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Capacity Development in the RAC Sector
Training & Certification
GIZ – Proklima, May 2015
Rolf Huehren
Tel Aviv, Israel
27th to 28th May 2015
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Training is a learning process that
involves the acquisition of knowledge,
development and sharpening of skills,
concepts, rules, or changing of attitudes
and behaviors to enhance the
performance of employees.
24.05.2015
Introduction
Training Objectives
Page 3
Introduction
In order to support the increasing demand on RAC
equipment quality clients require that refrigeration
equipment is
designed,
installed,
commissioned/decommissioned,
maintained and serviced,
to required standards, in a safe, energy efficient and
environmentally friendly manner.
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Training driven also by RAC business needs >
• To find employment and to optimize career path
• To compete with local & international competition
• To meet increasingly sophisticated requirements from the
sectors (food processing, retail, construction...)
• To comply with laws, regulations and standards that
forcing changes in the sectors
• To improve demand on installation, service and
maintenance quality in order to reduce costs (refrigerant,
replacement parts, number of call-outs) and to maintain
best possible system energy efficiency
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Should be
all Experts
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Benefits of Training and Certification
Improving the quality and standards of:
• Appliances and Installations
• Service and maintenance for RAC equipment
Maintaining expected efficiency and lowest energy consumption!
• The RAC equipment is reliable and it’s economic live is
prolonged
• End-users are more satisfied because of lower costs and no
need for additional repairs and/or early replacement
• There will be a marked for educated technicians applying
better service practices
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End-users are more satisfied
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Who should be trained?
Involved personnel dealing with appliances and RAC
systems
> from their conception up to destruction <
need to develop knowledge and skills to apply best
practices including strategic risk assessment
schemes..
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Training activities in theory and practical matters are based
and build on acquired knowledge and skills from already
established VETC training structures!
The scope of training is related to the actual work
responsibilities of employers, constructors, observers,
manufacturing lines assemblers, sales staff, installation
companies or workshop owners and practical service
engineers and technicians.
24.05.2015
What should be trained?
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• Thermodynamic properties of refrigerants and significant
differences
• Safety and risk assessment
• Design of RAC systems using NatRefs, standards and
regulations
• Specific tools and system components
• Refrigerant cylinder, cylinder storage and transport
• Safe refrigerant handling including charging and refrigerant
recovery and recycling
• Leakage control pressure- and strength testing
• System / Appliance decommissioning
• Reference EN 13313 – RAC, Competence of personnel
• Reference EN 50110 – Operation of electrical appliances
and installations
Standard Refrigeration Training Content (examples)
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Training in safe working (servicing)
practices
Human behaviour and habits have greatest influence on health
and safety without any regard to the specific refrigerant!
- Personal Safety (technician, client, society)
- Site Safety
- Environmental Safety
During servicing
- Higher probability of leakage (breaking into system)
- More refrigerant to leak (e.g., cylinders)
- More sources of ignition (service equipment) with NatRefs
- Etc..
Overall, risk of accident is 10× to 1000× higher during servicing
- Therefore, essential to focus on reducing risk whilst servicing
RAC systems
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Standard Title Guidance
EN378-1:2008 Refrigerating systems and heat pumps –
Safety and environmental requirements,
Basic requirements, definitions,
classification and selection criteria
Practical limit
Maximum charge sizes
EN378-2:2008 Refrigerating systems and heat pumps –
Safety and environmental requirements,
Design, construction, testing, marking and
documentation
Pressure test
Flared joints tightening
torques
EN378-3:2008
Refrigerating systems and heat pumps –
Safety and environmental requirements,
Installation site and personal protection
Location of ODU
HC detectors
EN378-4:2008
Refrigerating systems and heat pumps –
Safety and environmental requirements,
Operation, maintenance, repair and
recovery
Repairs to HC systems
Competence of
personnel working on
HC systems
Related standards
& personal competence requirements
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Related standards
& personal competence requirements
Standard Title Guidance
IEC 60335-2-40 Particular requirements for safety of
household appliances, electric air
conditioners, heat pumps and dehumidifiers
Electrical safety
Inappropriate
operation
EN13313 Refrigerating systems and heat pumps -
Competence of personnel
Job competences
and core activities
EN 50110 Operation of electrical installations Job competence
EN ISO/IEC
17024
Conformity assessment - General
requirements for bodies
operating certification of persons
Competence of
certification bodies
ATEX (Abbreviation ATmosphère Explosive)
is the name commonly given to the legal requirements for controlling
explosive atmospheres and the suitability of equipment and protective
systems used in them. Best servicing practices should follow the
principles of ATEX with regard to area classification and avoidance of
sources of ignition.
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Demand on Safety for NatRefs use
It is essential to provide a safe working
environment in general
To meet commitments to workers,
customers and society
To handle refrigerants with due care to
people, environment and equipment
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Accident prevention
Site safety
Safety of equipment and tools
Fire precaution and alarm
procedures
Basic Fire Fighting
Demand on Safety for NatRefs use
+ +…
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• Conformity to safety standards
• Quantitative risk analysis (in-use
and servicing)
• Accident prevention
• Site safety
• Safety of RAC equipment
• Safety of tools for Installation and
service
• Fire precaution and alarm
procedures
• Basic Fire Fighting
Demand on Safety for Flammables
Page 17
Specific providers for installation and servicing of
RAC equipment will need a license to operate.
The license will be only issued, if companies provide
respective certificates on their qualification.
The licenses will be provided through a national
licensing system.
(e.g. companies should have a minimum of required
tools and equipment. A set of prescribed technical
information must be available. Equipment Logbooks
and service records must be available)
Licensing Schematic Requiered
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Approach for Training and Certification
Legislation should prescribe certification at
company level and for the active engineers and
technician
Engineers and technicians must have the required
knowledge and skills
Certificates should testify these competences
Companies needs to have a minimum required
appropriate equipment and tools
Refrigerants only in the hands of certified
companies engineers and technicians
Equipment users will have the possibility to identify
if company and personnel can perform the
intended job satisfactorily
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Personal Job Competences
Verification
A person shall be deemed competent if it can be
demonstrated that he is capable of carrying out the
activities required.
The person shall demonstrate a level of predefined
competence of theoretical and/or practical ability as
necessary for the activity in question.
The competence of a person shall be assessed preferably
by an approved organisation.
The certification of competence shall be as required by
national regulations. If no national regulations or
procedures exist, the overview of assessment set as per EN
13313 and EN 50110 can be used.
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Certificated Competences Centre
Refrigeration
Laboratory
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Certificated Competences Centre
Electro
Laboratory
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Demonstration Units
Practical Demonstrations
Having Real Field used
Equipment
Self Experiences
Overcome barriers
Practical Assessment
Page 23
Brazing
Purging air from pipe-work with
Oxygen Free and Dry Nitrogen
(OFDN)
Tube and components joining by
press- connectors
Bending and flaring
Use of industrial manufactured flares
Tube supports and vibration
elimination
Thermal insulation
Create Competences in Tubing
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Avoidance of
mechanical
(screwed)
connections
within
the refrigerant
circuit
Sealed system provision
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Conciliate a strict work-
routine to maintain in the
fields
General topics
• Technician activities and
refrigerant handling
• Installation of equipment
• Commissioning of
installations
• Routine maintenance
• Service and repair
• Dismantling
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Start Up Data Sheet for Split Air-Conditioner
Installation Company
Address
Telephone & Fax
Technician Name
Registration No.
Client / Company
Contact Person
Installation / Appliance DATA
Model and No.
Date of Installation / Repair
Comments / Repair
Operating Data – Cooling Mode
Refrigerant Type R-290
Flammable Refrigerant
Refrigerant Name Propane
Refrigerant charge / kg
Suction Pressure P1
Suction Temperature equivalent P1
Air Temp. Entering Condenser T3
Air Temp. Leaving Condenser T4
Air Temp. Entering Evaporator T1
Air Temp. Leaving Evaporator T2
Performance Test: With appliance commissioning please operate the split– air conditioner
with HIGH indoor fan speed in mode COOLING for a minimum of 15 MINUTES. Measure air
inlet (T1) and air outlet (T2) temperature at the indoor unit. The temperature difference should
be at least 8 K.
Electrical Data
Power Supply (Voltage)
Overall Ampere Reading
Current draw Compressor
Other executions for system commissioning! Tick box for completion
Only use correct and reliable tools / equipment for system commissioning!
Functional AC system check including performance test!
Check the AC system for refrigerant leakage!
Check that electrical connections are tight!
Check that condensate drain is tight and with down-grade!
Check insulation of refrigerant transfer tubes and quick-coupler!
Check free run of condenser and evaporator fans!
Check system operation (indoor/outdoor) on abnormal operational
noise!
Clean system components including air filter (if indicated)
Check display of the remote controller!
Execute briefing of the AC system user!
Company signature and date:
Client signature and date:
Flammable Refrigerant R-290 Service
Company
Engineer Name
Address
Telephone & Fax No.
Registration No.
Flammable Refrigerant
This System
is charged with the natural
and environmentally protective
Refrigerant R-290
Refrigerant Charge in kg
Lubricant Type & Charge
Date:
Signature:
Reporting and Labelling
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Use of Appropriate Tools and Equipment
!
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Thank you!
24.05.2015
