Locked up!
Boxes, cages and crimes against condensers
Skills WORKSHOP
Commissioning hydronic systems
Are trade qualifications working for fridgies? June 2018 / ISSUE 112 
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call us today 1300 000 723 2 | HVAC&R Nation | www.airah.org.au/nation | June 2018
June 2018 / ISSUE 112
Licensed to chill 20 HVAC&R Nation is published by the Australian Institute of Refrigeration, Air conditioning and Heating (Inc). AIRAH – National Office James Harrison Centre 3/1 Elizabeth Street, Melbourne VIC 3000, Australia. Tel: 03 8623 3000
Fax: 03 9614 8949
www.airah.org.au/nation
Magazine team Communications Manager Matthew Dillon matt.dillon@airah.org.au Tel: 03 8623 3000
Editor Mark Vender mark.vender@airah.org.au Tel: 03 8623 3022
Contributing writer Sean McGowan
There are growing concerns in Australia that Certificate II technicians are taking on the work of Certificate III fridgies. Sean McGowan looks at the current trade qualification system, how it came about, and what members of the industry think should be done to fix its shortcomings.
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Glenn Douglas glenn.douglas@airah.org.au Ph: 03 8623 3018
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The Toolshed
Skills Workshop 15
See what’s new in the ‘Shed
John McGrath john.mcgrath@airah.org.au Ph: 03 8623 3007
8 Global Update Industry news from around the world
ISSN 1834-9522 HVAC&R Nation is printed on paper sourced from well manned forests and other controlled sources.
Commissioning hydronic systems
Exclusive to June
12 Industry Insider A new online directory for HVAC&R businesses
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Green Wedge Micro-recycling plants could turn our trash into treasure
Disclaimer HVAC&R Nation is an official publication of the Australian Institute of Refrigeration, Air Conditioning and Heating Inc. Statements expressed in HVAC&R Nation do not necessarily reflect the policy or views of AIRAH or its members. No responsibility is accepted by AIRAH, the Editor or HVAC&R Nation’s supply partners for the accuracy of information or for errors or omissions. HVAC&R Nation is distributed without charge to all financial members of AIRAH. The publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from advertisers and contributors against damages or liabilities that may arise from material published. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without permission of the Publisher.
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Cool Tech YT Industries’ Capra mountain bike is a downhill demon
24 Around the Nation Who’s in the news?
26
Safety Corner The importance of PPE for your ears
28 Smoko with . . . Q&A with Dane Berg
29 AIRAH News Who won the awards at ARBS 2018?
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Locked up! Here at HVAC&R Nation we get to see a lot of AC fails in our Lighter Side entries, and lately we’ve noticed a trend – homeowners putting outdoor units in boxes. We explore the problem, and the solution.
Lighter Side The shonkier side of the nation
PLEASE CONSIDER THE ENVIRONMENT AND RECYCLE THIS MAGAZINE IF YOU ARE NOT GOING TO KEEP IT.
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 3
Editorial
SHOWTIME!
Again, the enthusiasm and the passion of the attendees was obvious. There were some fierce criticisms of the current system of trade qualifications and training – voices were raised and words were not minced. The problems spoken about included the Certificate II/III issue, covered in our feature on page 20. Everyone in the room agreed that the industry faces a big challenge in attracting workers and making sure they are properly prepared for the job. There was also a lot of furious head nodding when the speakers talked about overhauling the current training system. But despite this, the hardest part might be forming a working consensus. We will see. Another highlight was visiting the stalls and talking to people about their businesses. From infrared heaters to cooling tower maintenance, it was a chance to learn more about the industry and the technology, and I soaked up as much as I could!
There’s a lot of enthusiasm, and it’s contagious.
There was plenty of leading-edge gear on show, and it got me thinking that just as the industry tends to be invisible, the products won’t often make your average Joe (or Jo) stop and stare. It’s been on my mind because of our feature on residential AC condensers, and the way some householders use boxes to hide outdoor units that they see as ugly. Maybe there’s an opportunity for manufacturers to design units that home owners want to show off, in the same way that people like showing off their Dyson vacuum cleaner, their Delonghi toaster or even their Calvin Klein underpants.
Would you buy a used manifold from this man?
Since the last issue of HVAC&R Nation, ARBS 2018 has come and gone, and what a whirlwind it was. Did you make it to Darling Harbour? If so, did you enjoy it? It was my first time at Australia’s biggest HVAC&R show and I was definitely blown away (boom tish). The scale of the event was impressive, as were the crowds. According to the organisers, more than 9,000 people filed through the doors over three days, making this the best-attended ARBS ever.
Two things that struck me were the intensity and the camaraderie. Time flew as I spoke to show-goers at the AIRAH stand about their work in the industry. There’s a lot of enthusiasm, and it’s contagious. I also got a chance to wander around, and one highlight was the Speaker Series session on the modern technician and the future of the refrigeration trade. It sounded like it might cover similar territory to our feature last month on future trends in HVAC&R; in fact, it looked at how crucial it is to improve training to make sure the industry has a healthy future.
More and more people are turning to the eskimo for independent residential air conditioning advice for consumers 4 | HVAC&R Nation | www.airah.org.au/nation | June 2018
Fridge manufacturers have already gone down this route – walk through any big whitegoods retailer and you’ll find homemakers drooling over the most stylish models. Perhaps if we could elevate air conditioning from the functional to the aspirational, we could not only tap into new markets, we could prevent some of the crimes against condensers that you’ll find on page 10. A big thanks to the organisers and for everyone who attended for an awesome event. We’ll have a full ARBS wrap in our July issue. @AIRAHnews
Mark Vender Editor mark.vender@airah.org.au
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June 2018 | www.airah.org.au/nation | HVAC&R Nation | 5
Toolshed 01
Chief technology officer Jonathan Eastgate said that cutting out the need for a separate SMS provider would allow businesses to save up to 60 per cent on their plans.
Cut the vibes with Victaulic
Victaulic made the most of the big crowds at ARBS last month to launch its Vibration Isolation Pump Drops Series 390 and Series 391.
“Our SMS services are run from simPRO, by simPRO, cutting the need for third-party providers,” he said. “This means a dramatic reduction in administrative stress and cost.”
“Victaulic’s Vibration Isolation Pump Drops combine all required pump dressing components into manufactured, ready-to-install units to connect the pump to the header,” the company says. “Unlike traditional pump builds that treat each valve, fitting and accessory as independent components, our pump drops provide a factory-tested, single-SKU assembly of products that speed installation and reduce risk on the jobsite.
SMS plans are available in Australia, New Zealand, the US and UK to complement simPRO's job management solution. Starting from just $10 a month in Australia, the SMS packages range from 110 to 1,250 messages, giving businesses plenty of options.
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“The range of SMS packages simPRO now provides means businesses can choose the right deal to suit their communication needs, and all the money businesses save can then be moved over to other operations budgets,” Eastgate said.
“Unlike flanged pump builds, no specialty flex connectors or bellows are required,” Victaulic says. “By utilising a combination of rigid and flexible couplings to assemble the units, the pump drops are value-engineered to isolate and attenuate vibration caused by pumps and other components in the system, reducing excess noise and stress on pipe joints.”
The service will suit organisations that prefer using SMS services to update and inform customers on work progress or alert workers of a new job or request, meeting or project reminders, either onsite or in the office. Go to simpro.com.au/features/sms n
The Series 390 and Series 391 Pump Drops are available in line sizes 3–12”/DN80–DN300, with a range of reducing sizes that connect to the pump.
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“This launch further highlights Victaulic’s commitment to creating products that are easy to install and reduce risk on the jobsite,” said David Ellis, Victaulic’s regional manager for east coast Australia and New Zealand. “We’re pleased to be bringing our latest innovations in isolation pump drops to the Australian market.”
Walk-in cool rooms are becoming increasingly popular in Australia, so ARBS was the perfect place for Actrol to reveal its plug-and-play refrigeration system for walk-in cool rooms: the DC-3. Actrol says the system is fully programmed, energy efficient and simple to install, with new brushless DC scroll compressor technology to reduce outdoor noise.
Go to www.victaulic.com n 02
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Actrol’s walk-in solution
Winning work boots for women
Project lead Roger Stringer, M.AIRAH, who unveiled the prototype at ARBS, says it was well received.
During June, safety footwear manufacturer Oliver Footwear is promoting its women’s PB 49 range with a big giveaway.
“Chatting to our customers about the new system, they were really excited about not only the new tech but also the potential savings to their energy costs,” he says.
“For years Oliver Footwear has recognised the rising numbers of women in industry aren’t as spoilt for choice when it comes to safety compliant and comfortable boots as their male counterparts,” says the company. And the PB 49 series could change that.
The control system is integrated into all three components of the system, enabling real-time adjustments to maximise the coefficient of performance (COP). Tests suggest energy savings of around 30 per cent compared to a conventional refrigeration system.
The range includes a lace-up boot in wheat (pictured), a zip-sided boot in wheat or black, and a black slip-on shoe, all of which have a steel toe, protection for the heel and ball of the foot, and slip-resistant soles that Oliver claims are resistant to mineral and organic oils/acids and heat resistant to temperatures of 300˚C. These models are all made of nubuck or full-grain leather (depending on colour). There’s also a grey/blue lace-up shoe made of microfibre and sports mesh. Like the boots, these have steel toes – but do not come with the pink laces.
“Suction and condensing pressures float to minimise energy input while providing very stable room temperature control,” Actrol says. “This will extend the shelf life of many products. Compressor cycling is almost eliminated and defrosts minimised.”
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The system also has a speed-boost function, which temporarily increases the compressor speed to assist oil return, EEV controlled oil return and liquid injection, and an evaporator washing cycle that flushes oil from the evaporator to maximise heat transfer. The DC-3 will be available this spring. Go to www.actrol.com.au n
All models comply with Australian and New Zealand safety standards. To promote the range, Oliver Footwear is offering a swag of prizes until the end of June: a $2000 Freedom Furniture voucher, two $500 Country Road vouchers and five $200 Sunglass Hut vouchers. For a chance to win, buy a pair of PB 49 series woman’s boots from a participating stockist, keep the receipt and complete the entry form.
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SMS smarts from simPRO
Technology company simPRO has launched an SMS plan that will give businesses the ability to use mobile devices in the job process without having to worry about added service providers and logistics. 6 | HVAC&R Nation | www.airah.org.au/nation | June 2018
GPI, an importer of world-renowned air conditioning and refrigeration products, has announced the arrival of a new condensate pump in the Blue Diamond range: the MicroBlue. Although it’s the smallest pump in the Blue Diamond range, it is claimed to have a maximum flow of 5 litres an hour, maximum head of 5m and a maximum lift of 2m – high performance for its size.
Go to www.oliver.com.au n
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Tiny diamond
05
GPI says that the Blue Diamond pumps – including the Micro, Mini, Maxi and MegaBlue – are ideal for condensate water removal in split air conditioning systems. “The pump range including the MicroBlue are silent running, ranging from (17–23dBA),” says the company.
Toolshed “All of our pumps can be mounted in any orientation while operating both wet and dry continuously. It has the ability to pump sludge and slime without the risk of burnouts, reducing the risk of premature failures.”
The silencers incorporate baffles with internal surfaces fabricated from perforated sheet metal, along with high density insulation such as Bradford Glasswool for broadband sound attenuation.
The pumps are said to run silently without an additional silencing device. The company also claims that they can continuously run dry, with no siphoning device to install or premature failures. They are dual voltage and use the company’s thermistor level sensing technology, as well as a reservoir that is claimed to eliminate the risk of stuck or sunken float switches.
In a company case study, Bradford Ultratel (48kg/m3) with Bradford’s Black Matt Facing was shown to provide both mass and absorptive properties for excellent acoustic attenuation across a range of sound frequencies. The Black Matt Facing also allows airflow while providing a clean aesthetic finish, which improves the durability of the acoustic baffles.
The rotary diaphragm has a simple two-piece assembly to make the pump easier to install and operate correctly. And it does not have tubing that will require replacement, making it a low-cost alternative to peristaltic pumps in the long term.
Bradford proudly claims that it manufactures to strict product tolerances and provides the most comprehensive warranty in the market with a lifetime cover on performance of product, “all backed by CSR, Australia’s oldest and most trusted building products manufacturer”.
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All of this is supported by a three-year warranty.
The DesignSmart team also offers services in projectspecific support, value engineering challenges, specification documentation, system design detailing, product installation and certification.
Go to www.gpimport.com.au
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Silence is golden
“The team has a wealth of construction experience and utilises industry-leading building science research for acoustic, thermal and fire insulation products,” says the company.
Bradford designSMART Technical Services is offering a selection of HVAC silencers that reduce noise transmission from air handling units to the rest of the building.
Go to BradfordDesignSmart.com.au n
Email mark.vender@airah.org.au All submissions received will be considered, though publication cannot be guaranteed.
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Derek Munn
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Ed Hanley
Joe Timi
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Innovation and Technology Manager
Architectural Support
Technical Sales Engineer
Technical Sales Engineer
Technical Service Manager
National Technical Manager
Call the DesignSmart team 1800 354 044 For more information visit BradfordDesignSmart.com.au
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 7
Global Update
USA
UK
GERMANY
MARS MISSION
HVAC HACKER HEIST
TEUTONIC TREND
One problem of controlling indoor climates in space is the lack of air to carry heat away. So a team of mechanical engineers at Worcester Polytechnic Institute in Massachusetts is developing a new electrical cooling system with no moving parts for use in space, particularly for missions to Mars.
Hackers have used a thermometer in a casino’s lobby aquarium to steal important information.
Last year heat pumps overtook gas for the first time to become the most popular form of domestic heating in Germany.
Spacecraft produce a lot of heat from their power systems, electronics, mechanical parts, and the bodies of the astronauts. Because these are all surrounded by a vacuum, there is no air to conduct or convect the heat away. Current radiative cooling systems are not efficient and produce noise and vibrations. The prototype electrohydrodynamic (EHD) cooler uses electrically charged fluids running through tiny tubes to carry away heat quietly and smoothly. The system is being tested aboard the International Space Station. n
USA
“The attackers used [the thermometer] to get a foothold in the network,” says Nicole Eagan, CEO of cybersecurity company Darktrace. “They then found the high-roller database and then pulled that back across the network, out the thermostat, and up to the cloud.” Hackers targeting internet of things (IoT) devices is a growing problem for UK companies. IoT refers to devices hooked up to the internet to allow monitoring of live data streams. “There’s a lot of IoT devices,” Eagen says, “everything from thermostats, refrigeration systems, and HVAC systems, to people who bring in their Alexa devices into the offices. It expands the attack surface, and most of this isn’t covered by traditional defences.” n
JAPAN
Based on figures released by the Federal Statistical Office, heat pumps were installed in 43 per cent of residential buildings. This edged ahead of of gas heaters, which represented 42 per cent of installations. Air-source and water-source heat pumps accounted for about 35 per cent, with geothermal representing 8 per cent. “The heat pump is increasingly being recognised by builders, planners and specialist contractors as the standard heating system for new buildings,” says Martin Sabel, managing director of heat pump association BWP. “The big advances in device efficiency, usability and design are driving demand.” In the overall market, gas (at 42 per cent) is just ahead of heat pumps. n
IRELAND
BIOHAZARD FRIDGE NOT RIDGY-DIDGE
JAPAN LENDS EXPERTISE
GRAND RAND PLAN ON TRACK
Medical thrillers such as Contagion have made us aware of the dangers of potent biohazards. Perhaps that’s why a refrigerator replete with biohazard markings caused evacuations when it was dumped on a major thoroughfare in Temple, a regional centre in central Texas.
The United Nations Industrial Development Organization (UNIDO) and the Japan Refrigerants and Environment Conservation Organization (JRECO) will collaborate on an initiative to promote the use of climate-friendly technologies in refrigeration and air conditioning applications.
As part of its global Climate Commitment, Ingersoll Rand has committed to a 35 per cent reduction of its greenhouse gas footprint from its operations by 2020. To deliver on this goal, it targeted a 10 per cent increase in energy efficiency from a 2013 baseline. The company has achieved the goal two years ahead of schedule.
“Japanese industries in the RAC sector have valuable expertise for accelerating the replacement of harmful refrigerants with low global warming potential alternatives,” says UNIDO’s Ole Nielsen. “JRECO can play a catalytic role in promoting the transfer of the technologies from Japan to the countries working with UNIDO.”
“Energy efficiency is a primary consideration in everything we do across our own operations and for our customers in the building, industrial and transport industries,” says Paul Camuti, the firm’s chief technology officer.
Police closed the road for two blocks either side of the store in front of which the refrigerator had been dumped. Businesses in the area were also evacuated. Markings on the refrigerator indicated it contained a biohazard, and the fridge was plugged in when it was found. Two bomb squads were called in, and every available police officer in the area was called in to help secure the area. After x-raying the refrigerator, bomb squad personnel discovered that it was empty. n
8 | HVAC&R Nation | www.airah.org.au/nation | June 2018
The groups will identify technical cooperation project opportunities to be implemented with funding from the government of Japan. n
The firm conducted an energy audit of its large facilities, and upgraded air conditioning systems, building controls and lighting, and eliminated energy leakage from its compressed air systems while measuring, validating and reporting the results. It reduced energy use by 22,000MWh. n
Good Design Award Winner
Modern design. Classic good looks. A beautiful, timeless design specifically developed to match well with a variety of wall colours and textures.
Different temperatures in different rooms at the same time. QUE comes with the ability for individual temperature control built in as standard.
Control without compromise. QUE is the most advanced integrated home air conditioning control platform yet. Coming with a sleek modern design and high-quality components, QUE’s easy to use interface brings home air conditioning controls into the 21st century. QUE is more than just a pretty face – it’s a control platform packed full of innovations and features, that can evolve with you and adapt to meet your changing needs into the future. And while QUE is one control platform, it provides many control options, allowing you to control the system from a variety of touchpoints:
Master Controller
Zone Controller
Remote Sensor
Mobile App
Smarty pants. 5.7” 1080x720 pixel, full colour touch screen and powerful dual core processor with 1GB RAM.
Life is wireless – now your controls can be too. You can now connect your zone controllers and room sensors wirelessly, allowing for a simple installation that minimises intrusions and can save time and money.
Complete control at your fingertips. QUE provides you with a level of control never before possible in home air conditioning, with features like Energy History, a Scheduling function, and an easy to use Master Timer.
Connect to comfort, wherever you are. The QUE platform comes complete with a mobile app, QUE Connect as standard.
It’s thanks to features like these that QUE delivers control without compromise.
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 9
Feature
LOCKED UP!
Sometimes the most valuable lessons come from those who never intended to give them. And nowhere is this truer than in HVAC&R Nation’s most popular monthly feature, The Lighter Side. We regularly see photos of shoddy split system installations – from odd locations of indoor units to poor condensate pipe set-ups. And increasingly, we’re seeing some very creative ways to disguise condenser outdoor units too. Many of these are no doubt the work of the home handyman rather than the installer. But we are hearing of so many systems not operating correctly due to the condenser being enclosed that we think it’s time to look at the dos and don’ts of condenser outdoor units. And if it must be enclosed, we’ve found out the best way to do it.
CONDENSER UNITS 101 Condenser units are a critical component of any split system air conditioner. They are designed to operate within free, outdoor spaces, and require adequate airflow across the heat exchanger to function properly. For this reason, they should never be enclosed, boxed in or placed in restricted spaces. In cooling operations, the heat removed from the home is discharged through the condenser. But when the suction airflow is restricted as a consequence of the unit being improperly covered, the high-pressure and high-temperature vapour from the compressor does not fully condense, thereby raising the condensing pressure of the system. As the heat is not fully discharged, the degree of sub-cool refrigerant produced is reduced, which may subsequently reduce the ability of the indoor unit to cool the room effectively. “In cooling operations, restricting the airflow will raise the condensing pressure and power input of the system, and reduce the capacity output of the system,” says Raj Singh, M.AIRAH, national product manager for Daikin Australia. “Hence, its ability to provide effective cooling of the occupied space is affected by the airflow restrictions on the condenser.” As well as affecting the unit’s ability to deliver cooling, the high condensing pressure also makes the compressor work harder. This not only creates greater wear and tear on the systems, but results in greater power input and higher energy bills for the consumer.
At last coun t, over 7 milli on single sp systems were lit non-ducte operating in d air conditio A ustralia – mo ning And for som st in domes e homeown ti c settings. ers, the outd an eyesore th oor units are ey’ll do anyth s o much of ing to cover investigates them up. Se the latest sp an McGowa ate of crime n s against co ndensers . . . 10 | HVAC&R Nation | www.airah.org.au/nation | June 2018
If the discharge of the condenser outdoor unit is also restricted, the condensing temperatures and pressures may rise and the hot discharge air could be recirculated back into the suction side of the condenser. “The higher temperature suction air further exacerbates the effects of high condensing temperatures and pressure, which in turn increases the compression ratio of the system, the degree of discharge superheat and the work done by the compressor, resulting in even higher power input,” says Singh. “This will increase the wear and tear of the system, impact on its reliability and longevity and ultimately lead to equipment failure.”
Feature
SERVE AND PROTECT
says Singh. “This is when problems will surface, which in severe cases can cause malfunction of the systems.”
Access for service and maintenance must also be considered, with sufficient space in front of the unit provided to enable the technician to work uninhibited (typically 500–600mm).
If noise attenuation is required, Singh says some models offer low noise settings that can be set from the outdoor unit field settings by a qualified technician.
Yet despite these recommendations, it is not uncommon to find split system condenser outdoor units covered – even on commercial projects. “On bigger commercial projects it’s quite often the architect that requires it, and even if the contractor did everything perfectly, it is not unusual for the builder to add a cover afterwards,” Kossen says. “At the domestic level, it’s quite often the home handyman that has knocked something up after watching a home renovation show on television.” In some applications where the condenser unit is either a security and/or accessibility concern (such as schools or public places), purpose-built guards can be used without impacting the airflow across the unit, or the ability for the unit to be serviced. According to Steve Markovitch, managing director of Pro Pipe Supplies in Adelaide, guards are simple to install, protect the condenser unit and allow the air conditioning technician to access the unit for servicing. Unlike homemade contraptions, these are purpose-made and feature iron frames, galvanised steel mesh and the ability to fasten the guard to a wall or concrete pad. The front access panel can also be padlocked for added security. “Our guards have been specifically designed to meet strict South Australian government specification,” Markovitch says.
Some enclosures are also available to attenuate noise, but need to be designed by a qualified engineer and are not suitable for all models of condenser outdoor units. To this end, Kossen says he would prefer to see soft furnishings and even plants (at sufficient distance from the unit, of course) used to attenuate noise rather than covering the condenser unit.
At HVAC&R Nation, we’ve seen many examples of homemade enclosures, made out of anything from timber decking to construction offcuts. And we’ve seen our fair share of poorly considered locations too.
And if the homeowner is hellbent on maintaining the aesthetics of their home, he suggests having the condenser unit’s cabinet colour-coded to match the colour of the building or fence – albeit it at the homeowner’s cost.
A Daikin technician even discovered two condenser units located indoors within a purpose-built cupboard, such were the lengths the homeowner went to achieve their desired aesthetics.
But one thing is for sure: by incorrectly installing a split system air conditioner, or covering the condenser outdoor unit, you are risking the manufacturer’s warranty.
“At times, the aesthetics of the final installation is given far greater priority compared to the design requirements of the condenser for proper operations,”
“If products are not installed as per the manufacturer’s guidelines and recommendations, warranties may be voided,” says Singh.
HIDE AND SEEK CHAMPIONS While we do not condone the covering of condenser outdoor units in any way, we have to laugh at the lengths some people will go to. Here are a few of our favourites.
CLEAR AIR According to Stefan Kossen, pre-sales engineer for Panasonic, split system outdoor condenser units should (if space allows) be installed at ground level on a separate slab not attached to the building, with a sand base under it. The recommended space required around the condenser outdoor unit differs according to the manufacturer, and whether the unit is a commercial or domestic model. All manufacturers recommend that domestic units not be obstructed in any way.
300mm or more from top
100m or mo m r f ro m e b a ck
mm 100 ore m r o si d e f ro m
A technician discovered this elaborate solution when called out for servicing. We’re not sure what to be more surprised about – the cupboard or the fact it’s all indoors! This homeowner sits on their condenser outdoor unit. We’re fairly sure there is very little air across the front of the unit, and hot discharge air is recirculating back through the system.
mm 30 0 o r e o r m si d e f ro m 1m o e tr fro r moree mf ro n t
Hidden in plain sight, this condenser probably didn’t last too long. Full marks for the owner in achieving a consistent, weathered timber look though.
Surely this enclosure wasn’t made for aesthetics? In trying to keep the rain (and maybe the dog) out with this timber lattice and steel combination, they’ve kept the air out too.
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 11
Industry Insider
ARE YOU ON THE LIST? Give your business a bump by signing up to AIRAH’s online industry directory.
For businesses, HVAC&R Search offers four types of listings. You can join for free for a basic listing, or select from the Essentials, Premium and Storefront packages. Each level includes more functionality, including the ability to add videos, images and articles, and upload information about products and services.
Look in the offices of HVAC&R businesses in Australia and there’s one book you’ll almost always find on the shelf: AIRAH’s Industry Directory. For more than 10 years it has been the reference of choice for companies working in the sector – pretty much the Yellow Pages of HVAC&R.
AIRAH CEO Tony Gleeson, M.AIRAH, says the new directory is a big step forward.
But as the gradual disappearance of the hard-copy Yellow Pages proves, the times they are a changing. Recognising the need for an online version of the directory that takes advantage of the latest functionality, AIRAH has relaunched its online page with a new moniker: HVAC&R Search.
“The features built into HVAC&R Search enable large and small businesses to showcase their diverse products and services in an impressive and professional manner. The powerful search function means users can find what they’re looking for quickly and efficiently.”
Boasting greatly enhanced features and allowing you to create and manage the listing for your own business, AIRAH’s HVAC&R Search website is set to become the go-to online guide for the industry. Users can browse and search in six main categories: heating, ventilation, air conditioning, refrigeration, building services and business services.
Tayler Stevenson, Affil.ARIAH, product manager of factored gases at BOC Limited, says HVAC&R Search is visually easy to navigate. He says that having individual product pages with images and the ability to upload video and articles allows businesses more scope than in a standard directory to showcase their wares.
“AIRAH’s hard-copy Industry Directory remains extremely popular,” he says. “But we felt the original online version was not providing the functionality required.
12 | HVAC&R Nation | www.airah.org.au/nation | June 2018
“Being on HVAC&R Search means potential customers can find your business by searching for products,” he says, “even if they don’t know your business or what it offers them.” Smaller businesses have also reacted positively to the new interface – and the ability to put themselves in the HVAC&R shop window. Paul Hawkins from software provider TopWise read about HVAC&R Search in these pages and signed up for a free listing. “It was very easy to do,” he says. “We’re hoping to reach small to medium HVAC&R companies looking to digitise, mobilise and empower their field staff. And we use the directory for leads.” EnviroChill, a small family business based in Brisbane, also listed for free. “I had a look through the directory before I registered and thought it was very easy to find services that most businesses would need,” says Trinity Bond from EnviroChill. “We are hoping to expand our coldroom cleaning and hygiene service as well as temperature monitoring this year, so any exposure we can get through industry sites like this is great.” Businesses that purchased a spot in the hardcopy 2018 AIRAH Industry Directory have automatically been listed on the new website. And until June 11 there’s a discount of 40 per cent off all paid listings – just use the promo code ARBSNATION. n For more information about HVAC&R Search go to www.hvacrsearch.com.au
ARBS AwardWinners_310x220.pdf
1
14/5/18
10:57 am
ARBS Industry Awards are proudly sponsored by
...and the 2018 ARBS Awards winners are…
YOUNG ACHIEVER AWARD Jason Harrison - Airmaster Australia
PROJECT EXCELLENCE AWARD F Mayer Refrigerated cold storage/distribution centre - Strathbrook Industrial Services & Danfoss Australia
PRODUCT EXCELLENCE AWARD
SOFTWARE/DIGITAL EXCELLENCE AWARD
ACDHUM-LD - Air Change
Clarity - HydroChem
OUTSTANDING INDUSTRY EDUCATION/ TRAINING AWARD
OUTSTANDING SERVICE & MAINTENANCE AWARD A.G. Coombs Group Pty Ltd
Mobile CO2 Training Unit - Danfoss (Australia) Pty Ltd
ARBS HALL OF FAME 2018 Pictured left to right: Stephen Gilchrist - CIBSE ANZ, John Bosci - AIRAH, Mark Padwick - AREMA, David Seedsman - AMCA and Warren Cole - RACCA
arbs.com.au
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 13
Green wedge
THINK MACRO, ACT MICRO As the world faces a recycling crisis, a new project at UNSW offers a potentially profitable way forward. Earlier this year, China brought in a policy that changed the global recycling game – the world’s biggest purchaser of other countries’ salvaged materials banned imports of 24 categories of solid waste. Recycling champion Professor Veena Sahajwalla founded the SMaRT centre in 2008.
For Australia and many other nations that had come to rely on shipping their recycling overseas, this forced a rethink. Urgent calls are now being made to government to build more local recycling facilities, and change legislation to require greater use of recycled raw materials in products. All of which takes time. Meanwhile, one group who has been working on a solution for years has made a very timely launch of a ready-to-go recycling concept: the e-waste microfactory. The factories are described as “micro” for good reason – they can operate on sites as small as 50m2. Based on the work of UNSW’s Centre for Sustainable Materials Research and Technology (SMaRT Centre), they use robots and furnaces along with patented technology to reform waste products into new and valuable resources. The micromaterials that are salvaged can be used in industrial-grade ceramics, while the specific quality plastics from computers, printers and other discarded sources can be turned into filaments suitable for 3D printing. Metal alloys can also be used as metal components for new or existing manufacturing processes.
“We have proven you can transform just about anything at the micro level and transform waste streams into value-added products,” says SMaRT Centre director Professor Veena Sahajwalla. “These microfactories can transform the manufacturing landscape, especially in remote locations where typically the logistics of having waste transported or processed are prohibitively expensive. This is especially beneficial for the island markets and the remote and regional regions of the country.” The next step for the SMaRT Centre is to commercialise and create incentives for industry to take up the technology. n
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14 | HVAC&R Nation | www.airah.org.au/nation | June 2018 HVAC HP Be Impressed 220X150 NoBleed v1.indd 1
19/10/2015 12:23 pm
COMMISSIONING Skills STEPS Workshop FOR HYDRONIC SYSTEMS HVAC&R
MODULE
112
PROUDLY SPONSORED BY
AIRAH
Skills summary n What?
A guide to steps required during the commissioning phase for hydronic systems. It covers cleaning, air removal, vents, control systems, water balancing and pump flow.
n Who?
PULLOUT
Especially relevant for anyone involved in the commissioning process for hydronic heating and cooling systems.
SYSTEM CLEANLINESS In the design stages, adequate provision must be given to the removal of all extraneous matter by flushing out the system. Removal of air is also of the utmost importance to minimise corrosion; therefore, extraction provision should also be allowed for in the design stages. Dirt and air can adversely affect the accuracy of the measuring instruments used to perform the balancing process.
TYPICAL CLEANING METHODOLOGY After the hydrostatic pressure tests have been approved and prior to putting the system into operation, the system should be drained and immediately refilled with a solution of water containing a non-foaming alkali detergent. The solution should now be circulated continuously for a minimum of 16 hours, cleaning the strainer as required. On completion, drain the system again, refill with fresh water and circulate for a further two hours. The system can now be drained, then refilled with water and chemical treatment to establish the correct pH level. On larger installations the cleaning of the system may be achieved by the continuous removal of water while the system is running over 24 hours, taking care to monitor the discharged water to establish an adequate state of cleanliness.
Hydronics is defined as the science of heating and cooling water, hence hydronic systems may be described as a heat transfer medium whereby the fluid from one source, such as a boiler or chiller, is circulated to a series of terminal units via a pump. This skills workshop describes tasks that should be conducted during commissioning of hydronic heating and cooling systems before they go into operation.
AIR REMOVAL
determine the amount of dissolved air released from the water: 80–50 = 30 litres per 1,000kg.
This section is largely an extract from material kindly provided by Tradelink Industrial Supplies. The removal of air is paramount to minimise corrosion and to ensure the internal surfaces (in regard to the heat transfer surface) are only in contact with water. This procedure must be carried out prior to any commissioning being performed.
HENRY’S LAW The water within a hydronic system will contain air that has been absorbed into the water as tiny air bubbles. If the corresponding pressure within the piping system drops below the ambient pressure, then air may be induced into the system and in turn be entrained into the water. The pressure of air dissolved in water can be explained by reference to Henry’s Law, which states:
When the pressure of the water is lowered from 400kPa to 220kPa, Henry’s Law can be used to calculate the amount of air released. as shown in Figure 2.
Litres/1,000kg
Temperature °C 0 20
Amount 80 of air released from 50 the water
80 100
0
300
Pressure kPa Litres/1,000kg
Figure 1.
Temperature °C 0 20
Amount 75 of air released from 40 the water
C = K x P C = Concentration of dissolved air (litres of air/1,000kg water)
80 100
0
K = Absorption factor (dependent on temperature in ⁰C)
220
Pressure kPa
P = Pressure (bar absolute)
400 Figure 2.
In this case the amount of dissolved air released from the water is 75–40 = 35 litres per 1,000kg.
Henry’s Law in a cooling system The lower the pressure, the greater the amount of air that can be released, as shown in figure 1. When the temperature of the water is raised from 0 to 20⁰C, Henry’s Law can be used to
As the temperature of the water in a cooling coil rises, air can be reabsorbed into the water. It is therefore important that air-bleed devices are fitted on the entry and exit pipe stubs, or on the tops of the coil water headers.
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 15
HVAC&R Skills Workshop It is also important to ensure that entrained air cannot enter the chilled water pump, because this can cause cavitation within the pump and damage the pump impeller.
Air released from an automatic air vent with increasing pressure l/sec
l/min
0.40
24
Henry’s Law in a heating system
0.35
21
0.30
18
In a heating system, as the water temperature decreases and the system pressure increases, air can be re-absorbed into the water.
0.25
24
0.20
12
0.15
09
0.10
06
0.05
03
As water passes through a boiler and the water temperature is increased, any entrained air will be released. If the air is not removed at this location, the air will be re-absorbed into the water where the system temperature is lower.
Litres/1,000kg
20
Amount 75 of air released from 40 the water
80 100
0
220
Pressure kPa
1 2 3 4 5 100 200 300 400 500
6 BAR 600 kPa Figure 4.
0
400 Figure 3.
When the temperature of the water is raised from 20 to 80⁰C, Henry’s Law can be used to determine the amount of dissolved air released from the water: 75–40 = 35 litres per 1,000kg. See Figure 3. When the pressure of the water is lowered from 400kPa to 220kPa, Henry’s Law can be used to calculate the amount of dissolved air released from the water: 75–40 = 35 litres per 1,000kg.
AUTOMATIC AIR VENTS Automatic air vents can be used on both heating and chilled water systems that are sealed. On opened systems, care must be taken to ensure that air is not induced into the system via these air vents. The automatic air vent consists of a float within the chamber. Air bypasses the float, causing the water level to decrease and allowing the vent port to be opened and the air to be expelled to the atmosphere. As the air is released the water level rises again and the float seals the vent port. Automatic vents should be located at all high points where the air will collect naturally. The best locations are within the water system where the highest temperature and lowest pressure occurs. The amount of air released via the automatic vents is dependent on the correct location of the vent point and the amount of dissolved air within the system. An indication of the relationship between air released and the system pressure is shown in Figure 4. In reality, even after the system has been filled with cold water and all the air released from the high points of the system, not all of the air has been removed.
The pump discharge must now be throttled to reduce the water velocity and system pressure. A better option is the use of a variable speed drive, which ensures better energy savings, or the replacement of the pump impeller to suit the actual system resistance available. This will in turn allow for more of the remaining air to be released at the high points within the system. The boiler should now be fired up and the system brought to the operating conditions to allow the entrained air to be released.
CONTROL SYSTEMS This is the final component of the commissioning process to ensure that the controls allow the individual components to attain their original design performance and ensure that the overall system design objectives are achieved. Due to the complexities of the types of controls used – pneumatic, electronic and digital electronic (DDC), which is becoming the standard within the industry – this topic will not be completely addressed in this Skills Workshop. Only an overview will be applied.
ACCESS TO EQUIPMENT The designer should make adequate provision for access to the equipment, not only for maintenance but also for commissioning purposes to facilitate the adjustment of flow rate to achieve the design intent.
BALANCING AIR VERSUS WATER SYSTEMS There is a considerable difference between air and water balancing requirements. Air balancing needs to be more precise within the balance, due to the air being the primary heating or cooling medium. A reduction in airflow rate below the design requirement will provide a linear (directly related) reduction in load carrying capacity. Water side flow rate will differ from that of air, since it is not linearly related to the terminal unit heat transfer capabilities. Therefore, the water flow rate does not need to be as precise as that required for the air balance on heating systems only.
16 | HVAC&R Nation | www.airah.org.au/nation | June 2018
A heating-only hydronic system can operate satisfactorily with a reduced water flow rate because of the water/air heat transfer relationship. A decrease of 50 per cent of the design flow rate can still achieve approximately 90 per cent of the design heat transfer capability. This is because the governing parameter is the airside heat transfer coefficient.
0
Temperature °C
Example: Heating
Previous experience with hot water system installations can lead the mechanical contractor to think it may not be necessary to have the system balanced; this practice is dangerous since short-circuiting and associated problems can occur from this omission.
Example: Cooling Chilled water terminals are far less tolerant to a decreased flow because the air-to-water temperature difference is much less than that of a heating terminal. The first noticeable loss is a reduction in latent heat capability due to the reduced water flow rate. This is followed by a loss of sensible heat. A reduction in chilled water flow rate to 50 per cent of the design flow rate can result in the following loss of capacity: • Latent heat of transfer equals 35 per cent of the design • Sensible heat of transfer equals 85 per cent of the design • Total heat of transfer equals 70 per cent of the design.
SYSTEM DESIGN AND BASIC DATA Head or pressure To solve any flow problem a basic knowledge of the physical properties of the fluid is required. Although the pressure of air at sea level is 101.325kPa, this is reduced to only 89.9kPa at an altitude of 1,000m. Most pressure gauges are calibrated with reference to atmospheric pressure, therefore care should be taken to obtain absolute pressure (gauge pressure + atmospheric pressure) when making calculations. Canberra, for example, has an elevation of 243.84m, equivalent to 98.44kPa.
Definition of common “head” terms When working with pumps the word “head” is generally used to define pressure. Note that the terms “head” and “pressure” are often mistakenly used interchangeably. • Dynamic discharge head is equal to static discharge head plus friction head plus velocity head • Dynamic suction head is equal to positive static suction head minus friction head minus velocity head • Dynamic suction lift is the sum of suction lift and velocity head at the pump suction (when the source is below the pump centre line)
HVAC&R Skills Workshop Flow velocity
• Friction head is the height of liquid (metres) that represents system resistance caused by flow
Flow velocities are usually determined during the design stage with a pressure drop in the main distribution branches ranging between 100 and 350Pa/m.
• Static head is the hydrostatic height of a fluid. In a closed system the static head has no effect on performance apart from the pump casing being able to handle the static head within the system
Flow rate tolerance It is suggested that the heating water flow rate should be between ±10 per cent of design, even though normal hot water systems can tolerate a wider flow deviation.
• Static suction head is the positive vertical height in metres from the pump centre line to the free surface of the fluid • Static suction lift is the distance in metres from the pump centre line to the free surface of the fluid (below the pump centre line)
The ±10 per cent tolerance is economically achievable, and can eliminate side-effects caused by issues such as low water velocity and air purge problems. However, terminals using low temperature hot water as found in heat recovery systems may require the tolerance to be within ±5 per cent of design flow rate.
• Suction head is the height of fluid above the centre line of the pump on the suction side of the pump. In order to size a pump, the following would apply for an open system only:
Varying pump flow
Static pressure – Suction head = Actual static head pressure loss
In some hydronic systems, the flow rate is changed by either varying the pump speed or by sequencing constant speed multiple pumps on and off.
• Suction lift is the height the fluid must be lifted within an open-type system on the suction side of the pump to reach the centre line of the pump
Varying pump speed is very popular because of the significantly reduced pumping cost brought about by the reduction in pump head and water flow rate.
PULLOUT
• Total dynamic head is the Dynamic discharge head + Dynamic suction lift, or Dynamic discharge head – Dynamic suction head
For a constant speed pump system, as the flow is reduced due to the load requirements, the pump head is increased with no resultant energy savings.
(Dynamic discharge head = Static discharge head + Friction head + Velocity head) • Velocity head is the height of fluid corresponding to the kinetic energy per unit mass of fluid divide by gravitational acceleration.
The technique in using variable speed pumps is that as the load diminishes, the water flow rate is reduced and at the same time the head on the pump is reduced. If the flow had not been reduced, most of the control valves would be closed or near closed at this time.
Effect of water/glycol mixture The use of anti-freeze agents in chilled water systems affects the derivation of flow from the differential pressure actually read by the instrument due to an increase in specific gravity of the fluid compared to water.
The use of a variable speed pump will not overcome or even help in any way the problems associated with a system that is poorly balanced If the flow rate is incorrect, it will stay that way as the pump head is varied.
Where a pressure drop is measured and the flow rate calculated by the normal process from a graph supplied by the valve manufacturer, the following step should be performed to correct the reading:
Actual Flow Rate =
Hence there is still the need to perform a water balance regardless of a variable speed pump being installed. The terminal units in most variable volume systems have individual two-way control valves that allow full diversity or random loading (0–100 per cent).
Pw x flow Pf
Where:
A minimum pressure differential must be allowed for in the design stage to ensure that all terminals receive the design flow rate at all times.
Pw = water density Pf = glycol density
Pipe diameters 15mm–50mm
Min velocity
POTENTIAL PROBLEMS It is not uncommon for project managers to allocate insufficient time for testing and adjusting at the end of a job. This is probably due to not fully understanding the extent of the work involved in the commissioning process. Commissioning is not a tangible and hence measurable item – unlike the construction phase of the project – hence the project manager tends to overlook it. Construction delays due to inclement weather and so on invariably result in lost time; usually, due to the reduction in profitability of the job, the commissioning period bears the brunt of the time shortfall. One of the other major problems facing commissioning is the deficiency in training of personnel.
System curves The frictional losses throughout the piping system will depend on the actual flow rate achieved. If only one set of friction pressure/flow rate data is available, a system curve can be obtained by using the principle that pressure varies directly as the square of the flow rate. When two values are known, the new flow rate or pressure can be calculated by the following formula:
P2 l/s2 2 = P1 l/s1 Where: P = pressure kPa l/s = flow rate
Example A system has a pressure of 100kPa with a flow rate of 1.6l/s Determine the new pressure at 2.0l/s Note that the system curve may not pass through zero due to the static pressure of the system. Frictional pressure does not develop until the pressure generated by the pump exceeds the static pressure and flow commences. The static pressure determines the starting point of the system curve at zero flow. n
MORE INFORMATION
Max velocity
Copper
Steel
Copper
Steel
0.75
0.75
1.0
1.5
RALIA THE AUST
TUTE N INSTI
, GERATION OF REFRI
AIR COND
1.25
1.25
1.5
3.0
HEATING ING AND
DA24 ST WATER SY
Over 50mm
ITION
EM BALANC
TION APPLICA
MAN UAL
ING
This month’s Skills Workshop has been taken from AIRAH Application Manual DA24 – Water System Balancing.
Table 1: Flow velocity in copper or steel pipes.
PROUDLY SPONSORED BY
AIRAH
Next month: EC Plug Fans in AHU Applications June 2018 | www.airah.org.au/nation | HVAC&R Nation | 17
GUIDE
AIRAH TIN G OF AN D HEA TIT UTE NIN GAIRA AN INS H GUID STR ALI CO ND ITIO E A guide to THE AU N, AIR Model WHS Law in Austra ERATIO lia for the REF RIG
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HVAC&R safety – an essential guide
WHS and OH&S regulations have a big impact on the HVAC&R industry and its stakeholders. With this in mind, AIRAH has published the Guide to Model WHS Law in Australia for the HVAC&R Industry. The guide sheds light on the ins and outs of regulations. And it helps provide an understanding about specific WHS issues and challenges that our industry members encounter in their work, in addition to the general duties assumed by employers and supervisors. Indeed, the guide outlines very clearly where individual responsibilities in the industry reside. AIRAH’s aim in publishing the guide is to raise awareness of legal responsibilities so that those onsite can safely install, maintain and operate HVAC&R equipment.
Buy a copy now at www.airah.org.au/store
18 | HVAC&R Nation | www.airah.org.au/nation | June 2018
Cool Tech
THE frank CAPRA ASSESSMENT Behold a mountain bike that combines downhill agility with uphill performance.
Image: Ale Di Lullo.
It’s been said in sports that it’s fine to talk a big game – so long as you can back it up on the field of play. Let’s just say Young Talent (YT) Industries, the folks behind the sleek, aggressive-looking Capra combo mountain bike, have not been backward when putting forward their machine’s bona fides.
“Once again, the Capra is setting new standards,” YT proclaims. “Confidence, creativity, endurance: this G.O.A.T. – the Greatest of All Time – will get you, and it will turn you into the rider you have always aspired to be.”
If you understand what that means then you’ll no doubt also be impressed that the all-carbon Capra frames are now full fibre, meaning no more alloy rockers or chainstays, which saves weight and is neater.
YT says the latest version of the Capra is a full-on downhill machine with the uphill performance of a trail bike.
“The modern geometry with short chainstays and a slack headtube angle perfectly unites the best of two worlds,” the company says.
“After years of rider feedback and learning about material durability and toughness, the latest frames have dumped a chunk of weight.”
“The new Capra delivers the most advanced combination of trail-bike agility and traction at downhill standard. The metric 250mm shock delivers the solid suspension travel of the Capra with a low leverage ratio, and fully convinces with a performance that’s hardly ever seen away from downhill courses.”
“The slick aluminium models also use unique new air-forming techniques to shave grams and achieve a smoother look,” says Dirt Mountainbike.
Of course, you get what you pay for. Basic models retail for $7,900. n Go to https://au.yt-industries.com
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 19
Cover Feature
LICENSED TO CHILL
Thirty years ago – as cra zy as it seem on who cou s – there we ld work on re re no restric fr ig e tions ra tion and air Despite all th conditioning e efforts ma systems. de since the full circle wit n, we may h h poorly tra ave gone ined technic of those mo ians taking o re qualified. n the work Sean McGo wan reports . For decades, many have argued that the Australian HVAC&R industry has suffered due to a lack of an occupational licence. It has resulted in refrigeration and air conditioning technicians competing with plumbers and electricians for the same work, and it has shown up the complicated differences in licensing between states. More recently, it has also aggravated Certificate III-qualified professionals who have watched on as less qualified Certificate II holders perform unlicensed work unchecked.
The introduction of these two qualifications supported the establishment of an environmental licence scheme, and in 2005 the government appointed the Australian Refrigeration Council (ARC) to administer the scheme. Certificate II qualifications were originally established to ensure only qualified tradespeople could install split system air conditioning systems and heat pumps – helping to fill a vital skills gap identified in the HVAC&R industry at the time.
20 | HVAC&R Nation | www.airah.org.au/nation | June 2018
According to the ARC, someone who obtains the relevant Certificate II-level qualification is eligible to obtain a restricted heat pump – split systems – installation and decommissioning licence. This licence entitles a person to handle refrigerant for the installation and decommissioning of any of the following: • A single-head split system air conditioner of less than 18kW • A two-part hot water heat pump of less than 18kW • A two-part swimming pool heat pump of less than 18kW. Certificate III qualifications are significantly more rigorous and represent the trade qualification for refrigeration and air conditioning (RAC). This is a four-year apprenticeship, and the length of the course reflects the complexity of the systems. “A person who obtains the relevant Certificate III-level qualification is eligible to obtain a full refrigeration and air conditioning licence,” says the ARC. “This licence entitles a person to handle refrigerant for any work in the refrigeration and air conditioning industry, excluding automotive and various other specialist areas.”
Cover Feature
I am now of the opinion that the Certificate II has exceeded its usefulness – Kevin O’Shea
“However, some training providers saw this as an opportunity to make money by giving qualification to people not already working within our industry, and who had not achieved the skills and knowledge required to work on split systems,” he says. “I am now of the opinion that the Certificate II has exceeded its usefulness and should cease to be delivered.” Having recently travelled across Australia for the Future:Gas roadshow, O’Shea says that the Certificate II is high on the list of concerns among RAC professionals.
The ARC administers licensing for refrigerant handling, but does not have the power to prosecute unlicensed work.
“I made a point of asking them, ‘If all Certificate II technicians had completed the 300-plus hours of training, would they then have an issue?’ None of them had a problem with this, so long as the correct training was delivered.”
COMPETING FOR WORK Some Certificate II qualified technicians have even reportedly moved beyond split system and heat pump installations, to more technical refrigeration work requiring Certificate III qualifications.
ARMA Queensland executive officer Lindsay Jahnke
RACCA president Kevin O’Shea
But somewhere along the line, Certificate II qualified technicians began to work on refrigeration and air conditioning systems outside their scope of qualification. And it seems they have been left – with little threat of punishment – to grow in number, to the detriment of fully licensed and qualified RAC professionals.
“Certificate II is mostly RPL (recognition of prior learning) as a peripheral trade for electricians and/or plumbers,” says Jahnke.
According to the ARC, it is notified from time to time of suspected cases of licence holders working outside the scope of their licence. “For issues relating to non-compliant activity, ARC’s role is to investigate and educate,” it says. “Cases of continued non-compliance are referred to the Department of the Environment and Energy who are responsible for enforcement.”
AN INDUSTRY VIEW
Although the course was originally intended to be taken across an 11-week period under the supervision of a fully qualified RAC technician, the path to Certificate II qualification has become considerably more basic and shorter. In fact, some registered training organisations reportedly offer the course in as little as two days.
Energy efficiency, safe work practices, excessive energy costs and refrigerant leaks are among the many risks of unqualified tradespeople carrying out unlicensed work in the RAC space. According to Ryan Ardill who owns and operates his own business in South Australia, Ryan Ardill Air Conditioning, there are hundreds of examples – some documented – of Certificate II qualified technicians carrying out unlicensed work. These include refrigeration cool room work, servicing, fault diagnosis and unlicensed work carried out on compressors.
Jahnke says because of recognition of prior learning, electricians and plumbers are only required to complete two units of competency to attain a Certificate II qualification. “It is not sufficient from a safety perspective or from an energy efficiency one either,” he says.
It’s fair to say that many in the RAC industry believe the current qualifications and licensing arrangements are failing them.
This view is shared by Kevin O’Shea, managing director of Cold Rae Air Conditioning and Refrigeration, and current president of RACCA (Refrigeration and Air Conditioning Contractors’ Association) Australia.
According to Lindsay Jahnke, owner of Western Downs Refrigeration and the Queensland executive officer for ARMA (Australian Refrigeration Mechanics Association), the current requirements for Certificate II qualifications are not sufficient.
He says that the Certificate II qualification was originally intended to be an assessment tool to assess the competencies of people who were already working in our industry without formal qualifications.
Many lament the loss of the master and apprentice training method. June 2018 | www.airah.org.au/nation | HVAC&R Nation | 21
Cover Feature
Despite the desire for better training and stricter trade qualifications, more and more apprentices are working on a limited range of equipment.
blood fridges at hospitals, supermarkets – basically anything to do with refrigeration.”
Lack of policing has seen
And Jahnke says fully qualified RAC professionals are also being squeezed by plumbers.
Certificate II technicians working
“Plumbers are taking over the commercial work and we, the trade qualified, are only hired to do the commissioning,” he says. “I have heard of plumbers using water to leak test a new installation, which is one of the worst things you can do.”
on cold rooms, blood fridges at hospitals, supermarkets – basically anything to do with refrigeration – Lindsay Jahnke
“They have no consequences for advertising and carrying out unlicensed work,” he says. “To my knowledge, there has been no prosecution or fine of anyone in Australia releasing refrigerant or carrying out unlicensed work ... they continue to be able to do this as there is no mechanism to stop them.” Jahnke tells a similar story. As well as the technical issues associated with unlicensed work going unchecked, he says the livelihood of fully qualified RAC professionals and their businesses is affected. “Certificate II holders have predominantly taken over the split system air conditioning installations – the stepping stone for a new refrigeration business to grow in this industry,” he says. “Unfortunately, the lack of policing has seen Certificate II technicians working on cold rooms,
NO EASY FIX Despite the calls for change – and a consensus among industry bodies that something must be done – there is no easy fix. According to Jahnke, appropriate regulation of the trade throughout Australia – and the introduction of an occupational licence for all refrigeration and air conditioning work (requiring Certificate III qualifications) – is vital if such problems are to be solved. He also thinks public awareness of the refrigeration and air conditioning trade is lacking, and this contributes to the problems. “There is limited recognition of Certificate III RAC being the trade qualified to carry out all HVAC&R works, and consumers are confused – they think it’s an electrician or plumber’s job, depending on the state you live in.” Others like Ardill would like to see a new industry body established to create a better system. “A new system must be given the power to inspect work carried out by Certificate II holders,” he says. “If it’s not up to standard, then they should be required by law to employ someone to carry out the necessary work to rectify the issue.”
22 | HVAC&R Nation | www.airah.org.au/nation | June 2018
O’Shea, who has lobbied for the abolishment of Certificate II qualifications for some time, thinks it is now too late for such a move to be successful. “Could we revert to the Certificate III only? Unfortunately, I believe the horse has bolted and there would not be enough Certificate III qualified technicians to handle all of the work. But it would be good to upskill Certificate II workers to an acceptable level.” Recently, the ARC RAC industry board conducted a review of Certificate II training and its alignment with the restricted split system licence. The review found a number of areas relating to shortfalls in competencies, which ARC says can be expected of qualifications that are over 10 years old. It also recognised the need to “tighten up” the evidence required by trainers as part of determining competency. The ARC RAC industry board has provided this report to the Department of the Environment and Energy, who control what qualifications align with each licence. We will watch this space with interest.
Editor’s note Issues of sub-standard training quality are investigated by the Australian Skills Quality Authority (ASQA). ARC assists ASQA with some of these investigations and has provided case studies on the Certificate II and III training modules to ASQA to support their initiatives. n For more information on the ARC’s refrigerant handling licences, go to www.arctick.org
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• Consultants Features list – HVAC&R Nation 2018
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July
Fans and ventilation
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www.airah.org.au/nation June 2018 | www.airah.org.au/nation | HVAC&R Nation | 23
Around the Nation 1
2
4
3
5
1
WIN PRIZES FOR THE PLANET
He shared the story of his company, which has doubled its revenue over the past 10 years to over $32 million.
Refrigerant Reclaim Australia (RRA) has launched an app that lets you record information about the refrigerant charge of systems you are replacing or uninstalling. The data collected goes into research to help limit the damaging effects refrigerant emissions have on the environment.
Attendees were then given a tour of the new Centre of Excellence, consisting of a dedicated R&D area with an ISO5801-accredited fan test rig, a standalone R&D area, a facility for product analysis under warranty, a completely new electronic lab with specialised equipment, and extended production and logistics facilities.
To encourage take-up of the app, RRA is offering a range of prizes, including four $200 vouchers from JB Hi-Fi, Bunnings Warehouse, BCF and Caltex. There are also two grand prizes of $5,000.
It was an opportunity to meet and talk to people at every stage of the production process – from research and design, to assembly and testing, and procurement and shipping.
A non-profit organisation, RRA states that it has already destroyed more than 6,500 tonnes of refrigerant resulting in the preservation of more than 10 million tonnes of stratospheric ozone, and the prevention of the emission of more than 10 million tonnes of CO2 equivalent.
AIRAH would like to thank ebm-papst for the invitation to the event, and for the opportunity to visit its cutting-edge facility.
“RRA relies on the benevolence and goodwill of ambassadors to help conduct its research,” says the organisation. “Various studies have identified more than half the refrigerant installed in Australia is in split air conditioning systems. To collect this refrigerant at end of life and further reduce environmental harm, we need information. So download the app and help make refrigerant waste a thing of the past.” Download the app from the Apple App Store or from Google Play. n
2
EXCELLENT ADVENTURE!
A group of AIRAH staffers took the opportunity to escape the office on Wednesday, May 2, for the opening of ebm-papst’s new Centre of Excellence in Laverton North, Melbourne. And we weren’t alone – it was a large gathering of people from the industry. Speakers included Johanna Trickett from Aurecon, Shannon Egan from Bitzer and Graeme Dewerson, Affil.AIRAH, from A-Gas. The event was opened by ebmpapst’s managing director Simon Bradwell, M.AIRAH.
Go to www.ebmpapst.com.au n
3
TIME UP FOR SHORT COURSES?
As noted in our feature on page 20, some registered training organisations (RTOs) are offering to complete Certificate II courses in Split Air-conditioning and Heat Pump Systems in as little as two days. In light of this problem, the Australian Skills Quality Authority (ASQA) carried out a review of unduly short courses and training product reform throughout February and March. This produced three recommendations. First, that the standards for RTOs be amended to include a definition of the “amount of training” that focuses on supervised learning and assessment activities. Second, that training package developers be able to respond to industry-specific risks by setting mandatory requirements, including an amount of training. And third, that RTOs be required to publish product disclosure statements that include the range of learning activities expected, including the amount of training, for each training product on their scope of registration.
24 | HVAC&R Nation | www.airah.org.au/nation | June 2018
The Australian Refrigeration Council (ARC) contributed to the ASQA review, and CEO Glenn Evans says: “Appropriate qualifications are the cornerstone of the licence scheme. This review is a step in the right direction.” n
4
WIZARDS OF THE SOUTH
Seeley is hoping that the installation of Climate Wizard air conditioners in six South Australian schools will lead not only to cooler and healthier classrooms, but also further work for the company as a result of energy savings. The 18 Climate Wizard units involved in these installations have been designed and manufactured at Seeley International’s factory in Adelaide’s southern suburbs. And according to the company, they use up to 80 per cent less energy than equivalent cooling capacity reverse-cycle systems. “We are pleased to see South Australian students benefitting from this world-leading technology and expect it will encourage schools across Australia to investigate,” says company founder Frank Seeley, M.AIRAH. “These school installations, made possible through state government funding, are expected to demonstrate that if Climate Wizard is installed as original equipment on future school buildings, it can achieve payback periods as short as 1.5 years,” he added. Go to www.seeleyinternational.com n
5
QUEENSLAND LICENCE DEADLINE
A new scheme in Queensland is aiming to protect employees from exploitation and improve workplace safety. It establishes a mandatory scheme under which licences will be granted once a labour company demonstrates that it is fit and proper to provide labour hire services.
Around the Nation 9
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Senior Slater and Gordon lawyer Tran Truong said the scheme would lead to improvements by labour hire providers across the state. “This will provide a safer workplace for workers because the legislation requires licensed labour hire providers to pass a fit and proper person test,” Truong said. “It also demands that they comply with all the relevant laws including workers’ compensation, wages and superannuation. “For the worker, this means that they are entitled to be paid at least the minimum wage, a safe workplace, reasonable hours, rests breaks and time off work and be treated fairly and with respect and free from bullying and harassment and discrimination at work. Existing labour hire providers have until June 15 to apply for their licence. However, they can continue to operate while their application is being considered, provided they have applied by this date. Go to www.labourhire.qld.gov.au n
6
ZEN AND THE ART OF DEMAND RESPONSE
The Clean Energy Finance Corporation (CEFC), through the Innovation Fund, has given Zen Ecosystems a $5 million equity investment boost for the further development and deployment of its Zen HQ and Zen Thermostat products. Unlike BMS that work best for large or industrial-use buildings, the Zen units are designed for smaller-footprint businesses that may be distributed across various sites, such as retailers, hotels and motels, schools, universities, car dealerships and fast food outlets. CEFC transaction lead Kristin Vaughan said: “Heating and cooling are typically responsible for around 40 per cent of total building energy consumption, representing significant energy costs for businesses and consumers. This technology also opens the way for individual users to participate in demand response initiatives, contributing to the continued stability and reliability of our energy system.”
Zen Ecosystems is one of eight companies working with ARENA and AEMO as part of a demand response project which aims to remove electricity load from the grid and to keep energy supplies stable, reliable and affordable during periods of peak demand. Go to www.cefc.com.au n
7
A-GAS MAKES GERMAN PURCHASE
A-Gas has purchased German refrigerant company Arthur Friedrichs Kaeltemittel GmbH. Located near Hamburg, Arthur Friedrichs Kaeltemittel GmbH has operated in the industry for over 60 years, primarily supplying refrigerant to the European automotive market. “This acquisition will allow us to further strengthen our global OEM automotive presence, where Friedrichs Kaeltemittel has made a considerable impact,” said A-Gas managing director John Ormerod (pictured). “We will invest in a reclamation plant and create new jobs by doing so. Reclamation will expand as the pressure on supplies of key gases continues and the need to reclaim grows ever more important.” The A-Gas acquisition is subject to clearance from competition authorities in Germany and Austria. This is the second A-Gas acquisition on the European mainland within the past 12 months, after the company purchased Netherlands-based reclamation business BTC in August. Go to www.agas.com n
8
SEEING THE LIGHT
On April 20 the Commonwealth of Australian Governments (COAG) Energy Council agreed to update energy efficiency regulations and thereby phase out inefficient halogen light bulbs in Australia. It will also introduce minimum standards for LED light bulbs in Australia and New Zealand in line with European Union (EU) standards.
The phase-out will remove remaining incandescent light bulbs and a range of halogen light bulbs from the Australian market, where an equivalent LED light bulb is available. The new regulation will align with revised EU minimum standards that will apply to LED light bulbs (planned for September 2020). The details of the new EU regulation are expected to be final in 2018. This decision was informed by advice from the Lighting Energy Efficiency Advisory Group, set up to operate in an advisory capacity to COAG Energy Council officials, who provide advice to COAG Energy Council Ministers on lighting policy. Go to energyrating.gov.au/document/decision-ris-lighting n
9
FREE TAFE IN VICTORIA
As part of its 2018/19 budget, the Victorian state government announced it would invest $172 million to make a selection of TAFE priority courses free from 2019 onwards. “Across the state, 30 priority TAFE and 18 preapprenticeship courses will be made free, with courses focusing on the skills our state needs,” read a press release from the government. “In addition to these free priority courses, the budget includes $303.8 million to create more than 30,000 new subsidised training places. The budget is also modernising apprenticeships, with $43.8 million to revamp learning materials, ensure consistent industry standards with new independent assessments, and bring back trade papers to recognise these qualifications.” At time of going to print only 20 of the 30 courses had been confirmed. Although the Certificate III in Air-conditioning and Refrigeration was not yet on the list, further consultation was pending. “We will continue talking to industry as the additional 10 courses are selected,” said the Office of the Premier of Victoria. Go to www.education.vic.gov.au n
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 25
Safety Corner
A MATTER OF LIFE OR DEAF Choosing the right PPE for your ears is crucial – listen up! Hearing loss due to industrial noise such as machinery, tools and traffic is one of the most widespread yet preventable workplace injuries. Hearing damage is irreversible and seriously affects quality of life, contributing to dementia, an increased risk of heart disease, stress, hypertension, tinnitus (ringing in the ears) and psychiatric disorders. It can also contribute to other workplace safety problems, such as a lack of awareness and reduced concentration, and leads to around 3,400 successful workers compensation claims each year. The good news is that hearing damage is entirely preventable with appropriate PPE. Correctly designed and fitted ear protection will keep industrial noise well below harmful levels, however, choosing the appropriate hearing protection – whether ear muffs or ear plugs, disposable or reusable – is critical.
Conversely, under-protection will lead to hearing damage, which in turn leads to greater difficulty communicating while wearing hearing protection, and thus a greater reluctance to wear it.
TESTING AND STANDARDS Australian standard AS/NZS 1270:2002 rates hearing protection in five classes: Class 1 is the lowest level of protection and Class 5 the highest. The system is based on the sound level conversion (SLC80) rating, which is the difference between the sound level of the environment in which the hearing protection is worn and the sound level reaching the wearer’s ears. This is converted to a recommended noise range.
THE SAFE NOISE THRESHOLD
OTHER SELECTION FACTORS
Eighty-five decibels (85dB) is considered the safe noise threshold and the level at which appropriate hearing protection must be worn. “Appropriate” is determined by the level of noise (see Table 1) and the required level of workplace communications.
As well as noise volume and communication factors, other considerations should include the hearing protection’s fit and comfort, health and hygiene, compatibility with other PPE such as hard hats, and suitability of the PPE for the worker, the work environment and task.
Too much hearing protection may increase workplace dangers by unnecessarily blocking critical communications or noise – a common reason workers choose not to use any hearing protection at all.
This range of variables has led to the development of different styles and designs:
Earmuffs Suppress unwanted noise by completely covering the outer ear. These styles come with a variety of features from adjustable headband to hard hat attachments to suit individual needs.
Class
SLC80dB
1
10–13
2
14–17
Disposable earplugs
3
18–21
4
22–25
5
26–36
Made from PU foam, these are designed to be compressed and then inserted into the ear canal, where they expand and seal against noise. These are economical, designed for single use and are available in uncorded and corded options.
26 | HVAC&R Nation | www.airah.org.au/nation | June 2018
Noise level examples
Class
SLC80dB
Allowable noise level
Ringing telephone – 80dB
1
10–13
Less than 90dB
Loud radio – 80dB
1
10–13
Less than 90dB
Busy traffic – 80dB
1
10–13
Less than 90dB
Bandsaws – 85dB
2
14–17
Less than 90dB
Power lawnmower – 90dB
2
14–17
90–95dB
Belt sander – 93dB
2
14–17
90–95dB
Tractor – 96dB
3
18–21
95–100dB
Electric drill – 98dB
3
18–21
95–100dB
Bulldozer – 105dB
4
22–25
100–105dB
Blasting – 110dB
5
26–36
110–115dB
Nail gun – 110dB
5
26–36
110–115dB
Chainsaw – 120dB
5
26–36
115–120dB
Propeller aircraft – 120dB
5
26–36
115–120dB
Gunshot – 130dB
5
26–36
125–130dB
Riveting hammers – 130dB
5
26–36
125–130dB
Jet engine aircraft – 140dB
5
26–36
135–140dB
Note: This table is a general guide only and is not an absolute basis for noise levels selection as some equipment may operate at different noise levels. Every worksite should be tested by OH&S.
Reusable earplugs Pre-moulded from washable silicone to fit snugly and be reused. Corded and uncorded options are supplied in a handy resealable plastic case.
Banded earplugs A convenient, easily inserted option for those who are constantly in and out of noisy areas.
Metal-detectable earplugs Contain a metal tab in each plug and a metalised cord that can be detected if the plugs accidentally fall into processing lines. n Thanks to Pro Safety Gear for providing the info in this article. Go to www.prosafetygear.com.au to see the company’s full range of PPE.
AIRAH TRADE NIGHTS AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry’s latest innovations. Whether you’re looking for the latest technology to improve your business, or extending your networks, there will be plenty on offer. AIRAH Trade Nights are free to attend and open to everyone, but you must be registered to attend.
June 7
Canberra
ACT
August 23
xTownsville
June 14
Brisbane
Qld
August 29
Bathurst
June 21
Perth
WA
September 5
Traralgon
July 14
Newcastle
September 27
Western Sydney
July 18
Darwin
NT
October 10
Bendigo
Vic
August 2
Melbourne
Vic
October 18
Adelaide
SA
August 21
Cairns
Qld
October 30
Rockhampton
Qld
NSW
Qld NSW Vic NSW
Free entry – Doors open at 4pm Exhibitors with the latest HVAC&R products and innovations. Drinks, food and more.
Register online at www.airah.org.au/tradenights
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 27
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28 | HVAC&R Nation | www.airah.org.au/nation | June 2018
AIRAH News Mark Padwick, M.AIRAH, Shane Carmichael, M.AIRAH (who accepted the award for Air Change) and HyrdoChem (company member) all took out prizes. The full list of winners was: The ARBS Young Achiever Award 2018 • Jason Harrison, M.AIRAH, Airmaster Australia The ARBS Product Excellence Award 2018 • ACDHUM-LD, Air Change The ARBS Project Excellence Award 2018 • F Mayer Refrigerated cold storage/distribution centre, Strathbrook Industrial Services and Danfoss Australia The ARBS Outstanding Industry Education/Training Award 2018 • Mobile CO2 Training Unit, Danfoss (Australia) Pty Ltd
Jason Harrison, M.AIRAH, of Airmaster accepts the Young Achiever award.
WINNING BIG AT ARBS Just as ARBS is a chance for the Aussie HVAC&R industry to get together, the ARBS Awards ceremony is a chance to celebrate the great work done by individuals and companies.
The ARBS Awards were announced last month, and there were plenty of AIRAH members on the winners list.
A big crowd gathered in the ICC Grand Ballroom, where host Tony Squires kept them entertained before the awards were announced. And this time the winners included plenty of AIRAH members – Jason Harrison, M.AIRAH, John Bosci, L.AIRAH,
The ARBS Software/Digital Excellence Award 2018 • Clarity, HydroChem The ARBS Outstanding Service & Maintenance Award 2018 • A.G. Coombs Group Pty Ltd The ARBS Hall of Fame 2018 • Stephen Gilchrist – CIBSE ANZ • John Bosci, L.AIRAH – AIRAH • Mark Padwick, M.AIRAH – AREMA • David Seedsman – AMCA • Warren Cole – RACCA. Congratulations to all the winners. n
The foremost resource EDITION 05 EDITION 05
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Australian Refrigeration and Air-conditioning Volumes 1 and 2 AIRAH is delighted to bring one of Australia’s foremost resources for training in the refrigeration and air conditioning industry to the education sector: Australian Refrigeration and Air-conditioning, Volumes 1 and 2, authored by Graham Boyle, F.AIRAH. The completely revised fifth editions have brought a new dimension to this highly regarded resource, with a new full-colour format, hundreds of updated and upgraded images and improved text, which make for easier reading and understanding. For more information, go to www.airah.org.au/ARAC
June 2018 | www.airah.org.au/nation | HVAC&R Nation | 29
The Lighter Side This month’s Lighter Side is brought to you by
Stocked at over 100 branches nation-wide. A huge variety of refrigerant products. A new level of service and support. Available at
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1 WINNER
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FF THE GAUGE OJason Brown from Altona North was
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called out to look at a system that had a refrigerant leak. On closer inspection the previous mechanic had used manifold gauge lines in the pipe up! n
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RUSTRATED BUILDER? FClaude from Port Adelaide has provided another great example of roof frame ingenuity. n
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OUBLE WHAMMY D“People are even installing redundancy in their own homes,” observes Glen from NSW. We reckon it all started with that two-for-one special. n
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BIG FAN OF CABLE TIES AThanks to John of South Australia for his photo of what he calls a “cable tie docking station”. Looks like they managed to use the whole packet. n
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HUT YOUR TRAP! SGrant from AirCon Solutions found this drain trap fitted to two wall splits and siliconed into a steel storm water line. “The drain line was run down the wall in green garden hose to the 20mm pressure that we can see in the picture,” says Grant. n
HAVE YOU COME ACROSS SOMETHING SCARY, UGLY OR JUST PLAIN FUNNY? If your entry is deemed the monthly winner, a 750ml bottle of Jim Beam will be on its way to your door. Please include a postal address with your entry. Entrants must be 18 or over. Send your hi-res (>500KB) photos to Editor, Mark Vender at mark.vender@airah.org.au
30 | HVAC&R Nation | www.airah.org.au/nation | June 2018
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Compact packaged refrigeration condensing units. The Compac is a new range of fully fitted packaged units with world leading Tecumseh hermetically sealed reciprocating compressors. Designed with space constraints in mind, the horizontal discharge condenser configuration suits unit placement in carparks, roofs, on the side of buildings and mounted above one another without restricting airflow. Installation is quick and easy, as every Compac is optioned straight out of the box. Once installed, you can relax knowing the premium compressors and large condensers will deliver reliable refrigeration when you need it most. Every Compac is built with high quality, corrosion resistant components, and extensive testing is completed on each unit, to ensure long life in the field.
Tecumseh hermetically sealed reciprocating compressors Horizontal discharge condenser con�figuration Can be installed on air conditioning wall brackets Small footprint with housing designed to optimise space
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June 2018 | www.airah.org.au/nation | HVAC&R Nation | 31
DAIKIN VRV AHU AN INDUSTRY FIRST VRV AHU DESIGNED AND ENGINEERED BY DAIKIN, CREATES NEW OPPORTUNITIES FOR APPLYING VRV INTO RETAIL, OFFICES, CINEMAS AND COMMERCIAL APPLICATIONS WITH LARGE OPEN SPACESV IV Heat Pump offers greater design flexibility, improved energy with Variable Refrigerant Temperature -performance Available in two types, Standard Series or Outdoor Air Series control, superior comfort and reliability of - Daikin’s VRV AHU are paired with VRV IV Heat Pump operations, outdoor and with a &wide of product offerings to unitscomes for superior EER COP range performance the all needs ofofthe commercial building. -meet Harnesses features VRVmodern IV Heat Pump including Variable Refrigerant Technology (VRT)*, Daikin’s Inverter Technology and connection to BM systems
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AIRFLOW RANGE
- TO -
- TO -
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OUTDOOR AIR SERIES
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25.7kW 566L/S
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*Applies only to Standard Series models