Refrigeration Mechanic (UIP) – Detailed Syllabus
Module-1 Fitting, Sheet metal & Welding
Safety – 2
Safety precautions 2
First Aids
Personal Protective Equipments (PPE)
Fire fittings equipments
Electrical safety
Fitting – 3
Different types of fitting hand tools, power tools
Functions, constructions, specifications & application of hand tools and power tools
Care and maintenance of hand tool & power tools
Machineries and equipments like drilling machines, grinding machines etc
Function, construction, specification, application, care & maintenance of machineries & equipments
Precision measuring instruments like verniercalliper, micrometers, vernier height gauge etc
Functions, constructions, specifications & application of precision instruments
Care and maintenance of precision instruments
Sheet metal – 2
Sheet metal tools, instruments, equipments
Construction, working, use, application and specification
Care and maintenance of sheet metal tools, instruments& equipments
Types of sheet metal joints
Rivets & riveting, their types and uses
Welding – 2
Welding tools and equipments, types specifications and use
Oxy-Acetylene welding equipments & accessories
Gas welding hand tools and safety apparels
Arc welding accessories
Classification of welding process
Methods of gas welding
Use of Oxy Acetylene, Oxy LPG, Air LPG and two stage regulator
Types of weld
Module 2 – Electrical
Electrical – 3
Electrical terms such as AC and DC supply, voltage, current, capacitors, resistors, power, energy, frequency etc
Conductors and insulators
Series circuits, parallel circuits, open circuits, short circuits
Material used as conductors
Joints in conductors
Measuring instruments such as voltmeter, ammeter, ohmmeter, energy meter, frequency meter etc
Earthing and its importance
Earth resistance, insulation, and continuity testing
AC Motors – 3
Single phase and three phase motors
Construction and working principle of Capacitor start Capacitor run induction motor (CSR), Split phase induction motor (RSIR), Capacitor start
induction motor (CSIR),Permanent Capacitor or capacitor run induction motor (PSC), Resistance start capacitor run induction motor (RSCR),
Shaded pole motor etc
Centrifugal switch
Methods of changing the direction of rotation
Construction and working principle of squirrel cage induction motor, slip ring induction motor
Common faults, causes and remedies in single phase and three phase motors
Motor starters – 2
Construction and working of Single phase and three phase motor starters such as DOL starter, Star delta starter, Auto transformer starter, Rotor resistance starter
Common faults, causes and remedies in single phase and three phase motor starters
Module-3 Electronics
Electronic components – 2
Active and passive components
Resistor, Capacitors, Semiconductors, Diodes, Transistors etc
Rectifiers (Half wave, Full wave, Bridge rectifier etc )
Zener diodes, voltage regulator, Amplification
Transistors-CB,CE,CC Configuration
Photo diodes, Photo transistors, Multi vibrator, SCRs, UJTs, ICs etc
Module-4 Basic refrigeration
Refrigeration tools, instruments ,and equipments – 4
Refrigeration tools, instruments, and equipments
Construction, working, use, application and specification
Care and maintenance of refrigeration tools, instruments& equipments
Fundamentals of refrigeration – 5
Fundamentals of refrigeration
Science related to refrigeration such as units, mass, weight, work, power, energy, force, pressure, heat, temperature, sensible heat, latent heat, super heating, sub cooling, saturation temperature, boiling point , freezing point, etc
Laws of thermodynamic, Laws of perfect gases
Different types of refrigeration system – 3
Construction and working of ice refrigeration
Construction and working of Dry ice refrigeration
Construction and working of Water vapour refrigeration
Construction and working of Liquid gas refrigeration
Construction and working of Evaporative refrigeration
Construction and working of Steam jet refrigeration
Construction and working of Thermo electronic refrigeration
Construction and working of Vapour absorption refrigeration cycle
Construction and working of Vapour compression cycle, fundamental operations, Sub cooling and super heating
Application of vapour compression cycle
COP, Ton of Refrigeration
Study of Ph, Ts, Pv diagram
Module 5 Refrigeration equipments
Compressor – 5
Construction, working, types and application of different compressors such as Reciprocating, Rotary, Scroll, Screw, Centrifugal, Swash plate etc
Volumetric efficiency, capacity control, factors influencing volumetric efficiency, piston displacement, compression ratio etc
Compressor lubrication oil, properties, types and lubrication methods
oil separator
Advantage and disadvantage of different types of compressors
Common faults, care and remedies in compressor
Condenser – 3
Construction, working, types and application of condensers such as air cooled, Water cooled, evaporative
Capacity of condensers, factors affecting the condenser capacity
Advantage and disadvantage of different types of condensers
De-scaling, methods of descaling, fouling factor etc
Liquid receiver
Drier, types and application
Description of desiccants
Cooling tower – 3
Construction and working principles of different types of cooling towers
Types of cooling towers
Capacity of cooling towers, factors affecting the cooling tower capacity
Advantage and disadvantage of different types of cooling towers
Cooling tower approach, range, efficiency etc
Water treatment, water softening plant
Expansion valve – 3
Construction and working principles of different types of expansion valves such as Thermostatic expansion valves (TXV), Automatic expansion valves (AXV), Float valve, Electronic expansion valves, Level master control (LMC),Capillary tubes etc
Selection of expansion valves
Evaporator – 2
Construction and working principles of different types of evaporators
Capacity of an evaporator, factors affecting the capacity of an evaporator
Types of evaporators such as Natural convention, forced convention, flooded evaporator, Dry expansion evaporator, Bare tube coil evaporator, Finned tube evaporator, Plate evaporator, Shell and tube, Shell and coil, Tube in tube evaporator, frosting evaporator, non frosting evaporator etc
Methods of defrosting such as Manual defrosting, Pressure control defrosting, Temperature control defrosting, Water defrosting, Reverse cycle defrosting, Simple hot gas defrosting, Automatic defrosting, Electric defrosting etc
Accumulator
Heat exchanger, their function, construction, application & advantage
Module-6 Refrigerant
Refrigerant – 5
Properties of refrigerant
Classification of refrigerants
Alternative refrigerants
Climatic impact of refrigerants
Ozone depletion potential (ODP)
Green house effect- global warming (GWP)
ODP & GWP of various Refrigerants
Numbering of refrigerants
Refrigerant cylinders, Cylinder colour coding
Handling of refrigerant cylinders & Flammable refrigerant
Refrigerant leak detection methods
Flushing, leak testing, Evacuation, Gas charging in different system
Retrofitting
Module-7 Refrigeration system
Refrigerator (direct cool) – 3
Construction and working principles of single door direct cool refrigerator
Study the electrical and mechanical components
Testing of electrical and mechanical components
Door gasket
Heat insulation materials, types & properties
Trouble shooting of refrigerator
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Frost free refrigerator – 2
Construction and working principles of frost free refrigerator (2 or 3 door)
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting of frost free refrigerator
Care and maintenance of frost free refrigerator
Installation method
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Refrigerator (inverter technology) – 1
Construction and working principles of refrigerator
Refrigeration cycle & Air cycle
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting of refrigerator
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Water cooler & Water dispenser – 2
Construction and working principles of water cooler & water dispenser
Types of water cooler & water dispenser
Refrigeration cycle of water cooler & water dispenser
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting of water cooler & water dispenser
Care and maintenance of Water cooler & Water dispenser
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Insulation materials
Visible cooler & Bottle cooler – 1
Description, Construction and working principles
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting of visible cooler & bottle cooler
Care and maintenance of visible cooler & bottle cooler
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Deep freezer/Display carbine – 2
Description, Construction and working principles
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting
Care and maintenance
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Installation method
Ice cube machine/Softy machine – 1
Description, construction, working
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting
Care and maintenance
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
installation method
Module-8 Air conditioning system
Window Air Conditioner – 5
Construction and working principles
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Energy Efficiency Ratio(EER)
Energy Efficiency labeling on Air-Conditioning system
Split AirConditioner (Wall Mounted, Floor, Ceiling/Cassette mounted, Ductable)
Construction and working principles
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Energy Efficiency Ratio(EER)
Energy Efficiency labeling on Air-Conditioning system
Multi split Air Conditioner – 2
Construction and working principles
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Inverter Split Air-Conditioner – 1
Construction and working principles
Study the electrical and mechanical components
Testing of electrical and mechanical components
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Electrical circuit diagram
Module-9 Commercial Refrigeration and air conditioning system
Ice candy plant – 1
Function, construction, Working principle
Circuit diagram
Capacity & types of compressor used
Brine solution types, properties
Testing of electrical and mechanical components
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging, Retrofit
Ice plant
Function, construction, Working principle
Circuit diagram
Capacity & types of compressor used, agitator
Brine solution types, properties
Testing of electrical and mechanical components
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Walk in cooler & reach in cabinet – 1
Function, construction, Working principle
Circuit diagram
Capacity & types
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Leak testing, Evacuation, Gas charging
Cold storage – 3
Function, construction, Working principle
Controls & Circuit diagram
Capacity & types of cold storage and its details
Trouble shooting and servicing
Installation method
Care and maintenance of refrigerator
Methods of Leak testing, Evacuation, Gas charging
Food preservation
Maintaining temperature in different places
Properties of commonly used refrigerants like ammonia
and its safe handling
use of vibration eliminator and shock absorber
Mobile refrigeration in transport vehicle
Deep freezing, Freezing tunnel, Blast freezing
Psychrometry – 4
Requirement of comfort Air-Conditioning
Study of psychrometric terms-DBI, WBT, RH, enthalpy, dew point, specific humidity etc
Study of psychrometric chart-Dry bulb temperature line, Wet bulb temperature line, Specific humidity or moisture content line, Dew point temperature line, Enthalpy (total heat) line, Vapour pressure line, Relative humidity line etc
Study of psychrometric process-Sensible heating, Sensible cooling, Humidification & Dehumidification, Cooling and adiabatic humidification, Cooling and humidification by water injunction, Heating and humidification, Humidification by steam injection, Adiabatic chemical dehumidification etc
Heat load calculation for commercial and industrial buildings
Central Air Conditioning system/HVAC plant – 3
Introduction to HVAC
Fundamentals of central Air-Conditioning/ HVAC plant
Types of central Air-Conditioning (direct & indirect)
Construction & Working
Components, Fault, Care & Maintenance
Temperature & pressure control used in AC plant
Construction and working of safety devices in AC plant
Cooling tower, Pipe lines
Preventive maintenance schedule of central AirConditioning plant
Maintain log book for daily operation
Modulating valve for temperature control
Package chiller, Screw chiller, Reciprocating chiller
Humidity control
Humidifier
Dehumidifier
Air washer
AHU, FCU
Chilled water system
Package Air Conditioner (Air cooled, Water cooled condenser) – 1
Construction & working principles
Types, application
Installation methods
Trouble shooting
Care and maintenance
Temperature & pressure control
Construction and working of safety devices
Split package – 1
Construction & working principles
Types, application
Study of various electrical & mechanical components
Installation methods
Trouble shooting
Care and maintenance
Temperature & pressure control
Construction and working of safety devices
VRV/VRF system
Details of piping
Common reason for error code
Types of ODU & IDU
Duct – 4
Function, types
Classification of ducts
Materials used for ducting
Duct designing
Pressure in ducts
Duct insulations
Properties of insulation materials
K-factors
Acoustic insulation
Air distribution methods
Air flow
Fan and blower
Function, types, classification of fan & blower
Static & Velocity pressure measurements
Air Filter – 3
Construction, Function of air filters
Types of air filters
Care & maintenance of air filter
Effect of chocked air filter
Clean room
Module-10 Automobile air Conditioning
Car Air Conditioner – 2
Construction, working
Study various electrical & mechanical components
Testing components
Electrical circuit diagram
Fault detection
Leak testing, evacuation, gas charging
Installation
Trouble shooting
Magnetic clutch operation
Free wheeling
Care and maintenance
Mobile Air Conditioner (Bus, Train)
Study the refrigeration cycle in automobile AC
Construction and working of bus AC
Magnetic clutch operation, free wheeling
Refrigerant used HCFC-22, HFC_134a, HFOs, Blends of
HFCs, and HFOs
Construction and working of train AC
Trouble shooting of Bus AC & Train AC
Planning for Preventive maintenance and scheduling
Maintenance actives in large AC and Refrigeration plant
NOTE: – It may be noted that apart from the topics detailed above, questions from other topics prescribed for the educational qualification of the post may also appear in the question paper. There is no undertaking that all the topics above may be covered in the question paper
