HVAC&R News April-May 2022 by AIRAH

NEWS Skills WORKSHOP

Building control circuits

Skills

WORKSHOP Building control circuits

Dicing with danger Top 10 issues with fire damper installations

DEEP DIVE

The AC upgrade that turned a decommissioned submarine into a hands-on classroom. April–May 2022 / ISSUE 145

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April–May 2022 / ISSUE 145

NEWS

Deep dive 20

HVAC&R News 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/hvacrnews

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 3001 Contributing writers Sean McGowan Louise Belfield

An air conditioning upgrade has turned the HMAS Onslow at the Australian National Maritime Museum into a hands-on classroom, as Louise Belfield reports.

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Glenn Douglas glenn.douglas@airah.org.au Tel: 0411 839 667

John McGrath john.mcgrath@airah.org.au Tel: 0419 556 108

ISSN 1834-9522

HVAC&R News is printed on paper sourced from well manned forests and other controlled sources.

The Toolshed

Global Update

Industry insight

Disclaimer HVAC&R News is an official publication of the Australian Institute of Refrigeration, Air Conditioning and Heating Inc. Statements expressed in HVAC&R News do not necessarily reflect the policy or views of AIRAH or its members.

No responsibility is accepted by AIRAH, the Editor or HVAC&R News’s supply partners for the accuracy of information or for errors or omissions. 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.

HVAC&R News regulars

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Skills Workshop 15

See what’s new in the ‘Shed

Industry news from around the world

Building control circuits

Exclusive to this issue

What sustainability on big projects means for the trades

Around the Nation Who’s in the news?

AIRAH Awards

We talk to Student of the Year – Trade, Jessica Lonsdale, Affil.AIRAH

Smoko with …

Q&A with Natasha Kirchner

Lighter Side

The shonkier side of the nation

Dicing with danger Sean McGowan looks at the 10 most common issues with fire damper installations.

9,034 September 2021

PLEASE CONSIDER THE ENVIRONMENT AND RECYCLE THIS MAGAZINE IF YOU ARE NOT GOING TO KEEP IT.

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Ed’s letter

MINDING THE GAP

training is somehow inferior to a university education.

The skills gap is an ever-present issue in our industry. It’s great to have loads of work, but wouldn’t it be wonderful if we had more people to do it!?

This issue I spoke with Jessica Lonsdale, winner of the 2021 AIRAH Student of the Year – Trade award. She told me about her journey to the world of HVAC&R, and how she only started her apprenticeship in refrigeration and air conditioning after working for several years in medical research, then as a driver in the mines. Finally, she was stoked to get an apprenticeship, which provided a solid, long‑term career option.

Lately, I’ve been hearing that the gap is growing. There are stories about businesses giving up advertising for technicians because they are receiving no applications. Others are losing apprentices who get better offers – often from completely different sectors. Someone told me the other day about lollypop workers (aka traffic controllers) earning $90 an hour. There’s not much in the way of career development, but money talks! With jobs like that around, the prospect of a long and not so lucrative apprenticeship becomes less attractive. We have heard that there are more apprentices coming through the system now. And it’s true, enrolment rates are up, mostly thanks to the pandemic support packages that cover the fees. But completion rates for refrigeration and air conditioning are down at around 65 per cent. In other words, one out of three of these apprentices won’t ever become a fully qualified fridgie.

“When I was at school they said, ‘Don’t bother with trades, go and get a degree’,” she told me. “But it turns out trades are actually quite important these days!” In this industry, we know how important trades are, as well as all the other workers. The cover story is one example of this – a project at the Australian National Maritime Museum that was both a technical success

Underneath all the practical issues is a cultural phenomenon too – the idea that vocational

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and a personal tribute. It’s another example of the amazing things that people in HVAC&R do. Here’s to spreading the word. @AIRAHnews

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Mark Vender Editor mark.vender@airah.org.au

April–May 2022

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HVAC&R News

Toolshed 1

Heavy goes big

Mitsubishi Heavy Industries Air-Conditioners Australia (MHIAA) has introduced a 10kW unit to its Bronte range of split systems. Designed for extra-large spaces, the 10kW Bronte is available with both single-phase and three-phase options.

The “Sterionizer” is the next layer, which is designed to create “pure air”.

“The Bronte range now features five capacity sizes ranging from 6.3kW to 10kW in both cool only (7.1kW only) and reverse-cycle models,” MHIAA says. “With a range of convenient functions and features, the Bronte 10kW unit is suitable for both residential and commercial installs, and is the largest wall-mounted split system available from MHIAA. “The unit also incorporates advanced fan blade technology to efficiently deliver 19m+ long reach airflow in cooling conditions, making this an ideal installation for large open-plan spaces.”

Finally, UVC LEDs have been included to kill bacteria, viruses and parasites by destroying their integral membrane protein.

5 2

“With the 10kW Bronte range, the end consumer was at the forefront of each development stage,” says MHIAA managing director Yuji Ito. ■

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Filtration excitation

Mitsubishi Electric Australia has introduced the Plasma Quad Connect, a high-grade filtration system designed to inhibit airborne influenza virus particles, dust, mould and other inhalable particles down to PM2.5. The new system is suitable for both new and existing installations, including selected units from Mitsubishi Electric’s range of wall-mounted, cassette or ducted air conditioning systems.

IAQ to go

“The system’s high-performance two-stage plasma technology … significantly improves indoor air quality by inhibiting six key indoor pollutants; Influenza virus, bacteria, PM2.5, allergens, mould and dust,” the company says.

Panasonic has launched the Portable nanoe X Generator as part of an initiative with flex space provider Hub Australia to champion the topic of indoor air quality and facilitate a new way for workers to return to the office. The initiative incorporates Panasonic’s nanoe X technology, which is designed to inhibit indoor pollutants and odours in the air and on surfaces through the release of nano-sized, atomised water particles, and which is now featured across the company’s air conditioning range.

“Nanoe X is technology that we are incredibly proud of – and it hasn’t come about overnight,” says Panasonic Australia Managing Director Paul Reid. “Backed by 25 years of dedicated research and development, the latest generation of nanoe X is proven by more than 140 independent laboratory tests across a range of use cases.” ■

The first layer of the device is a pre-filter that targets large particles, including dust, pollen, insects and animal hair. This is complemented by Ray Filter technology, which consists of three unique antibacterial layers that target fine particles (PM2.5 and PM10), germs, odours, bacteria, viruses, fungus, and mould spores.

Because the unit is electrically charged and connected via mounting brackets, it must be installed by a qualified technician. For more information, go to www.mitsubishielectric.com.au

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Daikin’s ‘streaming’ service

“Daikin is dedicated to ‘Perfecting the Air’ by delivering innovative and effective climate control and purifying solutions,” the company says.

Reliable pivot to the FLEXair

Reliable Controls has introduced a new generation of building controllers following the launch of the RC-FLEXair advanced VAV controller. The freely programmable RCFLEXair is a BACnet building controller designed for a wide range of variable air volume and room control applications. According to the company, it is the culmination of two years and tens of thousands of hours of research and development.

Mitsubishi says the system works as an electrical curtain, using an electrical discharge to filter and reduce even microscopically small particles in the air, including the capture of PM2.5 particles.

“Daikin’s Streamer Technology is a market-leading advancement in integrated air purification. The streamer discharge is a plasma discharge that generates high-speed electrons to continuously purify the air. Streamer Technology effectively removes bacteria, odours, indoor air pollutants such as formaldehyde and more than 99.6 per cent of pollen, mould and allergens. Daikin says Streamer Technology consists of three Cs to decompose these harmful substances:

Reliable Controls’ James Puritch says he had lofty goals when he began developing the new family of products.

•

Clash – Harmful substances are trapped by the High Efficiency Particulate Filter.

“The RC-FLEXair is the first of our RC-FLEX products, all built around dual Ethernet connection architecture and multicore processors,” says Puritch. “We’ve taken our 30‑plus years of technology and embedded it into this new hardware and firmware platform. The RC-FLEXair is highly performant for today’s building automation system needs and built to accommodate tomorrow’s advancements.” ■

•

Cycle – The deodorising filter decomposes odours in the air.

•

Clean – Bacteria is removed from all filters for maintenance‑free operation and increased longevity.

Streamer Technology is integrated into Daikin’s Alira X and Zena split systems and air purifiers. Go to daikin.com.au/streamer

Standalone purification

Clean-Air Australia is now supplying and installing Aura Air Purification units as standalone devices for business or domestic use.

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Top-level access

Australian company Astro Ceiling Access Panels has launched its line of manholes for commercial properties, offices, hotels and more.

The units feature UVC as well as patented HEPA Ray‑Filter technology. They provide real-time IAQ data via a smartphone app or API, which can be integrated into a BMS (building management system). 6

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April–May 2022

“After being in the air conditioning industry for more than 35 years, we distinctly remember the frustration of a particular job in a specialist’s office,” the firm says. “Trying not to make a mess over the receptionist’s desk added time to the job.

Toolshed Feeling in the way and knowing that it was inconvenient for the staff made it a lot harder than it should have been.

or an outback dusty track petrol convenience store,” Pumpmates says, “the CRCP-76-IP65 is designed to tackle the toughest locations … for years.”

“By creating a product never seen before in the marketplace, we help make accessing ceilings safer and easier for you or your workers, while creating less mess and disruption for your customers.”

Go to www.pumpmates.com.au

Go to astroceilingaccesspanels.com.au

Senva, a sensor manufacturer partnering with AB Controls in Australia, has released the TotalSense Series indoor environmental and air quality sensor.

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A tough pump

“As building occupancy begins to recover and we return to work after COVID-19,” says Senva CEO Kent Holce, “it puts the focus on indoor air quality (IAQ) for safety and peace of mind. The unique TotalSense Series utilises eight different technologies and a very wide range of options to ensure tenant comfort and prove efficacy of air purification and ventilation strategies, particularly in high-occupancy areas such as classrooms and auditoriums.”

The CRCP-76-IP65 Commercial “Slide‑Under” Refrigeration Cabinet Pump has been designed specifically for Australia’s humid conditions. A rugged-use cabinet pump, at 76mm height it has an Ingress Rating of “IP65.” “The CRCP-76-IP65 has sealing effectiveness against dust and moisture and all the creepy crawlies that get into the electrical,” Pumpmates says. “It’s versatile and can be installed either ‘Top’, ‘Back’ or ‘Side’ entry, all in one cabinet pump unit.”

Senva makes TotalSense

Designed, engineered and made in Australia, the ceiling access panels have a two-year warranty.

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According to Senva, many industry professionals and politicians have shifted their focus and budgets towards implementing better filtration and purification methods such as UV lights and HEPA filters. Yet the importance of measuring the effectiveness of these methods is often overlooked.

Pre-fitted with power and alarm cables, the unit now comes with lock-down seal catches, facilitating any maintenance.

“Senva aims to remedy that with the TotalSense,” says the company. “It monitors indoor conditions and provides valuable information to building owners about the effectiveness of their filtration.” ■

It comes with a Little Giant Pressure pump, IP65 splash‑proof enclosure and a one-year warranty. “Whether in a busy, well-lit supermarket in the city,

DO YOU HAVE A NEW PRODUCT TO GO IN THE TOOLSHED?

Email mark.vender@airah.org.au All submissions received will be considered, though publication cannot be guaranteed.

April–May 2022

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HVAC&R News

Global Update

GERMANY

REFRIGERATION INSPIRATION

WATER-BASED CHILLER IS A THRILLER

A zero-carbon refrigeration start-up company has received funding to commercialise its refrigeration technology, which aims to cut global emissions.

German refrigeration specialist Efficient Energy is claiming a world first with the launch of a climate-neutral chiller that uses water (R718) as a refrigerant.

Barocal, a spin-out from Cambridge University, has secured AUD$2.35m to develop the solid-state temperature changing materials that work in both heating and cooling applications. The barocaloric materials offer a zero-carbon alternative to gas‑compression cooling and heating. The materials absorb and release heat at different pressures as they change volume. They are also cheap and non-toxic, and easy to recycle at the end of their lifetime.

The chillers are suited to data centres and server rooms, industrial processes, machines and in technical air conditioning.

“Heating and cooling accounts for 38 per cent of the UK’s CO₂ emissions,” says Barocal co-founder, Dr Xavier Moya. “The government’s commitment to a 78 per cent cut in carbon emissions by 2035 means there is a growing need for new low-carbon domestic heating systems.” Barocal was a finalist in the 2019 Global Cooling Prize, selected out of 139 teams from 31 countries. The technology began as a joint project among Cambridge, the Polytechnic University of Catalonia, and the University of Barcelona. ■

“With Efficient Energy itself having been climate neutral since 2020, it’s the next logical step of our Green Pledge that our products should also be climate neutral. I hope as many companies as possible will be as resolute as us in implementing their sustainability goals.” ■

KENYA

BIG FINE FOR R22 SMUGGLER

WOMEN AT WORK

Faiz Abdallahi imported the R22 from China, but had it badged as R32. Abdallahi admitted he arranged for Chinese R22 to be delivered to the port of Long Beach, California, and then transported it via rail to the Dallas/Fort Worth area disguised as R32 to avoid seizure by US Customs and Border Protection. His accomplice, Severo Zamora, then repackaged and sold the R22 to HVAC companies in the US. Abdallahi admitted smuggling the R22 into the US without an authorised permit and, in October 2021, pleaded guilty to the improper importation of a class II substance, a felony under the USA’s federal Clean Air Act. He was sentenced to three years’ probation.

Since 2020, the US EPA has banned the production and importation of R22.

HVAC&R News

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April–May 2022

A one-day refresher on the safe use of hydrocarbons was held at the Nairobi Technical Training Institute for women in the Kenyan refrigeration and air conditioning (RAC) sector. Attended by 11 women, the session was designed to better understand the motivation, challenges, and opportunities for women working in this sector, and to encourage them to pursue careers in RAC. Some of the challenges were discrimination, tough working conditions (especially working at heights), difficulties during pregnancy, and sexual harassment. Capacity building and awareness-raising were among the top recommendations to address these challenges. GIZ Proklima, which is funded by the German government in collaboration with the National Ozone Unit (NOU) of the Ministry of Environment and Forestry, Kenya, has conducted various training sessions throughout the country. Aimed at RAC technicians, the sessions covered the safe use of hydrocarbons and other natural refrigerants.

Zamora pleaded guilty in January 2022 to being an accessory after the fact, and was sentenced to six months’ probation.

“Not only are we pioneers of sustainable refrigeration technology and stand for water as a refrigerant,” says Efficient Energy CEO Georg Dietrich, “but holistic climate protection and sustainable business belong to our unambiguous corporate values.

USA

A man who smuggled 2,300 cylinders of ozone-depleting HCFC refrigerant R22 into the US has been fined US$250,000 (AUD$349,000).

According to Efficient Energy, the RAC equipment used by the global refrigeration industry accounts for about 8 per cent of the world’s CO₂ emissions. But if the emissions from a chiller’s entire life-cycle are included – from raw material extraction to disposal – the impact is much greater.

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More than 1,000 RAC technicians have been trained, with only about 60 (6 per cent) women. ■

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April–May 2022

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HVAC&R News

Feature

DICING WITH

DANGER In the event of a fire, dampers play a key role in keeping occupants and emergency services safe – but only if installed correctly. Sean McGowan looks at 10 of the most common problems. “This guidance includes measures such as codes of conduct for building surveyors and fire safety engineers, fit-for-purpose inspection regimes and independent third-party review of fire and structural safety design.”

Although history shows that hazard management systems are remarkably effective in limiting fire and smoke spread in buildings, it only takes one incorrectly installed fire damper to undermine this effectiveness. In fact, the Australian Building Codes Board (ABCB) recently received macro-economic analysis of building defects in Australia. It showed that fire protection ranked equal fourth of 11 categories of defect.

While there are many drivers contributing to non‑compliance, one industry leader says a key issue is generally to blame. “The workflow complexities associated with managing and coordinating the design, construction and certification process is the key challenge in most instances,” says Warwick Stannus, M.AIRAH, Group Engineering Manager at A.G. Coombs.

“That analysis found that fire protection defects account for 10.5 per cent of rectification costs for Class 3 to 9 buildings in any given year,” says Gary Rake, CEO of the ABCB. The ABCB has released a series of resources in response to the 24 recommendations of the Building Confidence Report (BCR), including those relating to fire damper compliance.

“Contributing to the challenges are the design, installation and testing standards related to fire, smoke and air dampers, and industry practices that have evolved around these, adding further layers of complexity and confusion.”

“The ABCB has created model guidance for consideration of, and implementation by, state and territory government,” says Gary Rake, CEO of the Australian Building Codes Board (ABCB). 10

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So what kinds of issues arise? We look at the most common non-compliance issues found in the field. |

April–May 2022

DAMPER INSTALLATION ESSENTIALS In design drawings, it is common to see ducts passing through fire-resistant walls closer than 100mm to each other, and/or less than 50mm to the slab above. If the fire damper installation follows these designs, it will not comply with AS 1682.2, and via the hierarchy of standards and regulations will not comply with the NCC BCA Volume 1. In cases where the physical restrictions of the design demand that fire dampers are installed closer to each other, or the slab above, than the requirements allow, a tested prototype must exist that is specific to the compromised spaces provided. ■

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17/02/2022 11:51:35 AM | 11

HVAC&R News

Feature 1. INCORRECT DAMPER MOUNTING

3. OVERSIZED PENETRATIONS

COMPLIANCE CRUNCH? The rules around fire dampers are changing, with a note in the National Construction Code (NCC) requiring new testing methods noted in sections 10 and 11 of AS 1530.4. In the past, fire dampers were only tested for the spread of fire. Now they must also be tested for insulation properties to meet AS 1668.1-2015 requirements. Section 11 testing also requires dampers to withstand 300Pa under fire conditions. As of May 1, 2022, an installation will only be compliant if the fire damper has a valid test certificate, regulatory information report (RIR) or assessment report that is based on the latest testing standard.

Due to poor project communication, penetrations in the fire-resisting barrier can end up larger than required for the duct-mounted fire damper. In some cases, this gap is not sealed effectively or is simply left unfilled and not sealed at all. Lining out the oversized masonry hole with timber trimmers or other non-fire-rated material is not an acceptable solution.

Examples of incorrect damper mounting include: •

Mounting flanges not flush with the barrier or not attached correctly.

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Mounting flanges too small, not thick enough or of the incorrect material.

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Mounting dampers into fire-rated plasterboard barrier walls where the damper is supported by the plasterboard only and not the wall framing. In the case of large dampers, it is often necessary to install additional structural steel framing to support the fire damper, before the wall plasterboard is installed.

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It may be possible for the retaining flanges to be increased in size to twice the clearance, subject to manufacturer instructions being met. There are also proprietary fire-rated board materials that may be used to reduce oversized penetrations; however, these must be installed in accordance with the method used for the manufacturer’s approved prototype test or have been assessed by a registered testing authority.

Damper mounted into the penetration without any mechanical fixing, relying only on duct sealant to hold it in place.

4. RIGID DUCT/ DAMPER JOINTS

Damper used as a lintel to support the masonry block or brick wall constructed over the damper. Many building trades are under the false impression that fire dampers have structural adequacy, and they can therefore rely on the fire damper casing to support courses of bricks or blockwork over the damper. Fire dampers are only required to have a fire resistance level (FRL) in terms of integrity and insulation (refer Clause 2.4 of AS 1682.1) and are designed to be structurally independent of the wall opening.

It is not uncommon for ductwork connected to fire dampers to be moved during the installation of other ducts or trade services within the ceiling space.

AIRAH’s Design Application (DA) manuals are technical publications to assist you in your day‑to‑day work in the HVAC&R industry. Among the latest releases are DA05 – Guide to fire and smoke control in buildings using AS 1668 Part 1, and DA06 – Guide to fire, smoke and air dampers using AS 1682 Parts 1&2.

Examples of incorrect damper positioning include: Dampers that are installed upside-down so shutters cannot operate.

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Dampers that are installed back-to-front (i.e., against the direction of airflow).

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Dampers that are surface-mounted onto the fire barrier. AS 1682 requires that the fire damper fully penetrates the construction element, and the penetration being protected.

DA05 provides a holistic overview of smoke control in buildings, as applied by Australian Standard AS 1668.1-2015 The use of ventilation and air conditioning in buildings. Part 1: Fire and smoke control in buildings. It covers the fundamentals behind the six “methods” of smoke control and outlines how and where AS 1668.1 applies them, depending on the smoke control strategy called for by the building and building regulations.

It is important to note that surface-mount installations (outside the penetrated building element) do not comply with AS 1682 unless the manufacturer can provide installation data for such applications. 12

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Given that many of the fire dampers currently being installed will not be considered compliant come May 1, industry is urgently seeking a way forward. ■ Any forced duct movement following connection to the fire damper can damage the fire barrier and impede damper operation. In lightweight fire-resistant constructions, it is normally the fire barrier that is damaged the most, followed by stress to the fire damper that may render it inoperable.

DA FOR THE DAY‑TO‑DAY

2. INCORRECT DAMPER POSITION •

Despite a reasonable notice period for the change, manufacturers are still adjusting to the new rules – and understandably so. It takes a lot of time and money to redevelop and obtain the testing certificates for a fire damper. Complicating the issue, there are few facilities in Australia that can officially test the larger fire dampers, and with a raft of new products coming through the pipeline due to broader reviews of fire safety standards, wait times for testing can be up to 12 months.

DA06 steps through the entire damper life-cycle, from the fundamentals of fire, smoke, and air dampers, through to individual performance

April–May 2022

testing, design, and selection considerations. It also covers the details of installation, labelling, and commissioning; and the inspection and maintenance of dampers through their operational lives. The focus is on the major compliance standards – AS 1668.1, AS 1682.1/2 and AS 1851 – with sections of the manual dedicated to design, installation, commissioning, and maintenance topics. AIRAH members enjoy free digital access to a selection of the DA manuals, as well as discounted rates on hard copies. AIRAH also offers a range of face-to-face, online and in-house professional development courses on topics relating to fire dampers, including courses on Essential Safety Measures and Smoke Control and Fire Dampers. Visit airah.org.au for more information about accessing DA manuals and courses. ■

April–May 2022

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HVAC&R News

Feature 5. INADEQUATE ACCESS

replacement fusible link, because we don’t know how it will perform – improvisation has no place in fire safety. Check the product data and stick to the detail of the compliance documentation.

Examples of incorrect damper positioning include: •

No duct access panel provided to allow inspection and testing of a mechanical fire damper.

•

No access panel in false ceiling to provide access to damper.

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No coordination between the two access panels, rendering inspections or tests impossible.

8. INCORRECT PACKING

6. DAMPER INCORRECTLY APPLIED Inappropriate damper models used in aggressive environments, resulting in corrosion and early failure of the damper.

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Floor dampers installed in walls and wall dampers installed in floors.

Beyond the issues shown in this feature, A.G. Coombs Group Engineering Manager Warwick Stannus, M.AIRAH, says there are design issues related to the overall smoke hazard management system architecture and fire compartment separation. “The industry needs to focus on standardisation of the design and construction processes and practices to deliver more reliable outcomes,” he says.

Examples of incorrect damper application include: •

STANDARDISING DESIGN

According to Stannus, an important first step is a comprehensive review of the relevant standards including AS 1668.1, AS 4254.2, and AS 1682.1 and 2, to create a more clearly articulated set of design and installation requirements. There are many instances of damper installations where the expansion gap has been incorrectly packed, packed with the incorrect materials, or not packed at all. Packing must be in accordance with the manufacturer’s instructions and the FRL test.

7. DEBRIS

9. OTHER SERVICES Sometimes building services pipes and cables penetrate the damper flange or casing, or use the expansion gap as a convenient wall penetration for the passage of other services. AS 1668.1 requires that service penetrations and control joints associated with the ventilation or air conditioning system be protected in accordance with the requirements of AS 4072.1. Specification C3.15 of the NCC BCA Volume 1 and AS 1530.4 each provide guidance as to the minimum allowable clearance between penetrations for cables, pipes and ductwork.

Sometimes material is lodged in the damper mechanism that would prevent it from operating. Debris may even be purposely placed inside broken dampers to hold them open permanently.

10. INCORRECT INSTALLATION INSTRUCTIONS

Be sure to check for debris after all tenancy fit‑out work is completed (or confirm other parties will be responsible). “Debris” might also be identified as a “modification”, voiding the relevance of the associated testing approvals for the product.

Installation methods are damper and test report specific. It is not acceptable to get installation instructions and specific features or methods of installation for one manufacturer’s dampers and apply

A simple example of a potentially dangerous modification could be the use of an incorrect

“A simplified framework for assessing fire damper performance as part of a fire compartment building element also needs to be found. The current arrangements are expensive, overly complex and create reports that often generate downstream confusion and therefore mistakes.” With these in place, Stannus believes a number of industry initiatives can then be implemented with greater confidence to reduce the number of installation defects and improve system performance. These include development of consistent manufacturer’s data aligned to industry terminology and standards, OEM (original equipment manufacturer) wall supplier installation and wall opening guidelines, and design and installation training programs. “Most developers, designers, constructors and certifiers acknowledge the importance of essential safety measures to the safety of building occupants, business continuity and asset value,” he says. “The problem is generally not the intent, rather the execution challenges.” ■

DAMPER INSTALLATION ESSENTIALS AIRAH’s DA06 manual recommends the following commonplace checks: 1. Coordinate trades.

fire-resisting barrier in which it is installed so that it cannot dislodge during a fire event.

2. Follow manufacturer’s instructions.

8. Mount the damper with flanges on one or both sides, butt the flanges against the face of the barrier and fix the damper casing. Allow for expansion of flanges if only fixed to one side.

3. Ensure damper complies and is labelled appropriately. 4. Test reports match intended installation. The damper must be installed as it was tested.

9. Clearance for expansion to be provided, and packed if required.

5. The manufacturer’s installation orientation must be complied with.

10. Width of the retaining flanges not less than twice the clearance.

6. Damper is installed in correct orientation and airflow direction.

11. Breakaway duct connections used to connect any ductwork to damper.

7. The damper must be effectively retained in the

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12. Unless fire damper meets fire resistance level (FRL) insulation criteria, ductwork connected to the damper must be insulated or enclosed in a fire-resistant enclosure in accordance with AS 1668.1. 13. The damper is provided with sufficient access to allow inspection, testing (if applicable) and maintenance. 14. Damper label is visible and legible. 15. Damper installation label is visible and legible. 16. Damper is commissioned with the air systems running. ■

BUILDING CONTROL CIRCUITS

MODULE

145

PROUDLY SPONSORED BY

Skills summary

The majority of refrigeration and air conditioning plants rely on some form of automatic control system to maintain environmental conditions within the conditioned space. In fact, it would be fairly rare for a plant to operate under complete manual control. The HVAC&R technician is frequently called upon to locate and repair faults in automatic control systems of varying complexity.

■ What?

Building the control circuit for refrigeration and air conditioning plant.

■ Who?

Relevant for refrigeration and air conditioning technicians.

This Skills Workshop looks at building the control circuit.

Building the control circuit

The circuit in Figure 1 will operate on three-phase supply provided that: • • • •

Adequate power flows to the disconnect switch The disconnect switch is closed The fuses are good volts The contactor has been 415 415 manually closed.

Figure 3 modifies the above circuit with the addition of a thermostat for automatic control of operation according to the temperature.

power supply disconnect switch with fuses

If it is desired to close the contactor F F F electrically, a control circuit may be L1 L2 L3 added together with a switch, and an electromagnetic coil to operate contactor the contactor. Because a fan motor is essential for air conditioners, this may T1 T be added to the same circuit and 2 T3 compressor controlled by a parallel or doublemotor acting switch. Because small fan M motors are generally single-phase, the whole control circuit may be Figure 1 connected between one phase from the switch side of the contactor and a neutral, resulting in a 240 V circuit. Figure 2 shows a simple control circuit. Note that the contactor‑holding coil is shown in the control circuit although it is physically inside the contactor. The switch in the control circuit has three positions, these being: ‘1’ – off, ‘2’ – fan only, ‘3’ – fan and compressor together.

123

N c c c

thermostat c

Figure 3

All air conditioning systems require protection against excess current draw, high and low system pressures, and high motor temperatures. Because these controls are essentially heat- or pressure-operated, when the circuit is opened and the compressor stopped, conditions will again approach “normal” and the controls will reset, thus restarting the compressor. Figure 4 shows the addition of these controls to the switch circuit described above. Note that the compressor motor would stop, but not the evaporator fan. Again, switches are shown in their control, not physical, location.

To stop and start the compressor automatically, it is necessary to add an automatic device such as a thermostat. N compressor switch 240 volts

fan switch

123

c c c

contacts

compressor motor overload relay contact

compressor contactorholding coil

c c c

evaporator fan motor M

compressor motor overload relays (heaters)

Figure 2

high-pressure switch

NC auto reset type

thermal protector (thermostat inserted in motor windings)

low-pressure switch

Figure 4 April–May 2022

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HVAC&R Skills Workshop A weakness of this control system is that if motor overload or abnormal pressures still exist, the unit will stop and start repeatedly. To prevent this recycling and make the system “manual reset”, a reset or lock-out relay can be placed in the circuit with “normally closed” contacts.

415 volts

C-1

415 415

C C H

c c c

OL c

Figure 5

Figure 5 adds the reset relay holding coil in parallel with the switches. Should any of these “normally closed” protectors open-circuit, the high impedance of this coil in series with the compressor coil energises it and opens the reset relay contact. The contact will be held open even if the automatic protectors reset until the power is turned off as in Figure 6. The reset relay holding coil will be de-energised, closing the RR contact and allowing the compressor to restart, when the main switch is turned on again.

c OL

N compressor motor condenser fan coil and OL contact

Figure 9

L2 L3

c c EF

Crankcase heaters are considered by most designers to be an essential accessory for air conditioners, and for many refrigerators, to prevent compressor damage due to the accumulation of liquid refrigerant in the crankcase during “off” periods. The heater may be simply connected between any phase on the “live” side of the contactor and neutral, for continuous running, but most designers prefer to connect it so that it operates only during the compressor “off” cycle. If the compressor contactor can be fitted with a “normally closed” contact (which opens when the compressor runs), the heater may be connected here. See Figure 7.

compressor contactor NC contact C-1

Figure 10

Some systems may be equipped with a “pump-down” cycle in which the thermostat operates only a liquid line solenoid, and compressor cut-out depends upon the operation of the low-pressure switch. Figure 11 shows the simple connection which suffers the disadvantage that the compressor may recycle at any time, whenever the system pressure increases. Figure 12 shows a preferred non-cycling relay system which uses an auxiliary contact on the compressor contactor for holding the compressor out until the thermostat again calls for cooling.

R OL low high TOL

R OL

T2 T3

evaporator fan motor

Figure 6

heater

C C H

high TOL low

C C H

pump-down LP control CCH

compressor motor

evaporator fan contactor

EF EF EF

c c crankcase

OL A

L1 L2 L3

OL OL FM

C C H

415 415

c c

415 V condenser fan motor 415

R NC

c c c

Similarly, a three-phase evaporator fan may be substituted, connected from the main disconnecting switch but controlled by an evaporator fan contactor coil connected in place of the single-phase motor used earlier (see Figure 2). Figure 10 shows the basic circuit, with the compressor safety control circuit omitted, but with a two-phase 415V condenser fan dotted. In practice, a three‑phase condenser fan may also be used, or this circuit may be used to operate an evaporative condenser fan, or water pump, or to serve as a control circuit for three-phase condenser cooling equipment.

off and reset switch N

Figure 8

reset relay holding coil

L1 L 2 L 3

compressor motor

reset relay contact

3-phase condenser fan

C-1

thermostat

liquid solenoid valve

Figure 11 – Simple pump-down circuit Figure 7

The operation of the non-recycling pump-down cycle (Figure 12) is as follows:

Air-cooled condensers on both split and larger units require a cooling fan which operates with the compressor. This fan may be single‑phase, connected as shown in Figure 8 through the extra terminal on the contactor. If the fan motor is 415 V single-phase, it would be connected between two phases instead of between phase and neutral. If three‑phase, the connection may be as in Figure 9. 16

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In normal running operation, the thermostat energises both the liquid solenoid which is holding the valve open and the non-recycling relay (NRR) which keeps the NRR contact closed. Provided pressures are normal and there is no overload, the contactor coil is energised, keeping the auxiliary contact closed. A lock-out circuit is an optional feature, not shown in this diagram, with the low-pressure control being used for safety and pump-down.

HVAC&R Skills Workshop When the thermostat senses that the load is satisfied, it open‑circuits, closing the solenoid but opening the NRR contact. The compressor continues to run because the auxiliary contact is still closed, until the low‑pressure control opens the control circuit, de-energising the contactor coil. This in turn opens the auxiliary contact which prevents the compressor restarting, even if the pressure rises, until the thermostat remakes the solenoid valve and non-recycling relay contacts.

(a) Crankcase heater operates when the compressor is ‘off ’.

NRR NO contact

high

(d) In Position 3, the condensing unit is activated, and the compressor will run provided that:

NRR

liquid solenoid valve

nonrecycling relay c coil

aux

(b) Transformer supplies low voltage for control circuit.

low auxiliary relay coil

As thermostats and other control equipment become more widely spaced, with conditioned spaces, control panels, plant rooms and remote condensers many metres apart, there is a greater need for low-voltage controls which will permit adjustment of some control equipment without disconnecting the power. However, on any system, the advantages of safe low-voltage power are obvious only so long as the operator is aware that some of the circuit still operates at high voltage. In the circuit shown in Figure 14, the whole control system is connected to a safe 24 volts with the exception of the three main contactors and the crankcase heater. The circuit has been arranged showing the sequence of operation from left to right as follows:

aux. NO contact

24-volt control circuits

(i) The normally open evaporator fan contact is closed (i.e., the fan is operating). (ii) The necessary overloads are reset. (iii) The selector switch and thermostat both call for either heat or cool.

Figure 12 – Non-recycling pump-down cycle

(iv) The condenser fan starts and closes the CF contact to energise the compressor coil.

Figure 13 shows the control circuit with the inclusion of manual changeover switch, permitting the conditioner to operate either “cool‑off” or “off-heat” modes, thus avoiding the energy wasting (and system overloading) changeover directed from cooling to heating.

(e) When the selector is on heat and the thermostat is calling for heat, the reversing valve solenoid is energised and the indoor evaporator becomes the condenser, and the outdoor condenser the evaporator.

Also introduced to the circuit are two important safety devices – a control circuit fuse and a safety interlock contact (EF), which prevent the compressor running in any mode should the evaporator or “indoor” fan fail to run due to overload or other fault. When in the heating mode and the thermostat calls for heat, the reversing valve solenoid is energised directly, bypassing the “limit” and “defrost thermostat” contacts. The compressor also operates provided that there is no fault.

(f ) When ice accumulates on the outdoor coil, the de-ice thermostat closes and energises the de-ice circuit, switching off the solenoid. At a certain pressure which ensures complete de-icing, the limit switch opens to disconnect the circuit and normal heating recommences. ■ L1

When the outdoor coil temperature indicates that this coil has iced up, the defrost thermostat closes, switching on the “de-ice relay” (R) which in turn opens the normally closed R-1 contact and closes the normally open R-2 contact. This ensures that the de-ice relay remains until the rise in pressure opens the “limit switch”.

C OL 1

multi-core cable

When the thermostat and limit switches indicate that defrost is complete, power is cut off from the de-ice relay, and the R-1 NC contact reconnects the reversing valve solenoid.

C C

EF EF EF

CF CF CF

OL 1

condenser fan

compressor

CF on –off switch

evaporator fan

cool/heat selector

control fuse

N R-2 NO

defrost thermostat

TOL CCH

R-1 NC

reversing solenoid valve

Figure 13 – Control system for heat pump operation including de-ice control

EF C NO room t.stat RL OL high low TOL

N EF

CF OL CF

H H

DPS t.stat defrost

R2 NO

CF NO

R2 NC rev. sol.

Fig 14 – A complete circuit for a heat pump type air-

conditioner with 24-volt control circuit. Note the addition

O YOU HT T BY UG O

GIVIN

NCE 1920

ATION FRIGER NING LIAN RE IO URCE AUSTRA AIR-CONDIT L RESO NATIONA AND

EDITION

de-ice

low

heating

C C H

high

defrost limit switch

1 2

lock-out relay compressor coil

24 V

evaporator fan coil

C C 240 H V transformer

evaporator (indoor) fan coil

EF OL

crankcase heater 240 V

H or C selector switch C H

fan

condenser fan coil

thermostat

EF NO

1 2 3

C NC

THE I ND

T US

This skills workshop is taken from Australian Refrigeration and Air‑conditioning, Volume 2, authored by Graham Boyle, F.AIRAH.

of an interlock preventing the compressor coil (C) being energised until the condenser fan is also operating (CF NO).

Next issue: Leak detection, repairs and refrigerant handling

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Industry insight

A SEISMIC SHIFT Sustainability is becoming a core design and delivery imperative that impacts every part of construction – including trades.

How buildings perform affects their value. This places increasing pressure on engineering design – and the trades that deliver it – to ensure systems will function efficiently. And making this possible relies on increasing the capacity and knowledge of trade subcontractors. While subbies and tradies often have the least influence on overall project design and program decisions, you have more power than you might realise to influence final outcomes. This is evident in passive improvements such as making sure the final ductwork design is smooth and paying attention to the small but crucial details, such as quality of tapes and sealants. Other things that can be done that do not compromise timeframes or budgets include taking the time to understand the overall project design strategy so you can specify and build from that intent. It is also valuable to investigate the type of operation the system is expected to have, for example, has it been designed for realistic everyday operation versus designing for a peak load scenario? And if you are specifying systems that will cope with a climate-changed world, spell that out in your tender documentation. This kind of effort has a long-term pay off. For a trade or subcontractor to have sustainable projects on your track record is a positive market differentiator. Word of mouth

is also a powerful form of advertising – the engineer or builder who talks about the value a trade or subbie added to their recent project is the kind of promotion that helps attract non-competitive RFQs. This is a big win when you attract repeat projects because you are already doing things in a sustainable way. Increasingly we are also seeing public projects and institutional investor-led developments specifying requirements around the sustainability track records of the main contractors, such as HAVC&R. The time is not far away when everyone in the industry will have to get with the sustainability program.

contractor has a project culture that encourages dialogue and collaboration. It is up to everyone involved in projects to enable a learning mindset and not just behave in a super-contractual way with each other. I always encourage any trade subcontractor to ask questions. If you are working with a friendly engineering consultant, ask questions about sustainability and climate change adaptation. We are passionate about sustainability, so we are willing to have a chat. ■

There are a few strategies I use to help trades gain more expertise and knowledge in this space. One of the most important ones is taking a flexible approach to early design, so there can be flexibility during delivery. Another is ensuring climate change resilience has been incorporated into design and that the rationale for those decisions is explained to the trades who will deliver it. This is particularly relevant to HVAC&R where we have to ensure systems are right-sized for a warming world and have resilience to extreme events.

This article was provided by David Collins – Associate Director, Sustainability – Cundall

This kind of information can quite quickly pass from consultants to subcontractors when a construction

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Cover Feature

DEEP DIVE An innovative cooling system has allowed young and old to appreciate a piece of Australian naval history, and serves as a fitting tribute to a woman who believed in learning through experience. Louise Belfield reports. Sitting proudly in the water and moored alongside the Australian National Maritime Museum (ANMM) in Sydney’s Darling Harbour is a relic of the American‑Soviet Cold War of 1947–1991 – Australia’s HMAS Onslow submarine.

The existing ventilation system, comprising an axial fan, delivered unfiltered and unconditioned air through the air intake shaft within the conning tower into the cabins and was totally unsatisfactory. Tours had to be cancelled.

Decommissioned in 1999, this sleek, black, “silent patroller of the deep” clocked up more than 358,000 nautical miles in service before being donated to the ANMM.

“We have a number of volunteers and visitors doing regular tours of the sub, but with limited airflow and high temperatures, we had to stop that,” White says. “We looked at modifying the sub at one point by piping chilled water to it, but that wasn’t going to be viable. It was going to be far more cost‑effective to install a DX system.”

The sub is now an exciting and informative experience for young and old alike as they explore the cramped conditions and imagine what life was like for the sailors whose lives were in constant danger.

The challenge, however, was getting a system to fit into the tight space and meet the capacity requirements at the same time.

According to one ex-Navy officer, it wasn’t just the threat of enemy vessels that weighed heavily – the air quality was also “disgusting”, and the crew would go well over 12 hours a day without fresh air. Sadly, conditions inside the submarine as a modern tourist attraction have also been far from ideal.

UNSAFE TEMPERATURES Summer temperatures regularly topped 25°C, and the submarine cabins were 4–5°C higher. Conditions simply became uncomfortable and unsafe for visitors, volunteers and staff, says ANMM building services manager Craig White. Unsurprising really, with a black solid metal hull and deck and very little space inside. 20

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in. His late wife Samim had been an early childhood development expert with double master’s degrees in this field, before she succumbed to motor neurone disease (MND) in November 2019 [see breakout]. She always said that “children learn through experience”. So, to ensure that children could have that experience, and as a tribute to his late wife, Nathwani offered to design and, with the help of his family, cover the costs of the installation of an air conditioning system to ensure year-round access.

TIME FOR A SEA CHANGE

“Because of the very limited space and having to also maintain the historical aspects of the sub, we couldn’t just hang a modern aircon unit on the wall,” White says.

Aware that no ordinary system would do the job, Nathwani turned to the team at Aerotherm, who had successfully installed an unusual system he designed at a Sydney University laboratory called the Indoor Environment Quality (IEQ) laboratory.

“Another challenge was getting a fan coil unit to fit into the conning tower [the periscope housing]. Where you would normally put a fan coil system in the ceiling space of a building, the available entry space through an access hatch into the conning tower was only 450w x 600h.”

“But that lab is not quite as cramped as the sub,” Nathwani says. “I asked if we could convert the lab idea into an aircon system for a submarine and how big a unit we could fit in. That took some working out because there was a size constraint. It clearly needed to be custom made.

On learning that the tours of the submarine were being cancelled during hot days, including during summer school holidays, Ashakali (Ashak) Nathwani AM, researcher and senior lecturer in HVAC at the University of Sydney stepped

“The final design involved provision of a custom-built split air conditioning system with the air handling unit located in the snorkel mast, replacing the fresh air fan, and the condensing unit located in the chamber below the main cabins.

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Cover Feature “The selection of the system involved taking into account the high ambient dry bulb temperatures together with the high humidity conditions. Consideration had also to be given to the material selection, bearing in mind the corrosive outdoor conditions. This required working closely with the contractor and the unit supplier. The unit customisation also ensured that the supply air was filtered with the ASHRAE‑recommended MERV-13 air filters, to address COVID-19 concerns. “While the installation of the air handling component in the air intake within the snorkel mast was straightforward, though a bit awkward for the contractor, the condensing unit had to be brought in on a barge and craned into the chamber below where we ensured there was sufficient airflow to facilitate heat rejection.”

TRIP HAZARD Pasquale Belcastro, M.AIRAH, HVAC contractor and project manager with Aerotherm, agrees that the solution was in some ways straightforward, but required careful planning.

Early discussions in the project centred on which side access hatch to use.

“We basically came up with a split system that had a special inverter compressor that could handle the full outside air conditions,” says Belcastro. “The condenser itself had to be put in a space which could provide adequate cooling ventilation, and that was found inside the fibreglass hull on the upper deck of the sub. This had plenty of openings for the air to circulate through naturally.

And while it appears the tripping issue has not eventuated, Aerotherm is monitoring the condenser to see if it needs to be baffled. “It was essentially about selecting the right size equipment and configuration to do the job,” says Belcastro. “All the stuff is on the market, but ensuring we used the right type of compressor to suit the application was essential. Normally a compressor gets some sort of cooling effect because you have the conditioned air returning from the room already cooled passing over the indoor coil, which gives the system a chance to cope, but when you’ve got 100 per cent outside air at 35–40°C constantly on the coil, that puts a big load on the compressor and there is a chance it could fail and trip out.

“One of the problems we had to consider was recirculation of the cooling air drawn through the condenser within the hull space; we had to ensure the now-heated air could discharge down the hull without turning back on itself and re-entering the condenser, thus causing tripping issues.” To address this issue, the condenser was simply placed squarely onto the hull so that the condenser cooling fan blows in the fore-to-aft direction.

“So, for this job I went to the next size unit to handle the extra load (but still fit in the cramped conditions).”

A TIGHT SQUEEZE Physically getting the fan coil unit into the sub was also not without significant issues. The extreme summer heat during the installation was just one of them. “We had to climb in and out numerous times to get the disassembled unit through the access hatch into the conning tower,” Belcastro says, “then climb up a service ladder onto an upper deck, then clamber though the tight passageway of the main support structure to an opening adjacent to the periscope shaft! “Because the indoor unit is basically a box, we had to unscrew the casing panels, take the coil out, take the fan out, then reassemble in situ. We then had to have space for filters and of course have the space to service the unit.

NEED TO KNOW: MOTOR NEURONE DISEASE Each day, on average, two Australians die from motor neurone disease (MND) and two more are diagnosed, according to the MND Association of NSW.

And the average lifespan for anyone with this disease is three to five years after diagnosis. In Samim Nathwani’s case it was three years.

Around 10 per cent of MND cases are “familial”. That is, there is or has been at least one other person affected by MND in the family. The remaining 90 per cent are said to have “sporadic” MND.

It is an insidious disease. Nerve cells (neurones) that control the muscles that enable us to move, speak, breathe and swallow gradually weaken and waste. You can physically notice the difference and the sufferer loses weight. They also become more sensitive to environmental temperature changes, meaning they will feel colder during winter months and warmer in summer.

Samim Nathwani

MND takes several forms. For some people, the symptoms are widespread from the onset. However, it usually begins by affecting a single limb or aspect of motor function, becoming more generalised as the disease progresses. There is usually evidence of wasting and weakness in some muscles and fasciculation (twitching) of parts of the muscle, which may be visible under the skin. Sufferers may have only lower or upper motor neurone signs early in the illness but typically develop a combination of the two as the disease progresses. Diagnosis can take up to six months or more.

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Most people with MND remain mentally alert. “Samim was watching videos of her grandchildren 15 minutes before she passed away peacefully on November 2, 2019,” says Samim’s husband Ashak Nathwani AM. Discovered some 150 years ago, MND still has no cure. The only treatment currently available is Reluzole, taken in tablet form twice a day, which can extend the life of an MND patient by up to two months. “Increased research needs to concentrate on the cause and elimination,” Nathwani says. “If combined global effort could address COVID-19 and come up with vaccines in record time, so can a global effort make a difference to MND.” Ashakali Nathwani AM is the Ambassador for the NSW Motor Neurone Disease Association and the designer of the submarine air conditioning system. His wife, Samim, died from MND in November 2019. Her family donated the cost of the air conditioning system as a tribute to her, to allow ongoing early childhood experiences by visiting the HMAS Onslow. For more information visit: mndnsw.org.au

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Cover Feature Visitors can now visit the HMAS Onslow year-round.

Then we were able to crane in and manhandle the condenser onto the upper deck of the sub, which required a bit of coordination.

“We found a reasonable opening where we could take all the pieces to and then reassemble it – and it provided enough space for maintenance as well, which was also tricky to find.”

“The three-phase electrical supply to the air conditioning unit is via the existing landline power supply. An indoor zone-mounted thermostat maintains the pre-set conditions in the submarine’s cabins. And the units were applied with a special epoxy treatment to keep corrosion at bay.”

The fan coil unit was then connected with a large flexible duct, which was woven through the support structure within the conning tower, across to the air intake shaft for final connection. “Amazingly, the conditioned air just flows down that shaft and then feeds fore and aft right through the submarine and is exhausted on each end of the vessel,” says Belcastro.

With the easing of COVID-19 restrictions just before Christmas 2021, the HMAS Onslow was allowed to open briefly until it was closed once again in January because of the pandemic. However, it was open for long enough to establish that the system was a winner.

“It seems to work effectively and is a success – probably a bit too cold, but that’s just a matter of relocating the sensor or turning down the fan. It keeps the cabin air dry as well. Nothing out of the ordinary except the challenge of getting materials through the tight spaces and then having to work within them.

“We were getting temperatures of 4–5°C lower than the ambient temperature,” ANMM’s White says. “We are also looking at how to automate the system further through the site BMS system, so we can run it without the need for manual on/off controls.”

“To get the condenser unit inside the hull we had to get the large access hatch on the side of the submarine opened up and get the maritime boys to come alongside on a barge with the condenser.

Thanks to Nathwani’s initiative and innovative approach, there is air conditioned and filtered fresh air maintaining comfortable conditions in the

Closer view of the entry point into the conning tower, through which the dismantled indoor unit was brought in over many trips. 24

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submarine’s cabins, making it far more pleasant for both guides and the public. “This will allow the tours to remain open during the hot summer days, COVID-19 restrictions allowing, including school holidays,” says White. “It’s a peak time for the school age patrons to ‘learn from the experience’.” ■

PROJECT AT A GLANCE PERSONNEL ▲ Client: Australian National Maritime Museum (ANNM)

▲ Controls: Craig White, Building Services Manager, ANNM

▲ Head contractor: Pasquale Belcastro,

M.AIRAH, Project Manager, Aerotherm

▲ Design engineer: Ashakali Nathwani AM,

Researcher and Senior Lecturer in HVAC at the University of Sydney.

Inside the caisson fibreglass hull where the condenser unit was placed – cramped conditions as you would expect.

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Around the Nation 1

5 Cold Hard Facts 2021

December 2021

Gregor Riese

COOLEST. CONFERENCE. EVER.

“Matthew’s technical knowledge, experience, market contacts, and commercial acumen will support Hydroflow’s growth efforts across Australia,” says National Sales Manager David Clarke.

AIRAH is taking a new approach to its Refrigeration Conference this year, with the goal of opening the event to more refrigeration contractors, technicians and apprentices. It will be held in person in Sydney and online on May 17–18.

Go to www.hydroflowaus.com.au

The conference will begin on Monday, May 17, with an education session. This is split between three main topics: the fundamentals of refrigeration; energy efficiency in refrigeration; and a coolroom design workshop.

The Advisory Note provides information on the HFC phase-down and Montreal Protocol, the state of the current refrigerant market, HFC alternatives, refrigerant trends, and an assessment of what the phase-down means for commercial HVAC systems.

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SWANSON GOES WITH THE ’FLOW

“With the phase-down of HFC refrigerants, there will be reduced supply, and this is likely to result in increasing cost of the gas over time,” says A.G. Coombs. “This has been observed with an increasing cost of R134a over the past five years.”

Hydroflow Distributors has appointed Matt Swanson as Senior HVAC Business Development Manager. He will be responsible for business improvement across Australia through specification and sales of the IMI TA (Tour & Andersson) product portfolio.

The note advises keeping an accurate schedule of all assets incorporating HFC refrigerants, speaking with mechanical maintenance providers to identify any HFC plant operating inefficiently, preparing a refrigerant management plan, reviewing chiller plant replacement strategies, and considering systems that can offer both cooling and heating at the same time to leverage cost efficiencies.

Swanson comes to the role with significant experience in international product management and national sales management. He previously held the positions of National Industrial Business Manager with Crane Distribution Limited (Tradelink Plumbing Centres), and Country Manager for Australia and New Zealand with Frese Asia Pacific. Before moving into business development at 30, Matt was the youngest member of Crane’s Senior Management Team and Tradelink’s Guiding Coalition.

Go to bit.ly/3tPbdaI

Over more than 14 years, Swanson has built up a wealth of experience in HVAC product supply, valve sizing, fault-finding, and system value engineering, and has also spent time working in building automation. He developed an interest in fluid mechanics when completing a mechanical engineering degree at Monash University. 26

HVAC&R News

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CHOOSE WISELY, SAYS A.G. COOMBS

“As the world grapples with rising temperatures caused by the emission of greenhouse gases, refrigerants are under renewed scrutiny,” A.G. Coombs says. “Common refrigerants are classified as greenhouse gases, which can be hundreds or even a thousand times worse from a global warming potential (GWP) versus the equivalent volume of natural refrigerants such as carbon dioxide (CO2).”

Discount rates apply for students – just $75 to attend the full-day education session.

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A.G. Coombs has produced an update on its advice about refrigerant use for commercial HVAC systems.

The following day – Tuesday, May 18 – features a full day of conference technical presentations. Attendees will hear from both international and local experts as they review the latest from refrigeration industry.

Go to www.airah.org.au/refrigeration2022

Katanga Mangala

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NEW OPENINGS AT OPIRA

The Opira Group has announced the opening of a New South Wales office with the appointment of a new regional director: Gregor Riese, Affil.AIRAH. Riese joins Opira as an environmental scientist and |

April–May 2022

occupational hygienist with extensive experience in the waste management and recycling industries since 1996. He completed a master’s in occupational hygiene and toxicology and is also an accredited WELL AP and NABERS Indoor Environment Assessor. Opira has also welcomed a new team member to its Perth Office – Katanga Mangala. Mangala brings more than 10 years of experience in occupational hygiene and environmental consultancy across a variety of industries. Mangala is studying for his master’s in occupational hygiene and toxicology at Edith Cowan University. “We are excited about the new growth across our organisation,” says Opira, “and we look forward to supporting our customers with all their indoor air consultancy requirements.” Go to www.opira.com.au

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JUST THE FACTS

A new version of Cold Hard Facts – Australia’s definitive reference on the HVAC&R industry – has been released. The big takeaway is that Australia has probably passed “peak bank”. In other words, our total quantity of refrigerant is now starting to shrink, and with it, the associated emissions. This shows that Australia’s HFC phase-down and other efforts around the world are having an impact. The rapid transition away from R410A to R32 in air conditioners is continuing. Hydrocarbons are signalled as another growth refrigerant, especially in applications with charge sizes under 150g such as refrigerated display cabinets and portable air conditioners. But the transition to natural or alternative low-GWP synthetic refrigerants is not happening as quickly in other sectors. The report notes that despite a concerted move by major supermarket chains to deploy trans-critical CO2 systems, demand for R404A remains strong. In other words, although Australia has probably passed peak bank, there is still plenty of work to do. “With an existing refrigerant bank in installed equipment that has a total global warming potential of approximately 100 million tonnes (Mt) CO2e,”

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reads the report, “efforts at improved containment and effective recovery of refrigerants will be important to continue to drive down the total environmental impact of RAC services in Australia.” Go to bit.ly/3KDQygD

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MITSUBISHI HEAVY ADDS MASS

Mitsubishi Heavy Industries Air-Conditioners Australia (MHIAA) has formalised a partnership with turnkey HVAC solution providers Mass Electronics Group to deliver the local relay model for its latest zoning solution, FlexiZone. Mass Electronics will provide the MH-4ZRM relay modules to enable FlexiZone to be integrated into Mitsubishi Heavy’s ducted air conditioning systems. It will also allow users to turn off individual zones on or off as needed. “Our company was in search of a local hardware manufacturer for our four-zone relay model,” says GM Service and Technical for MHIAA John Bolger. “We required a plug-and-play solution and looked for an innovative, cost-effective, quality solution. This solution was specifically developed with the Australian market in mind.” Mass Electronics is a privately owned, Australian‑based electronics design and manufacture group, providing consultancy and new product development services from its facility at the Brisbane Technology Park. Founded in 1984, the company has won numerous awards and has been featured as a Top 400 Company in Queensland. Go to mhiaa.com.au

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VENTILATION VOUCHERS

Business will be able to access $500 ventilation vouchers to buy air purifiers, ventilators and other COVIDSafe maintenance. The government will also offer up to $5,000 for matched grants to eligible small businesses to improve ventilation to help reduce the spread of COVID-19. This could include investing in equipment, building works, and maintenance services.

National Precast Concrete Association Australia, Women in BIM, Green Building Institute and the Facility Management Association of Australia (FMA). Go to designbuildexpo.com.au/register

“Business and consumer confidence is critical for our continued economic recovery, and that’s why we’re investing in these programs to deliver a boost where it is needed most,” says Victorian Minister for Industry Support and Recovery Martin Pakula.

“Standards Australia is delighted to welcome AIRAH, a long-standing and strong contributor to standards development, to the membership of the company,” says Standards Australia General Manager Engagement and Communications Adam Stingemore.

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MELBOURNE MEGA‑EVENT

“The two organisations have enjoyed a strong working relationship over a number of years now, and official membership for AIRAH in Standards Australia is a natural and logical extension of this. We look forward to the liaison continuing for years to come.” ■

BE Summit, DesignBUILD, Total Facilities and Digital Construction Week will be held at the Melbourne Convention and Exhibition Centre over one week from May 10–13.

Covering industries ranging from planning and construction to technology and facilities management, DesignBUILD, Total Facilities, the Be Summit and Digital Construction Week will join forces to create what organisers are describing as “a unique built environment event for Melbourne”.

The Kaire Unit incorporates three stages of particulate filtration using custom-designed mechanical filters to deliver effective filtration of kitchen exhaust emissions with increasing efficiency through each stage at a minimal cost. A final gaseous filtration stage uses activated carbon media to remove odours.

“With the rise of building information management (BIM) systems, the various built environment sectors have become increasingly interdependent, so cross‑sector knowledge is more important than ever,” says Ormiston. “We have collected feedback and fine-tuned these events so this year we are confident of delivering an exceptional experience for both exhibitors and attendees.”

A $60 million program will help small businesses purchase equipment and upgrades to reduce the spread of COVID-19 in the workplace and improve customer confidence.

The event also brings together major industry groups including the Australian Construction Industry Forum (ACIF), Australian Institute of Building (AIB), Australian Institute of Quantity Surveyors (AIQS), April–May 2022

AWARD-WINNING FILTRATION

Camfil’s Kaire Unit has been named AIRAH 2021 Product of the Year. The Australian designed and manufactured multi-staged, combination filtration system was designed to control light to heavy kitchen exhaust emissions (smoke, grease and cooking odours) for all types of commercial cooking applications.

Commercial Manager Lynn Ormiston says the past two years have allowed time to create a new whole-of-industry style approach.

The Victorian government has launched a stimulus package to support businesses and entice people back into venues and workplaces, with funding aimed specifically at ventilation.

STRENGTHENING OUR STANDARDS

AIRAH has been granted membership of Standards Australia. As well as regularly submitting proposals to improve and update various standards, AIRAH is represented on 18 Standards Committees.

Information and guidance about improving ventilation in rooms and spaces in workplaces is also available through the government’s knowledge hub. Go to www.coronavirus.vic.gov.au/ventilation

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With restricted space in buildings, it can be advantageous to horizontally discharge kitchen exhaust instead of vertically above the roof line. But horizontally discharged kitchen effluent requires an engineered solution to remove particulates and odour, as per Australian Standards (NCC, AS 1668.1:2012 and AS 1668.2:2012). The Kaire Unit achieves this with staged particulate filters and activated carbon media. Go to www.camfil.com.au |

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HVAC&R News

AIRAH Awards

LONG WAY ROUND After a taking winding road to a career in refrigeration and conditioning, Jessica Lonsdale, Stud.AIRAH, has won the AIRAH Student of the Year – Trade award. The story of how Jessica Lonsdale, Stud.AIRAH, started her refrigeration and air conditioning apprenticeship is a familiar one.

Coming from a scientific background, she also enjoys the technical aspect of the trade, and has been pleasantly surprised by the detail involved.

“To be honest I didn’t even know refrigeration was a trade!” she admits. “I applied for a fitters apprenticeship with BHP, but wasn’t successful. Then I was offered the refrigeration apprenticeship. I had a quick Google, found out that it looked all right, and just went from there.”

“The way refrigerant works on its own, there’s quite a bit of science behind it,” she says, “so I found that really interesting.”

Lonsdale is not the first apprentice who entered HVAC&R because it was the best offer on the table. But it she wasn’t your average recruit. “When I left school, I was working in medical research,” says Lonsdale. “I did that for about 12 years, but then the funding dried up. So I was left without a job.”

Some might think that being a female in a heavily maledominated industry would be a challenge. But Lonsdale says it’s been positive.

Next, Lonsdale went into the mines, and spent about 18 months driving a truck. Finally, she decided to look for something solid that could sustain her back in Perth. A trade was the ideal option. “When I was at school they said, ‘Don’t bother with trades, go and get a degree’,” Lonsdale says with a laugh. “It turns out trades are actually quite important these days.”

“Everyone I’ve been working with, they’ve all been supportive, helpful,” she says. “Even these guys who have been doing it for 20–30 years, they’re really excited to see females getting in there. Everyone’s been very welcoming.”

Once on board with BHP, Lonsdale’s apprenticeship was spent mainly in the mines. As well as her fair share of straightforward split installations, she also had the opportunity to work on recommissioning an ammonia‑based underground cooling system that had been in care and maintenance for several years after an earthquake at the site.

“I have faced several challenges on my way here, but each one of them has only strengthened me to make me the person I am today,” she says, “someone who sets her eyes on a goal and does not lose sight of it.” ■

Having already completed a Certificate III in Engineering – Refrigeration Trade, Lonsdale is undertaking a Certificate IV in HVAC and Diploma of Engineering Technical (HVAC) at South Metropolitan TAFE. And she’s now seeing even more of the industry in a new role as a field officer for the Australian Refrigeration Council. Further into the future, Lonsdale is eyeing a potential path into engineering.

Gordon Brothers worked on the project, and Lonsdale was able to shadow the team and soak up their knowledge. It also involved some mechanical work to refurbish the heat exchangers, which she loved.

“That would bring my two passions together,” she says, “refrigeration and science.”

“Definitely more enjoyable than just swapping out PC boards and things like that!” she says.

Overall, Lonsdale is loving her new career in HVAC&R.

WINNERS’ CIRCLE To see all the winners of the AIRAH Awards 2021, go to www.airah.org.au/awards

2021 AIRAH AWARDS SPONSORS AIRAH thanks the Awards Gala Sponsor, Daikin, as well as individual awards sponsors Mitsubishi Electric, Superior Training Centre, A.G. Coombs, LG, HVAC&R Search and Ecolibrium. Gala sponsor

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April–May 2022

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Smoko with . . .

Name: Natasha Kirchner ia Company: Airmaster Austral tice Occupation: HVAC appren ut working in What’s the best thing abo ry day can be – HVAC&R? How different eve g is always there something new and excitin to learn. d in the How long have you worke rs. yea r industry? Fou about the job What has surprised you are so much ons since you started? Airc air. cold more complex than you on a If someone wanted to find for the k worksite, they should loo ing sing ly person who is: Most like while working away. Favourite tool: Gauges. ever Best on-the-job advice you stion is que b dum y onl received: “The .” ask n’t the one you did

nt What’s the happiest a clie rk? wo r you h wit n has bee ning after Getting an aircon up and run e else it eon the client was told by som simply s wa It needed to be replaced. and d fixe we t a small gas leak tha ing sav , day one commissioned in them before the summer. ck Ops.

Dream car: Ford F-250 Bla Dream holiday: Canada. Favourite smoko snack: Vanilla iced latte.

the What did you listen to on . ntry Cou ay? tod rk wo to way Sporting hero: Ken Roczen r). (professional motocross ride : When I’m not working I’m / bike Riding my mountain motorbike or wakeboarding.

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The Lighter Side This month’s Lighter Side brought to you by:

Education sessions and the latest technical insights. Special discount pricing for students. Go to www.airah.org.au/refrigeration2022 VOTE FOR THE WINNER!

Choose your favourite entry at www.hvacrnews.com.au/the-lighter-side And check out last issue’s winner: Going bush from Chris in Launceston.

EASY INSULATION

Jay found this “insulated drain” in North Lakes, Queensland. “Pretty rough job to just use clumps of ceiling insulation duct-taped to the drain,” he says. Graham says: Hard to tell from the image, but drain insulation is extremely important in the tropics. Any cold surface will produce condensate which can ultimately collapse a ceiling. Fibreglass insulation that isn’t vapour sealed will just get wet and lose any insulating properties in the long term.

ADVANCED COOLING

FAN TLC

Brendon spotted this unit at a service station in Queensland. “The air conditioner airflow didn’t reach the console operator,” says Brendon, “so somebody decided to move it closer.”

Mitchell was called out to look at this unit when the owner complained about (surprise surprise) a lack of airflow. To their credit, Mitchell’s crew pulled out the fan deck, gave it a full clean, and pressure washed it a few times to get it as good as possible.

Graham says: There is a difference between air conditioning and spot cooling. Unfortunately, the budget often gets in the way of doing the job properly. Innovative though!

Graham says: The air we breathe! There would be many fan decks around in a similar condition. We don’t design or budget for maintenance, yet it can become a health issue.

COOLING THE ROOST

At least this unit has some breathing holes, although they look like they were made for pigeons rather than a condenser. Thanks to Adrian for the photo, snapped on a pier in Melbourne. Graham says: Someone has gone to a lot of trouble to “hide” the air conditioner, but the unit will suffer in both capacity and longevity. Would have been a lot better with a water source heat pump than air source.

PLUG IT IN!

Regular contributor Mick has sent in another classic. “A cool room condenser has been jammed in with some sort of cover,” he says. “But look harder – they had the nerve to tap into the AC power supply with a GPO. Plug it in boys, good as!” Graham says: Interesting and innovative and probably not legal wiring. I would have thought an electrician would not have put his/her licence to that!

Additional comments and observations provided by Graham Boyle, F.AIRAH, portfolio manager, heavy automotive and refrigeration at South Metropolitan TAFE. Please note that the comments are provided on the basis of the photos only and should be read with this in mind – not all issues or solutions are apparent from a 2D image.

HAVE YOU COME ACROSS SOMETHING SCARY, UGLY OR JUST PLAIN FUNNY? If your entry is deemed the winner, a 700ml 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

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April–May 2022

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HVAC&R News April-May 2022

Articles inside

The Toolshed

AIRAH Awards

Industry insight

HVAC&R News regulars

Lighter Side

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