iti 14 April 2025
Mechanic (Refrigeration and Air-Conditioner)

ITI Mechanic (Refrigeration and Air-Conditioner) Trade Syllabus 

The ITI Mechanic (Refrigeration and Air-Conditioner) trade is a two-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in installing, servicing, troubleshooting, and repairing refrigeration and air-conditioning systems used in domestic, commercial, and industrial settings. The syllabus integrates theoretical knowledge, practical technical skills, and employability skills to prepare students for roles such as refrigeration technicians, AC mechanics, or service engineers in industries like HVAC, cold storage, or appliance manufacturing, or as self-employed service providers.

Course Overview

  • Duration: 2 years (4 semesters, each 6 months)
  • NSQF Level: Level 5
  • Eligibility: Minimum 10th grade pass with Science and Mathematics (or equivalent)
  • Objective: To train individuals in refrigeration and air-conditioning technologies for efficient system installation, maintenance, and repair to ensure optimal performance and energy efficiency.

Detailed Syllabus Breakdown

1. Trade Theory (Theoretical Knowledge)

Covers principles of refrigeration, air-conditioning, and system maintenance.

  • Semester 1
    • Introduction to Refrigeration and Air-Conditioning
      • Overview: principles, applications in domestic, commercial, industrial sectors.
      • Industry scope: career roles, safety regulations, environmental concerns.
      • Safety: PPE, handling refrigerants, electrical safety, fire hazards.
    • Fundamentals of Thermodynamics
      • Concepts: heat, temperature, pressure, laws of thermodynamics.
      • Refrigeration cycle: compression, condensation, expansion, evaporation.
      • Units: SI units, conversions, measurements (pressure, temperature).
    • Refrigerants
      • Types: CFCs, HCFCs, HFCs, natural refrigerants (ammonia, CO2).
      • Properties: boiling point, toxicity, flammability, ozone depletion potential.
      • Handling: charging, recovering, recycling, leak detection.
    • Tools and Equipment
      • Hand tools: spanners, screwdrivers, pliers, tube cutters.
      • Measuring instruments: pressure gauges, thermometers, multimeters.
      • Specialized equipment: vacuum pumps, recovery units, brazing torches.
    • Electrical Basics
      • Circuits: AC/DC, single-phase, three-phase systems.
      • Components: relays, capacitors, overload protectors, thermostats.
      • Wiring: diagrams, connections for compressors, motors.
    • Refrigeration Systems
      • Domestic systems: refrigerators, freezers, water coolers.
      • Components: compressors, condensers, evaporators, expansion valves.
      • Operation: single-stage, direct cooling, frost-free systems.
  • Semester 2
    • Air-Conditioning Systems
      • Types: window AC, split AC, packaged units, central AC.
      • Components: blowers, filters, ducts, cooling coils.
      • Psychrometry: humidity, dry/wet bulb temperature, enthalpy.
    • Compressors
      • Types: reciprocating, rotary, scroll, screw compressors.
      • Operation: lubrication, cooling, capacity control.
      • Maintenance: checking seals, belts, vibration analysis.
    • Condensers and Evaporators
      • Condensers: air-cooled, water-cooled, evaporative types.
      • Evaporators: direct expansion, flooded, shell-and-tube.
      • Maintenance: cleaning fins, descaling, checking airflow.
    • Expansion Devices
      • Types: capillary tubes, thermostatic expansion valves, float valves.
      • Function: regulating refrigerant flow, pressure control.
      • Troubleshooting: blockages, improper superheat adjustment.
    • Piping and Insulation
      • Piping: copper tubing, fittings, brazing, flaring techniques.
      • Insulation: foam, fiberglass, preventing heat loss, condensation.
      • Layout: designing efficient piping for minimal pressure drop.
    • Electrical Controls
      • Controls: thermostats, pressure switches, timers, defrost controls.
      • Automation: relay logic, basic PLC in AC systems.
      • Safety devices: fuses, circuit breakers, earthing.
  • Semester 3
    • Commercial Refrigeration
      • Systems: cold storage, walk-in coolers, ice plants, display cabinets.
      • Design: load calculation, capacity selection, multi-stage systems.
      • Maintenance: defrosting, checking insulation, monitoring temperatures.
    • Industrial Air-Conditioning
      • Systems: chilled water systems, VRF/VRV, precision cooling.
      • Applications: hospitals, data centers, factories, clean rooms.
      • Controls: humidity control, air filtration, energy management.
    • Troubleshooting
      • Fault diagnosis: low cooling, high pressure, electrical failures.
      • Tools: manifold gauges, leak detectors, clamp meters.
      • Solutions: refrigerant recharge, component replacement, recalibration.
    • Energy Efficiency
      • Concepts: EER, COP, star ratings, inverter technology.
      • Optimization: reducing power consumption, eco-friendly refrigerants.
      • Audits: assessing system performance, recommending upgrades.
    • Installation Techniques
      • Site survey: space, ventilation, power supply assessment.
      • Installation: mounting units, connecting pipes, electrical wiring.
      • Commissioning: vacuuming, charging, performance testing.
    • Environmental Regulations
      • Montreal Protocol: phase-out of ozone-depleting refrigerants.
      • F-Gas regulations: handling HFCs, record-keeping.
      • Disposal: safe recovery, recycling of refrigerants, components.
  • Semester 4
    • Advanced Refrigeration Systems
      • Systems: cascade, absorption, cryogenic refrigeration.
      • Applications: LNG plants, medical storage, food processing.
      • Controls: advanced sensors, IoT-based monitoring.
    • Automotive Air-Conditioning
      • Systems: car AC, bus AC, refrigerated vans.
      • Components: compact compressors, evaporators, cabin filters.
      • Maintenance: retrofitting, checking for vibrations, leaks.
    • HVAC System Design
      • Load calculation: heat load, cooling load, ASHRAE standards.
      • Ducting: design, airflow, pressure loss calculations.
      • Software: basics of AutoCAD, HVAC design tools.
    • Preventive Maintenance
      • Schedules: regular checks for filters, coils, refrigerant levels.
      • Servicing: cleaning, lubricating, replacing worn parts.
      • Records: maintaining logs, service reports, warranty tracking.
    • Professional Skills
      • Entrepreneurship: starting an HVAC service business, bidding contracts.
      • Industry trends: smart ACs, green cooling, AI-based diagnostics.
      • Customer service: handling complaints, explaining technical issues.
    • Quality Standards
      • Standards: BIS, ASHRAE, ISO for system performance.
      • Testing: pressure tests, performance evaluation, certification.
      • Documentation: installation reports, compliance forms.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in workshops and simulated refrigeration setups.

  • Semester 1
    • Safety Practices
      • Using PPE: gloves, goggles, masks for refrigerant handling.
      • Electrical safety: checking insulation, grounding circuits.
      • Fire drills: handling gas leaks, using extinguishers.
    • Tool Handling
      • Using tools: cutting tubes, flaring, swaging in labs.
      • Measuring: reading pressure gauges, thermometers, multimeters.
      • Brazing: joining copper pipes with oxy-acetylene torches.
    • Domestic Refrigeration
      • Assembling: installing compressors, evaporators in mock refrigerators.
      • Charging: filling refrigerants, checking pressures in labs.
      • Testing: running refrigerators, checking cooling, frost formation.
    • Electrical Work
      • Wiring: connecting motors, thermostats in mock circuits.
      • Testing: checking continuity, voltage with multimeters.
      • Repairing: replacing capacitors, relays in labs.
    • Leak Detection
      • Testing: using soap solution, electronic leak detectors.
      • Repairing: sealing leaks, recharging refrigerants.
      • Verifying: ensuring system integrity post-repair.
    • Project Work
      • Servicing a refrigerator: cleaning, charging, performance testing.
      • Report: documenting faults, repairs, outcomes.
  • Semester 2
    • Air-Conditioner Installation
      • Mounting: installing window/split AC units in mock setups.
      • Piping: connecting copper tubes, insulating lines.
      • Commissioning: vacuuming, charging, testing cooling.
    • Compressor Maintenance
      • Dismantling: opening reciprocating, rotary compressors in labs.
      • Servicing: replacing oil, seals, checking valves.
      • Testing: reassembling, checking performance, noise.
    • Condenser and Evaporator Work
      • Cleaning: removing dust, scale from fins, coils in labs.
      • Repairing: fixing leaks, replacing damaged tubes.
      • Testing: checking airflow, heat transfer efficiency.
    • Electrical Controls
      • Installing: fitting thermostats, pressure switches in mock ACs.
      • Testing: simulating control operations, checking automation.
      • Troubleshooting: diagnosing faulty relays, timers.
    • Piping Practice
      • Flaring: preparing copper tubes for connections.
      • Insulating: applying foam, tape to prevent condensation.
      • Testing: checking joints for leaks, pressure drops.
    • Project Work
      • Installing a split AC: mounting, piping, commissioning.
      • Report: documenting setup, performance data.
  • Semester 3
    • Commercial Refrigeration
      • Assembling: setting up mock cold storage, display units.
      • Servicing: defrosting, checking insulation, temperature controls.
      • Testing: monitoring cooling, energy consumption in labs.
    • Industrial AC Systems
      • Installing: fitting ducts, chillers in mock central AC setups.
      • Servicing: cleaning filters, checking water flow in chillers.
      • Testing: balancing airflow, humidity in mock rooms.
    • Troubleshooting
      • Diagnosing: tracing faults in mock refrigeration/AC units.
      • Repairing: replacing compressors, valves, sensors.
      • Verifying: testing post-repair performance, efficiency.
    • Energy Audits
      • Measuring: checking power consumption, EER in labs.
      • Optimizing: adjusting controls, recommending inverter upgrades.
      • Reporting: preparing mock energy audit summaries.
    • Refrigerant Handling
      • Recovering: using recovery units to extract refrigerants.
      • Recycling: filtering, reusing refrigerants in labs.
      • Charging: filling systems with eco-friendly refrigerants.
    • Project Work
      • Servicing a cold storage: troubleshooting, maintenance, testing.
      • Portfolio: presenting repair logs, efficiency reports.
  • Semester 4
    • Advanced Systems
      • Assembling: setting up mock cascade, absorption systems.
      • Testing: checking performance, temperature ranges in labs.
      • Servicing: maintaining sensors, automated controls.
    • Automotive AC
      • Installing: fitting AC components in mock vehicle cabins.
      • Servicing: checking leaks, recharging refrigerants.
      • Testing: simulating cabin cooling, airflow checks.
    • HVAC Design
      • Calculating: performing heat load for mock buildings.
      • Designing: sketching duct layouts, selecting equipment.
      • Simulating: using software for airflow analysis in labs.
    • Preventive Maintenance
      • Scheduling: performing routine checks on mock systems.
      • Servicing: cleaning coils, replacing filters, lubricating motors.
      • Logging: preparing maintenance reports, schedules.
    • Customer Interaction
      • Explaining: discussing faults, solutions with mock clients.
      • Quoting: preparing service estimates, invoices in labs.
      • Resolving: handling mock complaints, ensuring satisfaction.
    • Project Work
      • Designing an HVAC system: for a mock building with ducts, units.
      • Portfolio: presenting design, installation report, test results.

3. Workshop Calculation and Science

Supports refrigeration tasks with mathematical and scientific concepts.

  • Semester 1: Arithmetic (pressure, volume calculations), physics (heat transfer, gas laws).
  • Semester 2: Algebra (load calculations), thermodynamics (enthalpy, entropy).
  • Semester 3: Trigonometry (duct angles), fluid mechanics (airflow, refrigerant flow).
  • Semester 4: Statistics (efficiency analysis), applied physics (psychrometry, cooling load).

4. Engineering Drawing

Focuses on technical drafting for refrigeration systems.

  • Semester 1: Sketching tools, components, orthographic views.
  • Semester 2: Drawing refrigeration cycles, AC layouts, piping diagrams.
  • Semester 3: Designing cold storage plans, ducting layouts.
  • Semester 4: Creating HVAC system blueprints, wiring diagrams.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1: Communication (reporting faults), time management, basic IT (Excel, service apps).
  • Semester 2: Teamwork (collaborating with electricians), problem-solving (system faults).
  • Semester 3: Leadership (supervising installations), negotiation (vendor quotes), advanced IT (design software).
  • Semester 4: Entrepreneurship (HVAC business), client management, industry awareness (green tech).

Assessment and Certification

  • Examinations: Semester-wise (theory + practical).
  • Certification: National Trade Certificate (NTC) from NCVT, recognized nationally and internationally.
  • Evaluation: Based on installation accuracy, repair proficiency, system efficiency, and project work.

Career Opportunities

  • Employment: Refrigeration technician, AC mechanic, service engineer in HVAC, cold storage, or appliance industries.
  • Self-Employment: Starting an HVAC repair or installation service.
  • Further Studies: Diploma in Mechanical Engineering, B.Tech in Refrigeration, or certifications like EPA (refrigerant handling).

Note

  • This syllabus aligns with NCVT guidelines and may vary slightly by institution or state.
  • For the latest version, refer to the Directorate General of Training (DGT) or local ITI.

Trade Type

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