General Quality
What is the process of validating ICP Motors?
ICP motor cross reference guide -
From Windchill - 338824-2 (Current Rev AG)
What percent bare metal is allowed on supplier painted parts
0%
No chipped or raw metal is allowed on supplier painted parts or internal supplier parts. One spot of rust will spread and peel
QCI 7.63.1
VA: 8.63.0-3
True of False - Splits are allowed into the flare of a hairpin on an expanded coil.
True
Splits are not allowed into the bell or cup of a hairpin, they are allowed in the flare.
QS 5.3.9
True or False: Lightly burned / charred wires are ok for use?
False:
If a wire has been charred or burned from a brazing process it must be replaced
QS 5.3.3
Discharge Grille Torque Spec?
Nominal: 30 in-lbs. in Normal tops
Nominal: 60 in/lbs. in Deluxe tops
What is the proper procedure to attach a fan prop to fan motor
Screw on the flat. Top of hub flush with top of shaft
QS - 5.3.42
True or False - Minor tube wrinkles are allowed on discharge tubes?
False
Creates stress and fatigue point on tubes leading to premature failure
QS 5.3.9
True or False - Nitrogen is not needed at all brazing stations?
False
Online and offline brazing stations all require nitrogen, to prevent internal contamination to the units. Scale causes blockages in the filters driers
QCI 5.2.6
How do we know how many wire retainers are needed on a unit? Why are they necessary?
New Quality Picklist has a per unit amount for retainers and wire ties.
Proper use of wire retainers prevent fan props from cutting wires.
Compressor Bolt Spec
80 - 105 in-lbs., 92.5 in-lbs. nominal
Explain the process for containment of fully assembly suspect units?
Stop the process if possible. Acquire clean point (1st good after defect) and Start point (Problem Start)
What is the spec for pallet Mold and Moisture content?
No mold is acceptable
>22% moisture content unacceptable
What color hairpins are allowed on heating units?
Red or Pink (Trial copper - Purple and Brown) ….. (AC: Green, Yellow or Black)
VA 8.62.3A
How are compressor plug wires to be routed?
Compressor wires are to be routed to the inside / under service tube to prevent wires touching tubing.
VA 8.100.50
Fan Prop Torque Spec
100 - 140 in-lbs., 120 in-lbs. nominal
True or False - All units have the same color discharge and inlet grilles?
False
All units except Bryant Units (Black & Tan) will have the same color grilles on the top and on the body.
What supplier data is needed when we have defective of incorrect parts needing to rejected?
Need Date Code, Supplier, Part Number, & Quantity of suspect parts
What is the spec for rejecting a dented or dinged hairpin?
Blunt dents or dings greater than 20% of OD are rejected, all sharp bends are rejected
QS 5.3.9
How are Crank Case Heater-bands properly assembled to compressor?
Adjustment band on compressor seam: Wires crossed around crossed (X) around compressor
VA 8.100.50
Liquid Valve Spec
6.5 - 10.5 ft.-lbs. 8.5 ft.-lbs. nominal
When are long screws used and when are short screws used in unit assembly?
Grille Units: Long screw only in service panel (tube sheet)
Mid tier: Short screws attach louver to top, Long screw in the base pan and service panel
Deluxe: All Long screws
ICP : Long screw only in service panel
What is the purpose of using brazing blocks while brazing?
Ensures proper orientation of tube, repositioning of cooled tubes creates stress points throughout the tube, and susceptible to failure
QCI 5.2.6
Where is the proper location for Coil temp thermistor
Heat pumps - butterfly tube
Cooling : Distributor extension (above P/S)
EXV Unit: Distributor extension ( connected to EXV)
VA-ASSY-033
MES-001
Standard painted parts, paint thickness?
1.8 mils
VA 8.63.0-3