Installations
Part of the HVAC Technician training program
Overview
Learn the installation and commissioning of residential and commercial HVAC systems. This module covers air conditioning systems, heat pumps, furnaces, ductwork design, and the mechanical skills needed to properly install equipment to manufacturer and code specifications.
Sub-topics
Split System AC Installation
Practice complete split-system air conditioner installation including pad placement, refrigerant line routing, electrical connections, and system evacuation. Learn to size equipment using Manual S selection guidelines and verify performance through commissioning procedures.
Lessons
Equipment Selection & Placement
Learn Manual S load calculation for equipment sizing. Understand proper pad dimensions, drainage requirements, and clearance for service access.
Refrigerant Line Installation
Install copper line sets with proper support and insulation. Understand vacuum requirements and proper flare nut torque.
Electrical Connections
Make proper power and control wiring connections. Understand disconnect switches, wire sizing, and grounding requirements.
System Evacuation Procedure
Learn proper vacuum pumpdown sequence. Understand micron gauge readings and hold tests for system integrity.
Commissioning & Testing
Verify superheat, subcooling, airflow, and temperature split. Document all measurements and settings.
Practical Exercises
- Size split system for 2-ton load using Manual S
- Install 3/4 inch liquid line with proper support
- Make electrical connections to 24V control circuit
- Perform vacuum pumpdown to 500 microns
- Verify superheat and subcooling after charging
Required Tools
Heat Pump Systems
Study air-source and ground-source heat pump installations, reversing valve operation, defrost control strategies, and supplemental heat systems. Learn dual-fuel system integration with gas furnaces and smart thermostat coordination for optimal efficiency.
Lessons
Air-Source Heat Pumps
Understand refrigerant flow reversal for heating mode. Learn about capacity reduction at low outdoor temperatures.
Ground-Source Heat Pumps
Study closed-loop ground coupling and loop field installation. Understand higher efficiency but higher installation cost.
Reversing Valve Operation
Learn solenoid energization sequences for heating vs. cooling. Understand pressure temperature relationships in each mode.
Defrost Control
Study timed vs. demand defrost cycles. Learn about hot gas bypass and electronic defrost control.
Supplemental Heat Integration
Understand electric resistance and gas furnace backup. Learn about staging and lockout temperatures.
Practical Exercises
- Verify reversing valve operation with manifold gauges
- Test defrost cycle initiation and termination
- Measure heating capacity at low outdoor temperature
- Check supplemental heat sequencer operation
- Program thermostat for dual-fuel operation
Safety Checklist
- Verify power is off before changing valve connections
- Check refrigerant charge before and after mode change
- Test defrost termination to prevent overheating
- Verify supplemental heat lockout during defrost
- Check thermostat wiring for proper mode indication
Furnace & Heating System Installation
Install gas-fired, oil-fired, and electric heating systems including proper venting, gas line connections, draft regulation, and combustion air supply. Learn to measure AFUE ratings and ensure proper sizing using Manual N load calculations.
Lessons
Gas Furnace Installation
Understand gas pressure requirements, orifice sizing, and venting materials. Learn about induced draft and standing pilot systems.
Oil Fired Systems
Study burner operation, fuel pump pressure, and nozzle types. Understand storage tank requirements and fuel lines.
Electric Heat Installation
Install electric resistance elements and control contactors. Understand power requirements and overcurrent protection.
Venting Requirements
Learn Category I, II, III, IV venting requirements. Understand PVC, ferrous, and stainless steel vent materials.
Combustion Air Supply
Provide adequate combustion air per International Residential Code. Understand opening sizing and termination requirements.
Practical Exercises
- Install gas pressure regulator and test manifold
- Connect Category III vent to furnace
- Verify combustion air opening sizing
- Wire line voltage and 24V control circuits
- Test ignitor and flame sensor operation
Safety Checklist
- Verify gas pressure with manometer before lighting
- Check vent termination clearance to openings
- Test flame sensor with multimeter
- Verify combustion air is unobstructed
- Check for gas leaks with soap solution
Ductwork Design & Fabrication
Design duct systems using Manual D计算方法 with proper sizing, layout, and balancing. Practice sheet metal fabrication, flex duct installation, duct sealing techniques, and insulation requirements. Learn about duct pressure testing and leakage standards.
Lessons
Manual D Sizing Method
Calculate equivalent rectangular duct size from round duct. Understand friction rate and velocity considerations.
Sheet Metal Fabrication
Cut, bend, and assemble duct sections. Learn about locking seams, screws, and mastic sealing.
Flex Duct Installation
Support properly every 4 feet. Understand static pressure loss and minimum thickness requirements.
Duct Sealing Techniques
Use mastic, fiberglass tape, and aerosol sealants. Seal all joints, seams, and penetrations.
Insulation Requirements
R-6 for supply, R-4 for return. Understand vapor barrier requirements in conditioned spaces.
Practical Exercises
- Calculate duct size for 400 CFM supply register
- Fabricate 90-degree elbow from sheet metal
- Seal duct joints with mastic and reinforcing fabric
- Install flex duct with proper support spacing
- Measure duct insulation thickness with micrometer
Reference Materials
- SMACNA Duct Construction Standards
- ACCA Manual D
- Local mechanical code requirements
- Duct leakage testing procedures
- Insulation R-value charts
Learning Objectives
- Install a complete split-system air conditioner following manufacturer specifications
- Commission a heat pump system including defrost control and supplemental heat verification
- Install a gas-fired furnace with proper venting, gas connections, and combustion analysis
- Design and fabricate a duct system meeting Manual D specifications
- Balance airflow across all branches and verify proper system operation
- Troubleshoot installation errors and correct improper configurations