Service and repair land-based air-conditioning/ refrigeration systems

This standard covers the service and repair of land-based air-conditioning/refrigeration systems, including mobile air conditioning (MAC) and fixed plant refrigeration.  

The standard covers the operational principles, functional checks and maintenance of MAC and fixed plant refrigeration, (e.g. recovery/drying/charging, cooling rate/effectiveness, air flow/filtration, couplings/pipes/hoses, condensation/ insulation/icing, drive systems, TXV (thermal expansion valves)/FOT (fixed orifice tube)/climate control systems). It also includes leak testing, (using methods including: ultraviolet, visual, electronic and oxygen-free nitrogen testing).

When working with machinery or equipment you should be trained and hold current certification, where required, in accordance with the relevant legislation.

When working on high voltage (hazardous voltage/HaV) electric vehicles, de-energising must be done by a person who has been trained in accordance with the manufacturer’s procedures.

This standard is for those who work in land-based engineering using their initiative in a customer-facing role. It may include mentoring a junior colleague to assist in aspects of service and repair.

Note: anyone who handles refrigerants should hold a valid certificate that complies with current F gas handling regulations.

1. be aware of hazards and assess the risks associated with the activity and the location where it is to be carried out
2. be aware of the potential environmental impact associated with the activity and the ways in which this can be controlled
3. select and wear suitable clothing and personal protective equipment (PPE)
4. select, prepare, use, maintain and store the tools and equipment required to carry out the activity in accordance with the relevant legal requirements, manufacturer's instructions and company practices
5. check that the land-based equipment requiring service and repair is safe, prepared and isolated from power sources, where required
6. take the necessary precautions to prevent the escape of chemicals, gases and other substances and minimise dangers from contamination and hazards, where required
7. use a variety of methods to collect diagnostic information to identify defects and faults  
8. determine the requirements for service and repair
9. identify and establish the availability of replacement components required for the activity
10. remove and replace land-based air-conditioning/refrigeration systems and related components
11. dismantle, inspect and reinstate land-based air-conditioning/refrigeration systems and components
12. carry out service or repair activities following the legal requirements and manufacturer’s specifications
13. recognise and rectify air-conditioning, climate control or refrigeration faults
14. carry out operational checks or tests to ensure system functionality
15. remove and replace worn and damaged components in accordance with instructions and specifications
16. use suitable testing methods to assess the performance of the reassembled system on completion of the work and confirm that it performs to the operating specifications prior to returning the equipment to the customer
17. recycle or sustainably dispose of the different types of waste, including hazardous and non-hazardous, caused by the activity, in accordance with the relevant legal and environmental requirements and company policies 
18. complete records as required by the relevant legislation, warranty requirements and company procedures

1. how to identify hazards and assess risks when preparing to service and repair land-based equipment 
2. the type of clothing and personal protective equipment (PPE) suitable for the activity
3. the tools and equipment required to carry out the activity and how to select, prepare, use, maintain and store these safely and correctly, in accordance with the manufacturer's instructions and company practices
4. the relevant legal requirements for the preparation and use of work equipment
5. the methods for preparing land-based equipment for service and repair 
6. the dangers created by stored energy and how to respond to these during the preparation stage 
7. the hazardous chemicals, gases and other substances that may be present and how they should be dealt with 
8. the different methods that can be used for the assessment of defects and faults with land-based air-conditioning/refrigeration systems and for the identification of the root cause  
9. the typical defects and faults that occur with air-conditioning/refrigeration systems on land-based equipment 
10. the factors that determine whether it is worthwhile carrying out the service and repair, such as cost, estimated working life, or urgent need for the equipment
11. the components required for the service and repair and the company procedures for obtaining replacements 
12. the operating principles of air-conditioning and refrigeration systems and their components
13. the system types and configuration according to their application
14. how to remove and service or replace air-conditioning or refrigeration components
15. how to dismantle, inspect and reinstate air-conditioning or refrigeration components in line with the manufacturer’s requirements
16. how to rectify air-conditioning, climate control or refrigeration faults
17. the methods of testing equipment on completion of the activity to confirm that that it performs to the operating specifications prior to returning it to the customer
18. how to recycle or sustainably dispose of the different types of waste, including hazardous and non-hazardous, caused by the activity, in accordance with the relevant legal and environmental requirements and company policies 
19. the potential impact that the activity could have on the environment and the ways in which this can be controlled
20. the information that needs to be recorded, the company procedure for maintaining records and the requirements of data protection legislation

Activities  e.g. testing (leak, pressure, vacuum) recovery, flushing and recharging

Faults  e.g. drive/compressor failure, refrigerant loss, restricted refrigerant/air flow, faulty switch and/or temperature controls, under/over charge of refrigerant or lubricant

Hazardous chemicals and substances could include:

• fuels

• oils

• fluids

• gases

• dust

• compressed air

Instructions and specifications:

• drawings/plans

• schedules

• method statements

• Standard Operating Procedures (SOPs)

• manufacturer’s instructions

• customer requirements

• verbal instructions

Methods of diagnosis:

• visual inspections

• functional and operational tests

• diagnostic equipment

• remote electronic control and monitoring systems

• reviewing technical data

Operational checks e.g. compressor drive, switches/controls, power supplies, cooling rate/effectiveness, condensation, insulation, icing, air flow, filters

Stored energy:

• springs

• belt tension

• hydraulic pressure

• electrical discharge

• accumulator discharge

Systems and their components  e.g. compressor, couplings, pipes and hoses, condenser, evaporator, receiver drier, heat exchangers, thermostats, control and thermal expansion valves (TXV), fixed orifice tube (FOT), filters/separators

System types e.g. MAC (mobile air conditioning), fixed plant refrigeration, TXV (thermal expansion valves), FOT  (fixed orifice tube)