ITI Central Aircondition Plant Mechanic Syllabus: Course Structure, Detailed Syllabus

• Workshop & Personal Safety - Introduction to basic workshop tools & operations like measuring, marking, hacksawing & cutting. Tools used, their identification & classification, use care & maintenance, direct & indirect measurements,
• marking media.

• Introduction to files, their types and uses, care & maintenance, Bench & pipe vice, their constructional details & uses. Sprit levels & their uses, straight and angular measurements, Bevel Protractors.
• Introduction to precision measuring & least count. Micrometers, Venires & Height gauges.

• Constructional details, applications, care & maintenance.
• Dial gauge Vernier& indicator.
• Drilling, tapping & reaming, types of drills & reamers, different drilling operations, dies & die stocks.
• Drilling machines, their types & uses, holding devices & fixtures.
• Types of fasteners, threads.
• Adhesives & their
• applications.

• Introduction to sheet metal work & its applications, materials used for sheet metal work.
• Hand tools, measuring tools & gauges used in sheet metal work.
• Different sheet metal operations, their necessity & applications.

• Sheet metal joining processes, Sheet metal machinery, shears, forming & folding machines, bending & shearing machines seaming & nibbling machines.
• Development of surfaces for simple objects like boxes, cylinders, cones, prism & pyramids.
• Riveting practice, practice on removing dents on spherical &
• hemi spherical articles.

• Timber, its classification &sources, seasoning of timber.
• Plywood & alternative materials. Carpentry tools, their uses, care & maintenance, simple carpentry operations & commonly used joints. Glues & adhesives, polishing & varnishing.

• Workshop & personal safety - Metal joining processes.
• Introduction to gas & arc welding, advantages & disadvantages.
• Different hand tools are used in welding.
• Oxy- Acetylene gas welding plant.
• Welding accessories like regulators, nozzles cylinders, etc.
• Handling, setting of pressure.

• Welding machines & welding transformers, welding processes & positions, welded joints, welding symbols, weld depositions, & electrodes, their types & selection, care & maintenance.
• Distortion in welding, welding defects, their causes & remedial measures.

• Importance of brazing joint in R&A/C sector Selection of nozzle, Setting of line pressure. Importance of Right temperature of Brazing.
• PPE is required when brazing.
• Preparation before brazing, Swaging method, Flaring method filler rods, Fluxes, types & application.

• Safety - in electrical shops. Introduction of AC, DC Current Static & current Electricity, Description, specification, general care & maintenance of common electrical hand tools.
• Wires & cables - conductors, Insulators & semiconductors, their shapes, and sizes with respect to low, medium & high voltage.
• Different fluxes for different purposes on metals, Crimping equipment -Single & Multistranded conductors joining.
• Selected letters symbols and sign as per I. S. I. Rules for medium voltage.

• Resistance, Voltage, Current, open circuit and short circuits- Ohm's law - Voltage drop in series & parallel circuits, Power & energy relations, Electrical measuring Instruments, Multimeters, Insulation Testers.
• Common electrical accessories used in Industries, Bus-bars, Relays, Contactors, Circuit Breakers, etc.
• Fuses and their ratings, materials used.
• Earthing & its importance.
• Preventive maintenance, routine & periodical tests.

• Induction principles - Electro- magnetism- Faraday's Laws.
• Single phase & Poly phase system 3 phase star-delta connections, Impedance & power factor - Principles & Applications of DC Motors, Series, Shunt & compound motor - AC Motors.
• Transformers their types and applications.
• Chemical effect of electric current - Rechargeable batteries - Care & maintenance of cells.
• AC Motor starting with DOL Starter and Star - Delta Starter.
• Panel boards & their design.

• Use of electrical Control Instruments.
• Joints on single and stranded conductors and soldering.
• Care & maintenance and running of A. C.
• Single and poly phase motor, starters, and transformer.
• Single phase motor starting methods like RSIR, PSC, CSIR & CSCR and the use of Current and Potential relays.
• Measurement of current, voltage, power, and energy by voltmeter, Ammeter, wattmeter & energy meter.
• Measurement
• of resistance with Ohm Meters Formation of simple electrical circuit, series circuit, and parallel circuit, measuring insulation resistance & earth resistance.
• Verification of Ohm's law in D.C Circuit, Fixing and connecting electrical switches, holders fuses, plug sockets on T.
• W. Board and testing.

• ELECTRONICS
• Introduction to Electronics. Basic Principles of semiconductors, Principles, and application of Diodes.
• Identification of resistance value as colour code.
• Tools & Equipment used in Electronic trade.
• Fundamentals of electron theory -passive components semiconductor devices -Symbols - specifications - Diodes, Transistors, Uni-junction Transistor, Field effect Transistor Silicon Controlled Rectifier & ICs.
• Half wave, full wave & Bridge rectifier with filters, DC Power supply.
• Rectification and Rectifiers, zener diode as voltage regulator, Transistor parameters-CB, CC, CE configuration, amplification, photo diodes, transistors, multi vibrations CR & LR circuits, SCRs, UJTs &ICs.
• Multi-vibrator circuits and RC wave shaping
• Circuits.
• Wiring of SCR, UJT for power control circuits, applications of OP -AMP, Applications of photo transistor.
• Thermistor, RTDs, Electronic thermostat, principle of remote control & controllers.
• Use & specifications of contactors, starter & crankcase heater, etc.,Introduction to
• Microprocessors.

• Introduction to basic refrigeration, job opportunities, Safety precautions, and first aids, Applications and History of Refrigeration, and Air conditioning principle & need.
• Fundamentals of Refrigeration, units and measurements, Pressure & its Measurements Introduction to refrigeration Tools & equipment, Heat and temperature.
• Types of heat and its measurement.
• Thermometers & thermometric conversions.
• Atmosphere, air & its constituents.
• Properties of gases & gas laws. Measurement of pressure. Pressure gauges.
• Humidity, relative humidity & due point temperature.
• Constructional details of a refrigerator.
• Functions of

refrigeration system components i.e., condensers, evaporators and capillary tube.

• Compressor, its types & working principle.

Reciprocating compressors.

• Comparative study of sealed & open type compressors, Internal construction of a sealed compressor, its part & their functions.

• Electrically & mechanical testing of refrigerator components. i.e. condensers, evaporators, capillary tube, Relay, OLP, Compressor Terminal find out, defective compressor identification & remedy.

• Difference types of joint Procedure for temporary, Semi, and permanent Brazing Processes.
• Defects & remedial measures.
• Introduction to soldering & brazing, and their applications. Brazing Vs welding.
• Advantages & disadvantages. Maintenance of tools, instruments, and equipment.

• Compressor lubrication method. Lubricants & their properties.
• Selecting of lubricant for the refrigerant sector.
• Cleaning & flushing of the system with chemical cleaning & flushing.
• Special about safety.

• Environmental effect of refrigerant, Action taken, Alternative refrigerant.

• Status & states of the refrigerant in every spot of the cycle, Recovery, recycling of refrigerant & their procedure.

• Types of Refrigeration systems, Study the construction and working of the vapor compression cycle, low side & high side components of vapor compression system like, compressor, condenser, expansion valve and evaporator, functions and applications of

above components.

• Electrical circuit diagram of refrigeration cycle Refrigerator, Freezer, Bottle cooler.

• Repairing rewiring & servicing of a refrigerator. Carrying with R-134a Leak testing in the system Evacuation & gas charging of a refrigerator.
• Trouble shooting of

electrical & mechanical faults

• Study of Frost Free Refrigerators, Refrigeration system of Frost Free Refrigerators, components & their functions, electrical components, wiring, automatic defrost.

• Working on soft copper tubing like cutting, bending, flaring, swaging, pinching & preparing flare joints.
• Brazing of tube joints (Cu to Cu, Cu to Steel, Cu to Brass) using (i)Air-LPG (ii) 02- LPG (iii) 02-C2 H2 set up & use of the above gases with the right torches, Brazing Filler Rods.
• Distinguishing good joints from bad joints.

• Cleaning, Flushing, replacing capillary and drier, fault rectification, Advantage of proper evacuation, leak testing, gas charging in window A/C Refrigerant charging.

• Air cleaning: Filters, their types, and specifications. Air flow measurements Use of velocity meters. Performance Testing criterion.
• Scope and methodology of retrofitting HFC appliances with HC blend refrigerants, study of
• refrigerator components using

HC refrigerants.

• Comparative study of the performance of refrigerators using different refrigerants.
• Comparative study of appliances available in the market.

• Split type, its past, present & Introduction to Air conditioning future.
• Air conditioning

Fundamentals.

• Constructional details and functioning of room air conditioner.
• Air circulation system. Psychrometric & psychrometric charts, construction & use of sling psychrometer.

• Components of Split A.C. Role Study of mechanical & electrical of each part.
• Split A.C. its constructional details,

comparison with window air conditioner advantages & Disadvantages.

• Air cooled condensers: Constructional details & selection.

• Principles of pipe sizing & study of services valves for charging at the site.
• Principle of working of infra red remote control, study of electronic circuits.

• Testing all weather air conditioners.
• Trouble shooting electrical & mechanical faults.
• VRV/VRF system, Frost Free Refrigerator.
• (Double and Three doors) Identify faults; rectify defects, installation method, study wiring circuit, evacuation, leak testing & gas charging, and installation.

• Proper Installation procedure of Window A/C, Normal Split A/C Customer orientation service report preparation, Dealing with customers Proper Installation procedure of Duct able A/C, Cassette A/C.

• Types of insulation U-Value EER calculation as star rated calculation Checking and servicing Preventive maintenance and Trouble Shooting.
• Retrofitting with Hydrocarbons and HFC134a
• a) Water storage, distribution, and drainage
• b) Refrigeration system using R-
• 22 and components in lieu of R-
• 12, Retrofitting with HFC-134a & HCs
• c) Electrical and control system working and control, soldering of copper tubes with stainless steel, Trouble shooting of commonly faced problems like condenser Fan Failure, corrosion, etc.

• Deep Freezers description, Construction, and function, Low temperature thermostat, different types of deep freezer construction.
• Substituting R-22 with R-134a or Hydrocarbon (Montreal protocol)

1.

Professional Skill (Trade Practical)

1000

1000

2.

Professional Knowledge (Trade Theory)

280

360

3.

Workshop Calculation and Science

80

80

4.

Engineering Drawing

80

80

5.

Employability Skills

160

80

Total

1600

1600