at ‘0’ reading only or make sure the voltmeter has no
error.

TASK 6: Start the refrigerator unit.

1. Open the door(s) of the unit and see the internal 5 Switch ON the stabilizer.
conditions. It must be clean and dry.
6 Wait for 3 min to start the unit, if the stabilizer has time
2 Keep the door open for 2 minutes for replacing existing delay facility.
cabinet air with ambient air. Then close the door (S).
7 Observe the refrigerator gets ON by hearing mild
3 Make sure that the stabilizer is ‘OFF’ position noise (30-35 db) due to compressor is started.
4 Insert the 3 pin plug of refrigerator unit into the output
socket.

TASK 7: Test the performance of the unit.

1 Ensure that the door(s) of the unit closing well 4 Observe the ‘bulb/light in the cabinet glows during the
door kept open.
2 Make shelves in the cabinet with the materials which
are given separately or along inside of the unit. 5 Set the thermostat knob to Normal position (between
low cool and high cool position) by turning it clockwise/
3 Fill water (at normal room temperature) in the ice tray anticlockwise direction as required.
which will be in freezer section.
6 For Conventional(ordinary) Refrigerator feel the
chillness by keeping the hands over inner surface of
the freezer.

162 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.58
 For Frost Free Refrigerators feel the chillness by 9 Open the refrigerator door and observe the cooling in
keeping the hands before the air breeze at the fan the cabinet by feeling.
motor which is in the freezer.
10 Open the freezer door and ensure that the water
7 Put the sensing probe (of digital thermostat) inside the which is filled earlier (2 hours before) is became ice.
freezer and start watching the reading in the display
11 Set the thermostat knob to ‘low ‘ position.
(outside).
12 Keep the door closed and wait for some more time
8 Keep the freezer door and cabinet door(s) closed for
(30 min).
some time (2 hours). Let the unit to run without any
interruption for 2 hours. 13 Observe the unit(compressor) trips.
14 Fill up the check list as per the contents.

Installation - Check list

Date :
Type of refrigerator : Direct cooled / Frost free
Capacity : Lts
Brand name :

1 Unit found in good physical condition OK 6 Unit input voltage OK ............... volts

2 Unit location OK 7 Stabiliser output OK ............... volts

3 Unit standing floor level OK 8 Cooling satisfactory ............... degree Centigrade

(Temperature at evaporator)
4 Electrical plug point OK
9 Thermostat functioning OK
5 Current consumption ...............Amps

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.58 163
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.59

Identify electrical components of direct cool refrigerator

Refer Exercise 1.6.54 - TASK 1

Capital Goods and Manufacturing

R&ACT - Refrigerator (Direct Cool) Exercise 1.6.60

Identify mechanical components of direct cool refrigerator

Refer Exercise 1.6.54 - TASK 2

Capital Goods and Manufacturing

R&ACT - Refrigerator (Direct Cool) Exercise 1.6.61

Installation of refrigerator

Refer Exercise 1.6.58

164
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.62

Checking alignment of door and replacing door gaskets

Objectives: After completion of this exercise you shall be able to
• check the refrigerator door sealing.
• adjust the door gasket sealing and the twisted door.
• remove the defective gasket and replace it.
• adjust the dropped door and align the door assembly.
• check the compact close of the door gasket.

Requirements
Tools
• Pencil - 1 No.
• Adjustable wrench length 150mm - 1 No.
• Scissor - 1 No. Materials
• Gasket cutting steel width 25mm - 1 No. • Clean cloth - as reqd
• Philips screw driver set - 1 No. • Friction tape or sticking plaster - as reqd
• Double end spanner set - 1 No. • Self threading screws as per requirement - as reqd
• Steel tape measuring 2 m graduation - 1 No.
• Plastic feeler gauge 0.4mm - 1 No. Equipment
OR • Refrigerator with defective door,
• Thin plastic paper strip - 1 No. alignment and gasket - 1 No.

PROCEDURE:

TASK 1: Check the refrigerator door sealing

1 Stop the refrigerator, remove the plug, unload all the
food products and other things inside the refrigerator.
2 Open the door, place the plastic feeler gauge of 0.5
mm or thin paper strip against the cabinet front and
close the door.
3 Pull the strip, if it moves easily or fall on its own,
assure that gasket has gone perish. It has to be adjust
for proper sealing. (Refer Fig 1A & B)
4 Check all the way around the door especially by the
corners of the door, and mark the places with pencil.

TASK 2: Adjust the door gasket sealing and the twisted door

1 Wherever you find the sealing was leak, fold a paper 5 Keep the door open slightly and try to twist the door to
into thin strip and place it. the opposite direction as shown in the picture. (Ref.Fig
2 If not use the sticking plaster or friction tape, according 3)
to the length and thickness you need, in between the 6 Carefully twist and do not give much strain, bring back
gasket and the inner door. to correct position.
3 Always push the paper strip right - inside the gasket 7 Keep the door in position,then tighten the screws
gap, not to be visible outside. (Refer Fig 2) behind the door assembly.
4 Slightly loosen the screws behind the door assembly 8 Close the door and check the door is seating well.
to attempt, to straighten the door.
165
TASK 3: Remove the defective gasket and replace a new one.
1 Check that the size of he replacement gasket is right. 4 Replace the gasket in position, if the old screws are
rusty, change to new screws, match to the same and
2 Check the previous (old) gasket is fastened by screws tighten it.
or snapped into the groove.
5 The gasket which is snapped into the groove use the
3 If the gasket is tightened by screws, start remove the screw drivers carefully pull out the old gasket (See
screws in the upper half of the door, since it will be in Fig 2).
order, to remove the gasket easy.
6 Clean the groove and set and press the new gasket
to fit in correct.

TASK 4: Adjust the dropped door and align the door assembly.
1 Loosen the upper hinge screw.
2 Lift and adjust, make sure the edge of the door is in
line with the side of the refrigerator.
3 Hold the door in position and tighten the hinge screws.
4 If the lower hinge is worn, put some washers on the
hinge to adjust the height to level (Refer Fig 4) and
tight it.

TASK 5: Check the compact close of the door

1 Close the door with little force and check if the door 3 Follow the procedure of Task 1 to check the compact
is pulled by the magnetic gasket. close of the door.
2 Adjust the bottom level screws and make the door
close automatically when you open and leave the
door up to 800 angle

166 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.62
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.63

Tracing the mechanical components of refrigerator

Objectives: At the end of this exercise you shall be able to
• trace the mechanical components one by one
• list the mechanical components and enter in the table.

Requirements
Tools / Instruments Equipments
• Screw driver 200mm - 1 No. • Refrigerator
• Line tester 0-500 volts - 1 No.
Materials
• Cotton waste/ cloth

PROCEDURE
TASK 1: Trace the mechanical components of Refrigerator one by one. (Refer Figures in Exercise 1.4.54)

1 Prepare table for manufacturer specification on Table1. Table 1

2 Switch ‘OFF’ the mains, and remove plug.
SI.NO INFORMATION SPECIFICATION
3 Trace the compressor and observe its location.
1 Model
4 Check the mechanical connections to compressor.
2 Product code
5 Trace the condenser and observe its construction
and location. 3 Power supply
6 Check the connection to condenser. 4 Cooling Capacity
7 Trace the Filter/Drier and observe its location and its
5 Power Input
connections.
8 Trace the Capillary and observe its location and its 6 Current
connections. 7 Refrigerant
9 Trace the Accumulator and Evaporator and observe
their location. 10 Check the connection of Accumulator and Evaporator.

TASK 2: List the mechanical components and enter in the table

1 Draw a neat sketch of mechanical arrangement/

construction of parts and table the parts.
2 Table-2.
Table 2

S.No Name the mechanical part Location of the

part

167
Capital Goods and Manufacturing
R&ACT - Refrigerator (Direct Cool) Exercise 1.6.64

Tracing the electrical components of refrigerator

Objectives: At the end of this exercise you shall be able to
• remove Electrical wiring and components from given direct cooled refrigerator.
• test the components and wiring with multimeter
• refix the components and wiring after test with multimeter.

Requirements
Tools/Instrument • Knife - 1 No.
• Trainee kit - 1 No. Materials & component
• Cutting player - 1 No. • 3 core wire 2 mt. with 3 pin top - 1 No.
• Screw drivers - 1 No. • Cotton waste - as reqd.
• Tong tester - 1 No.
• Multimeter - 1 No. Equipments
• Soldering stick and wire lead - as reqd. • Defective conventional refrigerator - 1 No.
• Insulation tape - 1 No.

PROCEDURE

TASK 1: Disconnect (power) main wire from switch box after switch off.

1 Remove compressor terminal clip. Remove relay 3 Remove thermostat switch by unscrew the mounting
from relay box. (compressor) screws and sensing bulb.
2 After marking all wires remove the relay wire from 4 Remove cabinet light switch and light holder by
relay. If wires are soldered, desolder the wires and unscrewing.
remove it. 5 Remove junction box and wire connection after
marking all wires.

TASK 2: Testing components and wiring with multimeter

1 Fix multimeter black lead probe at –ve point of relay compressor (S) terminal meter will not show
multimeter and red probe at +ve point of multimeter. continuity. Turn relay upto down without removing test
Touch both lead and check meter. Needle show - lead. Meter will show continuity. So relay starting contact
continuity. OK.
2 Test compressor terminal. Touch compressor top pin Compressor (C) terminal meter will show continuity so
(C) common at terminal with black lead, the meter relay is OK. Refer (Fig 1)
other red lead. Touch with (R) pin of compressor
meter needle show ohm (continuity).
3 Testing relay
Two types of relay are used in refrigerator.
1 Box type relay
2 Kellick son type relay
1 Box type relay testing
Fix multimeter lead in - and + point black and red wire.
Clip black wire with relay terminal and red wire with relay
compressor terminal. Pin top (R) meter will show
continuity, without removing black lead touch red lead on

168
Kellickson relay also to be checked like this method. match stick. There by the meter will cut and OLP will trip.
(Ref.Fig 2). This is heat test. Connect multimeter wire black and red
with OLP. The meter will give continuity (note).
2 Kellickson Type Relay testing
3 OLP mechanical and electrical load test.
This type relay overload protector will come separate
with common terminal. Fix multimeter wires in meter - Connect OLP with some excess load. Connect ammeter
and + points. in series with motor.
Relay (R) terminal and (S) terminal come with relay coil Apply load (switch on motor) when motor draw more
(Ref.Fig 2). Fix meter black wire with relay terminal and amps than recommended by manufacturer, the OLP will
red wire with relay compressor (R). Terminal meter will trip and stop motor after 2 minutes. OLP disc get cooled
give continuity. again, motor start and trip and OLP is in good condition.
4 Checking thermostat switch with multimeter.
Connect multimeter with black in negative point and red
wire in positive point. Connect the meter to the thermostat.
Turn thermostat knob to anticlockwise. Switch will be off
and meter cuts continuity. Turn the knob to clockwise
then the switch will get on and meter will show continuity.
Turn the thermostat knob clockwise and switch on. Turn
anticlockwise and the switch will off.
Without removing meter wire, take one glass jar full of ice
and dip the thermal bulb of the thermostat switch. Sensor
bulb in that ice jar the bellows in the thermostat switch sink
and open switch continuity. When removing sensor bulb
from the jar the switch bellows expand and switch get
contact. Say the switch is in working condition.
Checking light switch and light
Without removing relay terminal only red wire fix with Connect the multimeter terminal for continuity in the light
relay starting terminal. There will be no continuity and switch.
without removing meter both wire turn relay upto down.
Touch both wires with refrigerator light switch terminal.
Now meter will show continuity. Say relay OK.
The meter will glow and shows continuity. Press switch
Checking OLP in two method. button and meter will not show continuity. Switch (off) so
light switch is OK.
1 By heat
When the light switch is not in pressing condition, the
2 By load
meter will show the continuity. Check bulb also by touching
OLP is always ON. If the compressor body gets over meter both lead on bulb - point, meter will show continuity.
heat, the OLP will trip if the body is heated by lighting Say bulb is OK.

TASK 3: Check junction and main wire by multimeter continuity testing method.

Refit components and wiring after testing with multimeter. Fix relay in compressor terminal box and clamp it.
Connect thermostat, light switch and locate sensing bulb Complete the wiring connection of refrigerator. See (Fig3).
with its clamp. Fix back junction box with removed
screws.
Fix light switch at removed place and connect to cabinet
bulb in the holder.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.64 169
170 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.64
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.65

Testing of compressor
Objectives: At the end of this exercise you shall be able to
• check compressor (Hermetic) pumping efficiency
• check compressor winding.

Requirements
Tools/Instruments Equipments
• Gauge manifold - 1 No. • Nitrogen dry cylinder - 1 No.
• Charging line - 1 No. • Hermetic compressor - 1 No.
• Ratchet wrench - 1 No. Materials/components
• Adjustment wrench - 1 No.
• Multimeter - 1 No. • Soap solution and brush - 1 No.
• Insulator plier - 1 No. • Clean cloth - 1 No.
• Line tester - 1 No. • Test board - 1 No.
• Condenser unit - 1 No.

PROCEDURE

TASK 1: Check compressor (Hermetic) pumping efficiency.

1 Connect the refrigerant cylinder to the process tube of 5 Start the compressor and run for few seconds to build
hermetic compressor using a pressure regulator as a head pressure of valve as given below. On attaining
per (Fig 1). the specified discharge pressure, stop the compressor
as table column given below.
6 Check for drop in pressure for a period of one minute
and verify whether it falls within specified limit in the
Table 1.
7 In case the drop exceeds the specified limit, the
compressor has a pumping defect otherwise the
compressor is perfectly okay.
Table 1
S.No. Leak rate in Head pressure
1st minute kg/cm2
2 Connect the discharge side of the compressor to a per min.kg/cm2
condenser coil having appropriate capacity. Now
connect the other end of the condenser coil to a 1 2.0 kg/cm2 8.5 kg/cm2
pressure gauge having a range of 0 to 20.5 kg/cm2.
2 2.5 kg/cm2 10.0 kg/cm2
3 Check for leakages at all joints using soap solution
4 Supply refrigerant vapour gas at a constant pressure 3 4.0 kg/cm2 13.5 kg/cm2
of 150 PSI in the process tube of the compressor.

TASK 2 : Check hermetic compressor winding by multimeter. (Fig 2&3)

Note : Always ensure that the compressor is in 2 Remove the wire clips from the terminal.
constant temperature (room temperature) 3 Use multimeter and set knob to resistance.
before checking
4 Two leads from the multimeter touch one in the ‘C’
1 Remove the terminal cover from the compressor other lead to be touched into ‘R’. The reading in the
terminal box. meter is 1 ohm.

171
5 Take a meter lead from ‘R’ and touch into ‘S’ the
reading shows 4 ohms.
6 Remove the meter lead from the ‘C’ and touch it in the
‘R’ and take reading in meter. It shows 5 ohms.
7 Like that resistance and continuity of the winding can
be checked.
S.No. Terminal connection Value reading
8 Record the observation about terminals of the
compressor. 1 C to R 1 ohms
2 C to S 4 ohms
3 S to R 5 ohms

TASK 3: Check short circuit grounded in compressor (Fig 4)

1 Select ohmmeter scale(R x 10000) as given for.

2 Place ‘A’ probe to compressor terminal.
3 Place ‘B’ probe to metal casing (must be against clean
metal).
4 Check continuity. If continuity is there compressor
grounded.
5 If there is no continuity compressor winding is ok.

172 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.65
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.66

Identification of compressor motor terminals

Objectives: At the end of this exercise you shall be able to
• identify compressor terminals by using ohmmeter
• identify compressor terminals by using test lamps
• identification of compressor winding.

Requirements

Tools/Instruments • Combination plier (insulated handle) - 1 No.

• Screw driver 200mm - 1 No. Equipments
• Line tester 0-500 volts - 1 No.
• Single phase induction motor
• Multi meter/ohm meter 0-250 ohms - 1 No.
• Series holders with 200 watts lamps - 1 No. Materials/components
• Loose wire - 1 No.
• Cotton waste/ cloth
• Soldering iron 35 watts - 1 No.
• Soft solder paste

PROCEDURE

TASK 1: Identify compressor motor terminals using ohmmeter.

4 Measure the pair of terminals resistance by ohm

meter.
- Running &starting MAXIMUM RESISTANCE
- Identifed remaining terminals is common
- Running& common MINIMUM RESISTANCE
- Identifed remaining terminals is starting

1 Remove the terminal box.

2 Remove the terminal clips.
3 Mark the terminals like XYZ or ABC or 1,2,3.

TASK 2: Identify compressor motor terminals using test lamps.

2 Mark the terminal XYZ.

Running & starting minimum light.
Identified remaining terminals is common
Running & common maximum light
Identified remaining terminals is starting
XY+ XZ = YZ Ω
Good winding resistance shows the above results.
1 Test & measure the pair of terminals.(x,y,xz abd yz)
1 By testing 200 watts series lamp in between pair of
2 They indicates different Ω
terminals.

173
TASK 3: Identification of compressor winding.

Terminals pins with Ohm meter of fraction horse power 4 Measure the resistance between A & B (40 Ohms)
compressor.
5 Record in the record sheet table.
Before carrying out the exercise remember the
6 Measure the resistance between C & B (60 Ohms)
following
7 Record in the record sheet.
- Running winding resistance always less than
starting winding 8 Identified ‘A’ terminal pin become common terminal.
- Starting winding resistance always higher than 9 Identified ‘B’ terminal pin become starting winding.
running winding 10 Identifed ‘C’ terminal pin run winding.
- Resistance of run and starting winding sum of
starting winding resistance and running winding Resistance value slightly vary from
resistance. manufacture to manufacturer. Instructor must
have compressor Manufacturer specification.
1 Set the ohm meter.
2 Measure the resistance between A and C (20 Ohms)
3 Record in the record sheet Table 1

S.No. Terminal connection Value reading

1 A and C .......
2 A and B .......
3 C and B .......

174 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.66
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.67

Start compressor with and without relay

Objectives: At the end of this exercise you shall be able to
• start the compressor with relay
• start the compressor without relay.

Requirements
Tools/Instruments Materials/components
• Cutting plier 150mm - 1 No. • Compressor(Hermetic) FHP - 1 No.
• Nose plier 150mm - 1 No. • Terminals clips - 2 Dozen.
• Wire stripper - 1 No. • Copper wire 1.5mm2 - 4 meter.
• Screw driver set - 1 No. • Relay PTCR with OLP - 1 No.
• Line tester 500V - 1 No. • Push buttom switch - 1 No.
• Clamp meter,0-500V AC - 1 No.
• Multimeter -0-500V - 1 No.

PROCEDURE

TASK 1: Start the Compressor with relay

1 Take the 1/6 or 1/8 HP sealed compressor.

2 Fix the PTCR relay & OLP to the compressor terminals.
3 Provide power supply to the relay (230V AC).
4 Switch on the supply & start the compressor.
5 Check the current drawn by compressor
6 Check the suction & discharge pressure by manual
sensing.
7 Switch off the power supply after testing over.

TASK 2: Start Compressor without relay

1 Take the 04 Nos of 1 meter length different colour wire

pieces
2 Skin the wire at one ends fix the clips.
3 Connect the Red wire into compressor 'R' terminals
series with the Ammeter.
4 Connect the Black wire into 'C' terminals.
5 Connect Blue wire to 'S' terminal through push bottom
switch.
6 Provide earthling for the compressor with green wire
7 Fix spin plug to Red, Black & Green wire 10 Release the push bottom switch and see the counted
induced (running)
8 Press the push bottom switch
11 Check the compressor working suction & Discharge.
9 Switch on the power supply and
12 Switch off & remove wire after test is over.

175
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.68

Testing the performance of refrigerator

Objectives: At the end of this exercise you shall be able to
• start the refrigerator unit
• test the performance.

Requirement
Tools/Equipment Equipment
• Thermometer (stem/digital type) • Domestic refrigerator( frost free) - 1 No.
- 5 to +50°C - 1 No. Materials
• Clean cloth/ sponge - 1 piece.

PROCEDURE

TASK 1: Start the refrigerator unit.

1 Open the door(s) of the unit and see the internal 5 Switch ON the stabilizer.
conditions. It must be clean and dry.
6 Wait for 3 min to start the unit, if the stabilizer has time
2 Keep the door open for 2 minutes for replacing existing delay facility.
cabinet air with ambient air. Then close the door(S)
7 Observe the refrigerator gets ON by hearing mild
3 Make sure that the stabilizer is ‘OFF’ position. noise (30-35 db) due to compressor is started.
4 Insert the 3 pin plug of refrigerator unit into the output 8 Check the voltage & current drawn by the compressor.
socket.
9 Check the suction & Discharge temp by physical
sensation.

TASK 2 : Test the performance of the unit.

1 Ensure that the door(s) of the unit closing well. 6 Check and record the Ice formation time.
2 Fill water (at normal room temperature) in the ice tray 7 Check and note the Compressor ‘Cut off’ time &
which will be in freezer section. temperature.
3 Allow the Refrigerator to run. 8 Check the compressor ‘Cut in’ temperature & time.
4 Insert the thermometer in the Cabinet & freezer 9 Refrigerator cabinet temperature should between 2
compartment. to 4°C
5 Check the temperature decreasing rate. 10 Check the Ice formation in the tray.

176
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.69

Clean and flush for contamination in condenser coil, evaporator coil in

conventional refrigerator
Objectives: At the end of this exercise you shall be able to
• strip out the components from conventional refrigerator
• clean and flush condenser coil with dry nitrogen
• clean and flush condenser and evaporator coil with trichloroethylene
• dry the condenser coil with hot air gun.

Requirements
Tools/Instruments Equipments
• Charging hose - 1 No. • Gas welding set - 1 No.
• Flaring block & yoke 4.7mm to 16mm - 1 set • Nitrogen regulator 2 stage
• Flaring block and swage punch - 1 No. with hand shut off valve - 1 No.
4.7mm to 16mm OD - 1 No.
• Hammer ball peen 220gms - 1 No. Materials
• Measuring tape - 2 mts - 1 No. • 6.0 mm flare nut - 2 Nos.
• Tube cutter 3mm to 16mm dia - 1 No. • 6.0 mm straight union - 2 Nos.
• Spanner double end 4.7 to 16mm - 1 No. • Dry nitrogen cylinder - 1 No.
cutting plier 200mm - 1 set • Hose clamp - 2 Nos.
• Nose plier 150mm - 1 No. • Silver rod - 1 No.
• Screw driver 10mm tip 200 mm length - 1 No. • Copper rod - 1 No.
• Screw driver 3mm tip 150mm - 1 No. • 6.0 mm copper tube - 2"
• Goggles, spark lighter - 1 set • Silver flux - 1 pocket (50 gms)
• Hot air gun - 1 No. • Static evaporator coil - 1 No.
• Line tester 500V heavy duty - 1 No. • Static condenser coil - 1 No.
• Power cord wire extension box - 1 No. • Small mirror - 1 No.
• 6.0 mm PVC hose (transparent) - 2 mts

TASK 1: Strip out evaporator coil and condenser coil from the Refrigeration system for Internal cleaning in
conventional refrigerator

1 Disconnect the electrical power supply to the 12 Check the evaporator coil mounting arrangement
refrigerator (normally front portion mounted on two bolts, back
portion lock arrangements)
2 Remove the relay cover clip.
13 Remove the mounting bolt, unlock the evaporator.
3 Gently pull the relay from the compressor terminal.
14 Remove the thermostat bolts from the evaporator.
4 Keep away wire harness assembly from the torch
flame reach. 15 Gently pull the evaporator from the refrigerator.
5 Recover the refrigerant in service cylinder. 16 De-braze the suction line from the evaporator outlet,
and debraze capillary tube from the inlet of the
6 Allow 5 minutes to escape all the refrigerant gas from
evaporator coil.
the surrounding if any.
17 Before debraze suction line and capillary tube from
7 Flame the torch and adjust to neutral flame.
the evaporator, keep wet cloth on evaporator copper
8 De-braze suction line, capillary tube from the outlet aluminium joints.
drier.
18 Now the evaporator coil, condenser coil is ready for
9 Unscrew the condenser coil mounting bracket. internal cleaning.
10 Separate the condenser coil from the refrigerator.
11 Remove the door by unscrewing top hinge to enable
to pull the evaporator coil from inside.

177
TASK 2: Clean and flush condenser coil with nitrogen.

1 Clean the condenser external surface with wire brush 12 Connect the other end of charging hose to the straight
union in the condenser coil
2 Cut 150mm length 6.0 mm tube for the coil.
13 Unscrew the dry nitrogen cylinder regulator valve
3 Insert 6.0mm flare nut at one end of the 150 mm stem and keep the hand shut off valve open
copper tube and make 6.0 mm flare with help of flaring
block and yoke 14 Crack the nitrogen cylinder valve (anti clock wise)
stem with the help of cylinder key
4 Swage other end to suit 6.0 mm Bundy tube with help
of flaring block and swage punch. 15 Check the cylinder pressure in the cylinder pressure

5 Insert swaged tube to Bundy tube of condenser 16 Slowly turn clockwise regulator spindle and maintain
coil. (Fig 1) 7.0 kg/cm2 outflow with the help of testing pressure
gauge
6 Braze the joints (Bundy tube & copper tube) with silver
rod use suitable flux. 17 Hold your hand on condenser outlet as shown in
(Fig1).
7 Ensure the joint properly fitted with silver rod
18 Close the outlet mouth for few seconds with your
8 Check with small mirror, opposite side are also covered finger than leave your finger
properly
19 Repeat the above procedure till (Max.5 min) all the
9 Connect 6 mm straight union in the flare nut contamination come out.
10 Check charging hose, ensure rubber bushes are After flushing cap the end of the condenser coil. Now
there in both end. the coils is ready for assembling.
11 Connect one end of charging line to dry nitrogen 20 Still contamination present. Condenser coil requires
cylinder and hand shutoff by tightening clockwise cleaning with trichloride ethylene.

178 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.69
TASK 3: Clean and flush evaporator with dry nitrogen, (follow the same steps as done in condenser)

Note : In conventional refrigerator we are using (0.031") small bore capillary tube of single feeding
contamination in capillary tube. Cleaning is very difficult. So it is not advisable to clean the capillary.
Advised to replace the capillary tube. In refrigerator capillary tube soldered along with the suction line.
So capillary tube alone cannot be replaced. Advised to replace capillary tube along with suction line.

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.69 179
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.70

Replacement of capillary tube and drier

Objectives: At the end of this exercise you shall be able to
• flush the capillary tube
• braze capillary in position
• find out the filter-drier is clogged.

Requirements
Tools/Instruments Equipment
• Cylinder valve key - 1 No. • Gas welding set - 1 No.
• Double end spanner - 1 set. • Fridge - 1 No.
• Needle file set - 1 No. • Capillary tube - 1 No.
• Tube cutter - 1 No. Length and dia as old - as reqd.
• 6" sharp knife - 1 No. • Filter drier - 1 No.
• Leather gloves - 1 No.
Materials
• Goggles - 1 No.
• Safety shoes - 1 Set. • Banian cloth

PROCEDURE

TASK 1: Flush the capillary tube

1 Flush capillary tube as shown in (Fig 1). 7 At the end of the capillary place a piece of white cloth
and check for colour change. If there is no colour
2 Connect the capillary tube to the dry nitrogen cylinder change that indicates that the line has been flushed.
3 Open the cylinder valve with the cylinder key Otherwise repeat the flushing till the colour changes
to white in the cloth.
4 Tighten pressure regulator so that the test pressure
gauge reads 17 Kg/cm2. 8 Close the nitrogen cylinder and disconnect the capillary
assembly from the flushing line.
5 Open hand valve fast and close. Repeat several
times. 9 Cut the 6 mm copper tube and swage,clean and keep
ready for brazing.
6 Then keep valve opened for 3 min continuous.
10 Flush evaporator and condenser with dry nitrogen.

180
TASK 2: Braze the capillary tube assembly in position.

1 Place a metal sheet between the cabinet and liquid

line as shown in (Fig 2).
2 Braze the filter entry to the condenser outlet from the
area where the old filter was removed. Note the arrow
mark on the filter drier.
3 Install the capillary tube carefully touch it to the
suction pipe use brazing torch with low flame and
solder the capillary to the suction pipe.
4 Then braze the other end of the capillary.
5 Ensure that the cloth pieces of the pipes are removed.
6 Fig 3a. A shows the correct position of the capillary Small circulating particles will be guided directly
in the strainer. However positioning as shown in Fig towards the capillary tube and the probability of
3b may bring about various problems during operation. observation is thus increased.

TASK 3: Find out if the dehydrator (filter drier) is clogged

1 Start the refrigerator. Run for one hour 3 If there is sweating in the evaporator then check the
filter drier by hand
2 Check the evaporator for cooling. There should be
snow formation in the evaporator. 4 If the filter drier is cool then indicate that the dehydrator
(filter drier) is clogged.

TASK 4: Replacement of dehydrator (filter drier).

1 Cut charging line release gas wear goggles and
ensure proper ventilation around working place.
2 Carry out debasing procedure as explained in previous
exercises.
3 Select the new dehydrator (filter drier) to correct size
compare with removed one.
4 Select new capillary size of old cut capillary.
5 Braze the capillary to filter drier (dehydrator).
6 Flush the dehydrator (filter drier) and capillary.
7 Flush evaporator and condenser . 9 Carry out leak test as explained in next exercise.
8 Braze the dehydrator (filter drier) inlet to condenser 10 Evacuate the system.
outlet and capillary outlet to evaporator inlet as shown
in (Fig 4).

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.70 181
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.71

Install gauge manifold in the system

Objectives : At the end of this exercise you shall be able to
• identify the parts of the gauge manifold
• how to use the hand valves of a gauge manifold for various service operations
• connecting the charging cylinder to gauge manifold.

Requirements
Tools/Instruments
• Gauge manifold -1 no.
• Flexible charging hose -3 nos.
shut off valve
• Sight glass 6 mm

PROCEDURE

TASK 1: Identify the parts of the gauge manifold.

1 Identify the names of labelled parts and use of a turned all the way in, high (condensing) pressure can
gauge manifold. be checked.
2 Record in table 1 of record sheet 4 When both valves are open (turned out by twisting to
3 This gauge manifold shows hand valves, gauges and the left) high pressure vapour will flow into low side.
refrigerant openings. Gauges will always show a When only low pressure valve is open, one can
pressure reading. When low pressure hand valve is charge the system or evacuate it, put oil in system or
turned all the way in, the low evaporator pressure can clean it.
be checked. When high pressure hand valve is

TASK 2: Use the hand valves of a gauge manifold for various service operations.

1 (Fig 1) For reading gauge pressures only.

2 (Fig 2) Gauges show pressure low side is now open
to centre opening. (For charging 1, evacuating 2 etc.)

3 (Fig 3) Gauges show pressure high side is open to

centre opening for purging 1 for pressure testing 2
4 (Fig 4) Gauges show pressure both valves are open
middle openings in cap high side pressure travels into
low side 1.

182
 5 (Fig 5 & Fig 6) Gauges show pressure both valves are
open. Refrigerant gas is going from centre opening to
both high side and low side.

TASK 3: Connect the charging cylinder to gauge manifold. (Fig 7)

Table 1
1 Identify the names of labelled parts of charging
manifold. SI.No Name of the parts
1
2 Enter in record sheet. (Table 1)
2
3
4
5
6
7

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.6.71 183
Capital Goods and Manufacturing
R&ACT - Refrigeration (Direct Cool) Exercise 1.6.72

Leak testing, evacuation and gas charging in refrigerator

Refer Exercise 1.6.56

Capital Goods and Manufacturing

R&ACT - Refrigeration (Direct Cool) Exercise 1.6.73

Check electrical wiring of refrigerator

Refer Exercise 1.6.57

184
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigeration Inverter Refrigeration Exercise 1.7.74

Trace the electrical circuit and check frost free refrigerator

Objectives: At the end of this exercise you shall be able to
• dismantle all part of electrical system and wire in frost free refrigerator.
• check all electrical part removed from frost free refrigerator.
• fix back all electrical parts after check with multimeter.
• testing frost free refrigerator after fixing.

Requirement
Tools / Instrument Equipment
• Trainee’s kit - 1 No. • Defective frost free refrigerator - 1 No.
• Multimeter - 1 No.
Materials and components:
• Cutting player - 1 No.
• Screw driver - 1 No. • Insulation tape - 1 roll.
• Test lamp - 1 No. • Multicore wire - 3 mtr
• Volt and amp meter - 1 No. • Wire clip - 12 Nos.
• Knife - 1 No. • Cotton waste - as reqd.

PROCEDURE:

TASK 1 : Trace the electrical circuit

185
TASK 2: Dismantling of all parts (electrical) in frost free refrigerator

1 Switch off refrigerator power and remove 3 pin top

from switch board.
2 Remove compressor relay clip and relay.
3 Note down the colour of the wire while removing.
4 Remove relay wire and junction wire.
5 Remove thermostat switch by unscrewing.
6 Remove freezer fan motor by unscrewing the fan
blade.
7 Remove light switch and light holder and bulbs. 8 Remove timer switch and strip heater wire only.

TASK 3: Checking all electrical parts removed from frost free refrigerator by multimeter.

1 Connect the multimeter to the compressor terminal 5 Check thermostat switch.

and check for the continuity.
6 Check the cooling coil fan motor (Fig 2)
2 Connect black lead to compressor top terminal (c),
and red lead of meter unit to compressor (R) terminal 7 Check the timer.
the meter shows ohms. Then without removing black 8 Check the bimetal heater.
lead touch red wire to compressor (S) terminal, now
you will get starting winding ohms. Without removing Check fan motor bush bearing by shaking up
black lead, touch red wire to compressor body, if you and down.
get ohms, then compressor motor get burnt out
otherwise winding OK in normal condition. Check fan motor winding with multimeter if
get ohms (continuity) motor winding is normal,
3 Check relay. otherwise winding burnt out.
4 Check light holders and light switch.

186 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.7.74
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.75

Checking fault finding and testing of electrical components in frost free

refrigerator
Objectives: At the end of this exercise you shall be able to
• check and test timer
• check and test bimetal thermo
• check and test defrost heater
• check and test PTC relay
• test overload protector
• check and test fan motor.

Requirement
Tools/Instrument Materials
• Multimeter analog type - 1 No. • 5 mts./1 sq.mm multistrand wire
• Line tester 500V - 1 No. • Bulb holder - 1 No.
• Cutting plier length 200mm - 1 No. • Electrical test board - 1 No.
• Nose plier length 150mm - 1 No. • Dry ice - as required.
• Phillips Screw driver set - 1 No.
Equipments
• Frost free Refrigerator - 1 No.

PROCEDURE

TASK 1 : Check and test timer in Frost free refrigerator with test lamp, multimeter and power source

1 Prepare table for manufacturer specification on Table1.

RECORD SHEET
Table 1

S.No. Timer Specification

1. Model No. 3 Check the test lamp by touching Probe ‘A’ with Probe
‘B’. Bulb is glowing. Prepared test lamp is OK.
2. Serial No.
4 Check timer motor winder continuity between timer
3. Operating voltage
terminal 3 & 1. Touch ‘A’ probe in Timer Terminal 3,
4. Current B probe is Timer Terminal 1. If the bulb is glowing
timer motor continuity is OK. If the bulb is not glowing
5. Power consumption
timer motor is faulty. Refer Figs (3 & 4).
6. NC points
5 Check the continuity of NC ( Normally closed) point.
7. NO points Touch Probe A at point 3 in Timer. Touch Probe ‘B’ at
point 4 in Timer. If the bulb is glowing NC point is OK.
Refer Figs (3 & 4).
2 Prepare Test lamp as per diagram. Ref. (Figs 1 & 2).
6 Check the continuity of NO points (normally open).
Place the Probe A at Timer Terminal point 3. Place
Probe B at Timer terminal point 2. If the bulb is not
glowing NO point is OK. Refer Fig (3 & 4).

187
 8 Connect Timer to the power source as shown in the
(Fig 6). Mark the shaft position. Touch and feel
whether the motor is working. Allow 15 minutes time
to run the motor. After 15 minutes check the shaft
position. If shaft is moved from the Mark the timer is
OK.

7 Check Timer with multimeter. Set the knob at Ohms

measuring position. Place Probe A in Timer Point 3
and Probe B in Timer Point 1. If the needle of the
Multimeter deflected, Timer motor winding continuity
is OK. Check NC points for continuity. Check N.O.
points for no continuity. Refer Figs (3, 4 and 5).

TASK 2: Check and test bimetal thermo. (Fig 7)

1 Prepare test lamp. (Refer Fig 1 & 2 in TASK 1)

2 Check continuity between A & B of bimetal. If the bulb
is not glowing bimetal thermo OK.
3 Keep the bimetal thermo in dry ice of 5 minutes. After
5 minutes check continuity between A & B. If bulb is
glowing bimetal thermo is OK.

TASK 3: Check and test Defrost heater (Fig 8 & 9)

1 Prepare table for manufacturer specification 3 If the operating voltage is 220 V AC power supply
connect the power source as per diagram for 2
2 Check continuity with Multimeter point A and B. If the minutes and disconnect the power source. Touch
needle is defected continuity of heater is OK. Check your finger on the heater and observe heat. If heat is
the resistance of the heater and register in the Table. developed, heater is OK.

188 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.7.75
TASK 4: Check and test PTC relay (Fig 10 & 11)
1 Check continuity between C and A with multimeter. If 2 Connect the relay in the FHP compressor. Allow the
the needle deflected continuity is OK. A terminal compressor to run for 5 minutes. Disconnect the
connected with Main winding. B terminal connected power supply. Measure the resistance between C &
with starting winding. Check resistance between C B. Resistance approximately 30,000Ω.
and B. Resistance approximately 30Ω.

TASK 5: Check and test Overload protector (Fig 12)

Check continuity with test lamp between 1 and 2 and 3

also. If the bulb glow OLP is OK.

TASK 6: Check Evaporator Fan motor (Fig 13)

Check continuity of motor winding with test lamp. If the

bulb glows continuity is OK. Connect to the power
supply. Run the motor. If motor shaft run smoothly the
fan motor is working OK.

RECORD SHEET
TABLE 2

S.No. Defrost heater Specification

1. Make Very narrow winding wire used in timer and

evaporator fan. So that use low wattage bulb test
2. Operating voltage
lamp
3. Watts

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.7.75 189
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.76

Check air distribution system in frost free refrigerator

Objectives: On completion of this exercise you shall be able to
• check air flow in freezer compartment, fresh food compartment, meat keeper compartment (if provided)
• check the temperature (by remote sensing bulb thermometer) in freezer compartment, fresh food compart-
ment and meat-keeper compartment.
• check frost accumulation in freezer compartments.

Requirements
Instruments and tools Equipments
• Thermometer with remote bulb • Domestic frost-free refrigerator single
sensor - 1 No. or double door - 1 No.
• Screw drivers (set) - 1 No.
Materials
• Allen key (set) (if necessary) - 1 No.
• 5 amps fuse wire and insulation tape - 1 No.

PROCEDURE

TASK 1: Check air flow in Freezer compartment, fresh food compartment, meat-keeper compartment (if
provided)
1 Start the refrigerator and ensure that the refrigerator
fully loaded with commodities both in fresh food
compartment and frozen food compartment.
2 Allow the refrigerator to run for at least for 2 hours
before carrying out the subsequent tasks.
3 By opening the door of the refrigerator, remove the
door switch and short the terminal with 5 amps fuse
wire and insulate the open terminals of the door switch
with insulation tape and install back door switch in its
original place from where it is removed. Now the
evaporator fan will run continuously even if the refrig-
erator kept open.
4 Now reach out your hand to evaporator fan outlet to
feel air flow in the freezer compartment of fresh food
compartment and make sure if evaporator fan is in
running condition (Refer Figs 1 & 2)

6 Examine whether the fan blade is fitted well with blade

set screws. If not tighten blade set screws and put
back the cover of Evaporator Fan Compartment using
short Screw-Drivers (Refer Fig 1)

Note: Refrigerator door switch terminals short

with 5 amps fuse wire be removed after pulling
out insulating tape and door switch to be fitted
5 While the refrigerator is still running but cannot able to back in its original place to avoid continuous
obtain required temperatures. Stop the unit and open running of fan blade even if the refrigerator
the cover of evaporator fan compartment by using door is open.
short screw drivers.

190
TASK 2: Check the temperature (by remote sensing bulb thermometer) in freezer compartment, fresh food
compartment and meat-keeper compartment.

1 By taking the remote sensor bulb of thermometer to 2 Also examine the dampers control air deflector to
the freezer compartment check the temperature and fresh food and compartment temperature control air
list the temperature in the Record Table I. Record duct to meat keeper and freezer compartment working
temperature from fresh food compartment and meat- properly.
keeper compartment also in the Record sheet.

TASK 3: Check if frost accumulated in freezer compartment and meat-keeper compartment, besides high humid
air flowing in fresh food compartment.

1 By inserting thin paper in between door gasket and 4 Observe the thermostat setting. It should trips to
gasket sealing area on the body of the refrigerator, normal cool position. If not remove thermostat and
while the refrigerator door still kept in closed position, replace it.
pull out papers to ascertain the sealing of gasket is
5 Check the condition of heaters time-delay switch. In
normal and if the paper inserted in between comes out
case of any defect in time-delay switch due to long
easily. Moisture from ambient enters the refrigerator
run, it stops heaters to run thereby allowing the frost
to get deposited as frost inside freezer cabinet.
to accumulate.
2 Change the door gasket to avoid leakage of moisture
6 Remove defective time delay switch and replace it
from ambient air to refrigerator compartments.
with new one.
3 Reset thermostat to normal cooler position from low
temperature setting and allow the refrigerator to run
further.

RECORD SHEET - I

Particulars Temperature Required Temperature Noted

Freezer compartment
Temperature 0°C (32°F)
Fresh food compartment
temperature 4°C (40°F)
Meat - Keaper compartment
(if provided) -1°C (30°F)

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.7.76 191
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigeration Inverter Refrigeration Exercise 1.7.77

Service components of frost free refrigerator

Objectives: At the end of this exercise you shall be able to
• service the condensing unit of the refrigerator
• service the evaporator cabin of the refrigerator
• service the inner and outer cabinet
• check the accessories and electrical contacts.

Requirements
Tools/Instruments Equipments
• Thermometer - 1 No. • Frost free refrigerator - 1 No.
• Tong tester - 1 No. • Air blower (small) - 1 No.
• Voltmeter - 1 No.
Materials/components
• Nylon brush - 1 No.
• Screw driver - 1 No. • Clean cloth - as reqd.
• Cutting plier - 1 No. • Mild detergent powder - as reqd.
• Oil can - 1 No. • Bucket water - as reqd.

PROCEDURE

TASK 1: Service the condensing unit of the refrigerator.

1 Stop the refrigerator, remove the plug from the socket

2 Remove the items kept inside the refrigerator and pull
the unit little forward
3 Unscrew the back cover and make the condensing
unit visible (Ref. Fig 1) for location of condensing unit)
4 Connect the air blower to the socket and blow the air
to the condenser fins. Clean the fins with nylon brush,
clean the compressor and remove the dust. Keep off
the blower
5 Wipe the compressor and condenser with dry cloth
6 Lubricate the fan motor and wipe, fan , motor and the
base of the condensing unit, then cover the back and
tighten the screws.

TASK 2 : Service the evaporator cabin of the refrigerator.

1 Open the top door of the cabin and wipe the freezer 3 Remove the evaporator fan grill. Wipe the fan and the
cabin with mild detergent solution wet cloth grill with dry cloth then fix the grill.
2 Again wipe it with clean water wet cloth, finally wipe it 4 Keep the top door open till the evaporator cabin
with dry cloth become dry then close it

192
TASK 3: Service the outer inner cabinet and door of the refrigerator.

1 Close the door slowly and check the door is pulled by 8 Lubricate the door hinges and latches by oil can. Then
the magnetic arrangement when the door reaches to settle the shelves to the proper place.
the nearest closing point
9 Clean the handle, lock, hinges, name plate with soft
2 Take 4 cm (breadth) x 10 cm (length) newspaper wet cloth, then wipe it with dry cloth.
place it as half portion is visible outside on the edge of
10 Check the thermostat temperature control knob and
the door and close it.
set it for normal or centre range for usual operation.
3 Now pull the paper and check if the paper is holed by
11 Finally after wiping the external area of the fridge
the gasket tight. Check all the surrounding of the door
apply little fridge wax polish and polish it till all the
gasket by this method.
sides shine with soft cloth
4 If certain place the gasket is not holding tight assume
12 Connect the plug and on the refrigerator switch. Open
there is a chance of cool air leak from inside
the door and check inner cabinet light is glowing and
5 Fold the newspaper neatly and insert in between the check for off-on by pushing the door switch and
gasket and the door inner wall. (Paper should not be leaving.
visible).
13 After 10 minutes check by touching the evaporator
6 Close and see if the door is shut firmly. When slowly plate and feel the chillness.
closing the door, if door is leaving gap, not in the
14 Now the refrigerator is ready and can load the food
magnetic reach means the fridge level as to be
stuffs and cool drinks etc. in proper racks.
balanced for automatic closing.
7 Adjust the bottom level screws and make the door to
close by balances automatically while you close the
door slowly even.

TASK 4: Test the operation of the refrigerator.

1 After checking of electrical and mechanical 5 Keep the sensing probe of digital thermometer inside
components, reassemble then test the performance the cabinet
of the unit.
6 Let the unit to run 2 hours without any interruption
2 Ensure that the door(s) of the unit is closed well, then
start the refrigerator. 7 After 2 hours open the freezer door and check the
water kept in the ice tray become solid ice.
3 Fill water in the ice tray and keep it in the freezer
components. 8 Find the temperature shown in digital thermometer
and compare with initial temperature.
4 Set the thermostat knob to normal position (medium
cool) 9 Check if the unit is running with normal

Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.7.77 193
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigeration Inverter Refrigeration Exercise 1.7.78

Testing performance of frost free refrigerator

Refer Exercise 1.6.68 TASK : 1 and TASK : 2

194
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.79

Identify three and four door no frost refrigerator

Objectives: At the end of this exercise you shall be able to
• identify three door refrigerator
• identify four door refrigerator
• distinguish between normal refrigerator and 3/4 door refrigerator.

Requirements
Tools/Instruments Materials/components
• Line tester - 1 No. • Clean cloth - 1
• Three door refrigerator - 1 No. piece.
• Four door refrigerator - 1 No.

PROCEDURE

TASK 1: Identify three door refrigerator:

1 Identify three door refrigerator and check its
Fig 1
construction and parts.
2 Lable the parts in Figure 1.

TASK 2: Identify four door refrigerator.

1 Identify four door refrigerator and check its construction

and parts. Fig 2

2 Lable the parts in Figure 2.

TASK 3: Distinguish between normal refrigerator and 3/4 door refrigerator.

1 Check the construction and design of the both

Note : Do not start the refrigerator without
refrigerators.
permission
2 Distinguish between the refrigerator and make a
Do not use cotton waste for cleaning.
note of it.

195
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.80

Stripping the components of Inverter refrigerator

Objectives: At the end of this exercise you shall be able to
• strip the electrical wiring and controls
• strip the Refrigeration system components.

Requirements
Tools/Instruments
• Piercing valve - 1 No. • Screw driver 3mm tip 150mm length - 1 No.
• Refrigerant exchaust pipe. - 1 set. • Safety goggles - 1 No.
• Gas welding set - 1 No. • Line tester 500V heavy duty - 1 No.
• Spanner (double ended)
Equipment
4.7mm to 16mm - 1 Set.
• Cutting plier 200mm - 1 No. • Inverter Refrigerator with defective
• Nose plier 150mm - 1 No. refrigerator system - 1 No
• Screw driver 6mm tip 200mm length - 1 No.

PROCEDURE

TASK 1: Strip the electrical wiring and controls

1 Disconnect the electrical power supply to the 4 Remove the main PCB& Inverter PCB from the unit
refrigerator. carefully.
2 Remove the relay cover clip & gently pull the wire from 5 Remove the connector on top of freezer door remove
terminals. the display panel.
3 Remove all the wires and semer placed on evaporator
coil.

TASK 2: Strip the Refrigeration system components

1 Connect piercing valve to service line. 7 Debraze suction line from the evaporator outlet and
capillary tube from the inlet of the evaporator coil.
2 Connect recovery unit to piercing valve if the system
is charged by HFC refrigerant and recover it in a Note : Before de brazing the suction line,
separate service cylinder. capillary tube from the evaporator keep wet
3 Connect refrigerant exhaust pipe to piercing valve cloth on evaporator copper aluminium joints.
and exhantat the room it is HC Refrigerant
8 Check the evaporator coil mounting arrangement
4 Allow 5 minutes to escape all the refrigerant gas from (normally front portion mounted on two bolts, back
the surrounding if any. portion lock arrangements)
5 Flame the torch and adjust to neutral flame. 9 Remove the mounting bolt,& unlock the evaporator.
6 Debraze suction line, Discharge line from compressor 10 Now the evaporator coil condenser coil are ready for
capillary tube from the outlet of drier. internal cleaning.

196
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.81

Tracing electric circuit of Inverter refrigerator and testing the components

Objectives: At the end of this exercise you shall be able to
• trace and identify main PCB and test
• trace and identify inverter PCB and test
• test and identify compressor and control wiring circuit.

Requirements
Tools/Instruments
Equipment
• Line tester 500V heavy duty - 1 No.
• Inverter Refrigerator - 1 No
• Screw driver 3mm tip 150mm length - 1 No.
• Multimeter - 1 No.
• Cutting plier - 1 No.

PROCEDURE

TASK 1: Main PCB Testing

1 Check DC Voltage supply part. 3 Overload protector.

From the noise filter ,AC Voltage is supplied and the Check over load protector by multimeter it should
power generated in DC 12V, 5V is sent to electronic show 1 to 10 otherwise it should be replaced.
part.
4 NTC ( Negative temperature co-efficient )semer.
2 Fan motor driving part
Check the sensitivity between two terminals the
Check the Voltage at the fan motor terminal it should resistance various with temperature, normally it is 4 to
be from 8.3 volt to 12 volt. 6 Ω at Room temperature (or) 5 Ω at 25°C.

197
TASK 2: Inverter PCB
1 Check compressor input voltage
Check compressor output voltage at Inverter PCB the
DC voltage should be around 90 to 110V in all the
terminals with capacitor ground.

TASK 3: Check compressor motor resistance

1 Check the resistance between u~v, v~w and u~w it 2 If the resistance varies between the three, the
should be 13.4 Ω in all three terminals. compressor is defective,
Resistance formula for Inverter compressor 3 BLDC compressor motor is used in inverter refrigerator
(u~v) = (v~w) = (u~w)

198 Capital Goods and Manufacturing - R&ACT (NSQF Level - 5) Exercise 1.7.81
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.82
Testing the components of inverter refrigerator
Objectives: At the end of this exercise you shall be able to
• use of diagnostic aid kit
• check the and test inverter compressor testing
• check and test electronic board testing.

Requirement
Tool Instruments Material
• Screw driver 100mm 6mm tip - 1 No. • Insulation tap - 1 No.
• Cutting plier 200mm • Cotton waste - as reqd.
• (Insulated handle - 1 No. • 2M 1.5 sqmm Wire - as reqd.
• Philips screw driver set - 1 Set. • Test board fitted with voltmeter
• Double end spanner & ammeter - 1 No.
(622mm) - 1 Set.
Equipment
• Multimeter - 1 No.
• Test cord - 1 No. • Inverter Refrigerator 3/4 door - 1 No.

PROCEDURE
TASK 1: Use of Diagonostic Aid kit
Diagonostic Aid Kit: The diagonostic aid kit may assist performed by accessing the main board on the back of
the technician to functionally test individual components. the refrigerator and plugging into the harness extended
from the board.
A diagonostic aid kit can be assembled and consists of a
key pad temperature control assembly and wire hardness. Note : After plugging in the diagonostic aid kit,
The parts required are WR55X10390 and WX05X14999. if the display is blank, press and release any of
the temperature pads. The display will show
Using the kit diagonostic can be performed by removing
actual temperatures.
the base grill and plugging into the diagonostic aid wire
harness located on the left side. Diagonostics can also be

TASK 2: Check and test inverter compressor testing. 9 Place meter leads on inverter wire connector (White
1 Using diagonostic mode or the diagnostic aid, place and Red).
the unit into 100% run mode code1-2. 10 You should read between 4vdc and 6vdc or between
2 See if you can detect compressor operation. 57 Hz and 104Hz - if not go to next step, otherwise
check compressor windings - any two terminals
3 If the compressor does not operate pull the refrigerator
away from the wall. should read 10 Ω and also check each terminal to
case, replace compressor if any winding are defective
4 Remove the rear machine cover. - if not, replace inverter.
5 Set meter to ACV. 11 Remove cover from Main Control Board.
6 Place meter leads on inverter wire connector ( Black 12 Place meter leads on J15 pin 1 and J15 pin 2.
and Orange). 13 You should read between 4vdc and 6vdc or between
7 Should read line voltage - if not check wires and 57Hz and 104Hz - if not replace Main Board.
repair, otherwise go to next step. 14 If correct readings at J15 pin 1 and J15 pin 2 , replace
8 Set meter DCV or Hz. wire harness that connects main board to the inviter.

TASK 3: Check and test Electrical Board Testing

To test board signal for compressor operation, place your
mete leads as shown in the above example.
Remember that the compressor gets it’s voltage from the
Inverter must get a “signal” from the main board of
between 4vdc/57Hz to 6vdc/104Hz and this is measured
between J15 pins 1 and 2.
199
Capital Goods and Manufacturing
R&ACT - Frost Free Refrigerator Inverter Refrigerator Exercise 1.7.83
Leak testing ,evacuation & gas charging (inverter technology)
Objectives: At the end of this exercise you shall be able to
• test leak in refrigerator system
• evacuate the refrigerator system
• charge refrigerator by weight.

Requirements
Tools/Instruments • Tubecutter - 1 No.
• Nitrogen cylinder with two stage • Tongtester - 1 No.
pressure regulator - 1 No. • Safety goggles - 1 No.
• Charging hose 1/4”(6mm) - 3 Nos. • Micron vaccum gauge - 1 No.
• Combination plier - 1 No. Equipements
• Cylinder key - 1 No. • Refrigerator - 1 No.
• Gauge manifold - 1 Set. • Vaccum pump 2 stage
• Double ended spanner up to 500 micron - 1 No.
6/7 to 16/17 - 1 Set . Materials
• Adjusting spanner 250mm - 1 No. • Soap solution - as reqd.
• Flarring tool - 1 Set. • Soft copper tube 6mm -150mm - 2 Nos.
• Oxy- acetylene brazing set - 1 Set. • Flare nut 1/4 (6mm) - 2 Nos.
• Weighing scale 0 to 10 kg 5gms - 1 No. • Schrader valve 1/4” - 2 Nos.
• Service thermometer-50°C to +50°C - 1 No. • Brazing rod copper to copper - 1 No.
• Pinch off tool - 1 No. • R 600a refrigerator (can) - 1 No.

PROCEDURE
TASK 1 : Test leak in refrigerator system
1 Connect Nitrogen cylinder to gauge manifold.
Note : For leak testing use nitrogen only do not
2 Connect the charging line from gauge manifold to use compressor air oxygen or Refrigerant.
service line schrader valve.
4 Check all joint for leakage by soap solution.
3 Insert Nitrogen pressure upto 150 psig and wait for
30min. 5 If no leak is found release the nitrogen pressure.

TASK 2 : Evacuate the refrigeration system.

4 It is mandatory to do two side vacuum sing
1 Connect vacuum pump to gauge manifold.
5 The vacuum contain from 500 to 1000 micron in 15
2 Vacuum the inner cycle using 2 stage vacuum pump. min after switching off the vacuum pump.
3 Vacuum must operate for atlest 30 min up to 500 Note : Vacuum sing should be done only by 2
microns stage vacuum pump do not use compressor
back pressure, anti moist etc.

TASK 3 : Charge Refrigerant by weight .

7 Pinch the charging line twice by pinch off plier at
1 Connect the R 600a refrigerator can to the base of
different intervals and position and check for leak.
adopter & rotate.
8 After conforming that there is no leak braze the end.
2 Place the base adopter & refrigerant can on the
weighing scale. Note : Do not interchange the refrigerant like
3 Set the weighing scale to zero. R600 to R134a & vice versa.
4 Connect the charging line between Refrigeration • Do not change refrigerant by gauge or
system & adopter pressure. Always use weighing scale with
5 Open the adopter valve and charge refrigerant as per proper calibration.
weight recommended by the manufacturer. • Do not vent refrigerant into basement
6 Once the required quantity in charged close the valve. opening, low laying room, sewer system etc
as R600a is heavier than air.
200