woolworths limited - Lipman Tender Portal

2011
AIR CONDITIONING &
MECHANICAL VENTILATION
DESIGN BRIEF
WOOLWORTHS LIMITED
This document is prepared as a guide for the design and installation of Air Conditioning &
Mechanical Ventilation for a Woolworths Supermarket.
This document shall be read in conjunction with the other elements of the issued Design Brief
Kit prepared by Woolworths Limited and the standard drawings.
Amendments
Description By Date
General Issue MR 14/2/2011
Page 1 of 157

TABLE of CONTENTS
1.0 SCOPE ............................................................................................................... 5
1.1 INTENT .............................................................................................................. 5
1.2 DRAWING REVIEW ........................................................................................... 5
1.3 NOMINATED DESIGNERS ............................................................................... 5
1.4 CONTRACTOR/TENDERER ............................................................................. 6
1.5 DEFINITIONS ..................................................................................................... 6
1.6 EXTENT OF HVAC SYSTEMS .......................................................................... 7
1.7 DESIGN .............................................................................................................. 8
1.8 WORK BY OTHERS .......................................................................................... 9
1.9 DEFECTS LIABILITY PERIOD ........................................................................ 10
1.10 MAINTENANCE DURING DEFECTS LIABILITY PERIOD .............................. 10
1.11 TECHNICAL DOCUMENTS ............................................................................. 11
1.12 GUARANTEES ................................................................................................. 11
1.13 REGULATIONS ................................................................................................ 11
1.14 OCCUPATIONAL HEALTH AND SAFETY ...................................................... 12
1.15 DESIGNER RESPONSIBILITIES .................................................................... 17
1.16 INSURANCE .................................................................................................... 18
1.17 CONSTRUCTION PROGRAM ......................................................................... 18
1.18 CONSTRUCTION NOISE ................................................................................ 18
1.19 SITE ACCESS .................................................................................................. 18
1.20 SITE INSPECTION .......................................................................................... 18
1.21 PROVISION OF SAMPLES FOR APPROVAL ................................................ 19
1.22 APPROVAL ...................................................................................................... 19
1.23 QUALITY ASSURANCE .................................................................................. 19
1.24 NON CONFORMANCE TO THE SPECIFICATION ......................................... 19
2.0 DESIGN CONDITIONS .................................................................................... 20
2.1 GENERAL ........................................................................................................ 20
2.2 DESIGN CONDITIONS .................................................................................... 20
2.3 NOISE LEVELS ................................................................................................ 22
3.0 GENERAL DESIGN REQUIREMENTS ........................................................... 24
3.1 AIR DISTRIBUTION SYSTEM ......................................................................... 24
3.2 REFRIGERATION CABINETS ......................................................................... 24
3.3 ACTIVE HUMIDITY CONTROL (SUPERMARKETS ONLY) ........................... 24
3.4 HEATING ......................................................................................................... 24
3.5 OUTSIDE AIR CONTROL ................................................................................ 25
3.6 ECONOMY CYCLE .......................................................................................... 25
3.7 COLD AISLE RETURN AIR (SUPERMARKETS ONLY) ................................. 25
4.0 SYSTEM FORMS ............................................................................................. 26
4.1 GENERAL ........................................................................................................ 26
4.2 CENTRAL PLANT (PLANTROOM) .................................................................. 26
4.3 CUSTOM PACKAGE UNITS ........................................................................... 29
4.4 ROOF TOP PACKAGE SYSTEMS .................................................................. 30
4.5 VRV / VRF SYSTEMS..................................................................................... 30
4.6 POLYVALENT SYSTEM (REVERSE CYCLE CHILLED WATER) .................. 31
4.7 MECHANICAL VENTILATION ......................................................................... 32
5.0 SYSTEM APPLICATIONS ............................................................................... 35
5.1 TRADING AREAS ............................................................................................ 35
5.2 OFFICE & AMENITIES AREAS AIR CONDITIONING SYSTEMS .................. 35
6.0 EQUIPMENT .................................................................................................... 37
6.1 REFRIGERANTS ............................................................................................. 37
6.2 CORROSION PROTECTION .......................................................................... 37
6.3 AIR HANDLER UNITS ..................................................................................... 37
6.4 FAN-COIL UNITS ............................................................................................. 38
6.5 VRV OR REVERSE CYCLE SPLIT DX SYSTEMS ......................................... 38
6.6 COOLING COILS ............................................................................................. 39
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6.7 HEATING COILS .............................................................................................. 40
6.8 COMPRESSORS ............................................................................................. 41
6.9 AIR COOLED CONDENSERS ......................................................................... 41
6.10 DRY FLUID WATER COOLED CONDENSERS ............................................. 43
6.11 VIBRATION ISOLATION AND FIXING ............................................................ 46
6.12 LIQUID RECEIVERS ........................................................................................ 46
6.13 PUMPS ............................................................................................................. 47
6.14 FANS ................................................................................................................ 47
6.15 CHILLERS ........................................................................................................ 52
6.16 PIPING, VALVES AND FITTINGS ................................................................... 52
6.17 DAMPERS ........................................................................................................ 59
6.18 VARIABLE SPEED DRIVES ............................................................................ 60
6.19 ELECTRIC DUCT HEATERS .......................................................................... 61
6.20 BASES AND PLINTHS..................................................................................... 61
6.21 EQUIPMENT EXTERNAL NOISE MEASUREMENT ...................................... 61
6.22 DOWN DUCT NOISE ....................................................................................... 62
6.23 BOILERS .......................................................................................................... 62
6.24 FILTERS ........................................................................................................... 63
7.0 DUCTWORK .................................................................................................... 66
7.1 SCOPE ............................................................................................................. 66
7.2 DUCTWORK CONSTRUCTION AND INSTALLATION ................................... 66
7.3 DIFFUSERS, REGISTERS, GRILLES AND LOUVRES .................................. 71
8.0 ELECTRICAL ................................................................................................... 74
8.1 GENERAL ........................................................................................................ 74
8.2 REQUIREMENTS ............................................................................................ 74
8.3 INTERRUPTION TO SUPPLY ......................................................................... 74
8.4 DIAGRAMS ...................................................................................................... 74
8.5 INCOMING SUB-MAIN .................................................................................... 75
8.6 SWITCHBOARDS ............................................................................................ 75
8.7 FIELD WIRING & CABLING INSTALLATION .................................................. 80
8.8 VSD INSTALLATION – FIELD WIRING ........................................................... 81
8.9 CONDUITS, CABLE TRAY & LADDERS ......................................................... 81
8.10 CONDENSERS & OIL COOLERS ................................................................... 83
8.11 COMMISSIONING ........................................................................................... 83
8.12 DEFECTS LIABILITY & MAINTENANCE ........................................................ 83
8.13 RESIDUAL CURRENT DEVICES (RCD’S) ..................................................... 83
9.0 CONTROLS ..................................................................................................... 84
9.1 GENERAL ........................................................................................................ 84
9.2 TEMPERATURE / HUMIDITY CONTROL ....................................................... 84
9.3 ENERGY MANAGEMENT ............................................................................... 84
9.4 REFRIGERATION PLANT CONTROLS .......................................................... 86
9.5 COMPRESSORS ............................................................................................. 89
9.6 CONDENSER FAN CONTROL ....................................................................... 89
9.7 OFFICE, AND AMENITIES AREA AIR CONDITIONING UNITS..................... 90
9.8 MECHANICAL VENTILATION ......................................................................... 90
10.0 PAINTING AND LABELLING .......................................................................... 93
10.1 GENERAL ........................................................................................................ 93
10.2 PAINT COLOURS ............................................................................................ 93
10.3 LABELLING ...................................................................................................... 93
11.0 COMMISIONING, TESTING, MAINTENANCE AND SERVICE ..................... 94
11.1 COMMISSIONING ........................................................................................... 94
11.2 CONTROL SCHEDULE ................................................................................... 94
11.3 TEST WITNESSING ........................................................................................ 96
11.4 PUTTING INTO OPERATION .......................................................................... 96
11.5 MAINTENANCE AND SERVICE ...................................................................... 96
12.0 OPERATING AND MAINTENANCE ............................................................... 99
12.1 GENERAL ........................................................................................................ 99
12.2 INCLUSIONS ................................................................................................... 99
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12.3 PLANT MAINTENANCE LOG BOOK .............................................................. 99
12.4 METAL BOX ................................................................................................... 100
12.5 DISTRIBUTION .............................................................................................. 100
13.0 REFURBISHMENT WORKS ......................................................................... 101
14.0 APPENDIX A – STANDARD ELECTRICAL COMPONENTS ...................... 102
15.0 APPENDIX B: SCHEDULE OF TECHNICAL DATA ................................... 104
15.1 GENERAL ...................................................................................................... 104
15.2 AIR HANDLING UNIT CASING ..................................................................... 104
15.3 REFRIGERANT .............................................................................................. 104
15.4 COOLING COIL ............................................................................................. 104
15.5 SUPPLY AIR FAN .......................................................................................... 104
15.6 AIR FILTERS .................................................................................................. 105
15.7 COMPRESSORS ........................................................................................... 105
15.8 CONDENSERS .............................................................................................. 105
15.9 AIR COOLERS - DRY .................................................................................... 105
15.10 CHILLER SET ................................................................................................ 106
15.11 AUXILIARY FANS .......................................................................................... 106
16.0 APPENDIX C: TEST DATA SCHEDULE ..................................................... 107
16.1 AIR QUANTITIES ........................................................................................... 107
16.2 REFRIGERATION SUPERHEAT ................................................................... 107
16.3 PLANT CAPACITY ......................................................................................... 107
16.4 CONTROLS ................................................................................................... 108
16.5 PLANT OPERATING CONDITIONS .............................................................. 108
16.6 ELECTRICAL ................................................................................................. 108
16.7 NOISE LEVELS .............................................................................................. 109
17.0 APPENDIX D: APPROVED SUPPLIERS & EQUIPMENT .......................... 110
17.1 MECHANICAL CONTRACTORS ................................................................... 110
17.2 SWITCHBOARD MANUFACTURES ............................................................. 111
17.3 COMPRESSORS ........................................................................................... 111
17.4 CONDENSERS .............................................................................................. 111
17.5 HEAT EXCHANGERS.................................................................................... 111
17.6 PUMPS ........................................................................................................... 111
17.7 VRF UNITS .................................................................................................... 112
17.8 ROOF TOP PACKAGE UNITS ...................................................................... 112
17.9 FANS .............................................................................................................. 112
17.10 AIR CURTAINS .............................................................................................. 112
17.11 CHILLERS ...................................................................................................... 112
17.12 VARIABLE SPEED DRIVES .......................................................................... 113
17.13 BOILERS ........................................................................................................ 113
18.0 APPENDIX E - SCHEDULE OF DRAWINGS ............................................... 114
18.1 GENERAL ...................................................................................................... 114
19.0 APPENDIX F - CONTROLS APLICATION MANUAL (CPC) ....................... 131
19.1 EXECUTIVE SUMMARY ............................................................................... 131
19.2 CONTROL STRATEGY OVERVIEW ............................................................ 132
19.3 WIRING / POWERING ................................................................................... 136
19.4 CONTROL STRATEGY ................................................................................. 141
19.5 GENERIC NAMING CONVENTION .............................................................. 153
19.6 GENERIC PARTS .......................................................................................... 154
19.7 PRE COMMISSIONING SIGN OFF SHEET .................................................. 155
19.8 SENSOR LOCATIONS .................................................................................. 156
19.9 POWER MONITORING ................................................................................. 157
Page 4 of 157 4

1.0 SCOPE
1.1 INTENT
The intent of this Air Conditioning and Mechanical Ventilation Design Specification is to
define the air conditioning and mechanical ventilation services requirements for the
following Woolworths Limited retail businesses:
• Woolworths Supermarkets
• Woolworths Liquor
• Dan Murphy’s
• BWS
• Dick Smith
• Progressive Enterprises (NZ)
This Design Brief forms part of and shall be read in conjunction with current Design Briefs,
the Standard Drawings and the Control Plan applicable to Woolworths Retail Business
mentioned above.
This Design Brief shall be used as the basis for a complete design and for:-
• The preparation of a complete Air Conditioning and Mechanical Ventilation
Scope of works.
• The preparation of Design and Working drawings.
• Supply, delivery and installation of all plant, equipment and system to suit the
project.
• Commissioning and testing of all the installed plant, equipment and system.
• Preparation of Operating and Maintenance Manuals covering all of the installed
plant, equipment and system.
• Preparation of “as built” drawings covering all of the installed plant, equipment
and system.
• Maintenance of all of the installed plant, equipment and system during the
Defects Liability Period.
1.2 DRAWING REVIEW
The following information shall be submitted to Woolworths Senior Mechanical Engineer
for comments and/or review on completion of the design work and prior to the
commencement of equipment ordering and construction:
• Cooling/heating load calculations (Camel data required)
• Technical schedules indicating equipment selection
• Drawing indicating extent of air distribution system (including supply, exhaust
fresh and make up air volumes)
Any comments given by Woolworths shall not relieve the Designer and/or Contractor of
any real or intended contractual obligation for providing a complete, accurate and correct
installation; complying with all relevant rules, regulations, Building Code of Australia
(BCA) (including the latest applicable amendments) and Australian Standards,
appropriate and relevant to the project. Particular attention shall be given the Section J of
the BCA and its implications to the design of the Air Conditioning system.
The Designer and/or Contractor shall be responsible for verifying all dimensions on site
and to coordinate with all site conditions and services.
1.3 NOMINATED DESIGNERS
In the interest of uniformity the list of Design and Construct Contractors has been
included hereunder to form the basis for competitive tendering. No other Design and
Construct Contractors shall be used.
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A Consulting Engineer may be engaged for the preparation of a site specific
specifications and full design but only with the prior approval of Woolworths and only after
the proposed Consultant has been fully briefed by Woolworths.
It is mandatory that the proposed Consultant be conversant with Woolworths'
requirements and that the Consultant be fully briefed by Woolworths before the
commencement of documentation.
The Consulting Engineer or Design and Construct Contractor, hereinafter called
Designer, shall be responsible for the preparation of a complete design satisfying ALL
requirements of this Specification.
When a Consulting Engineer is engaged, the Consulting Engineer shall be responsible
for the preparation of tender drawings and specification, calling of tenders, analysing the
tender submissions and recommending the successful tenderer for acceptance. The
Consulting Engineer shall check and approve workshop drawings, as-installed drawings,
operating and maintenance manual.
The lessor/developer engaging the Consulting Engineer shall pay all Consulting
Engineer's fees and costs.
The Consulting Engineer shall ensure that only the Design and Construct Contractors
nominated herein are invited to submit a Tender Submission for the works. No other
mechanical contractor shall perform the mechanical services works.
The Consulting Engineer shall, during the course of the project, carry out not less than six
(6) site inspections and issue inspection and progress reports to Woolworths ; namely 3
evenly spaced during construction, 1 at handover, 1 at 6th month and 1 at one month
before end of defects liability period. The consulting Engineer must ensure that all defects
noted during the inspections are rectified by the mechanical contractor. The final report
shall be forwarded to Woolworths Senior mechanical Engineer.
Where Design and Construct Contractor is used, on completion of the works, a Certificate
shall be submitted to Woolworths stating that the installation complies with this Design
Specification.
1.4 CONTRACTOR/TENDERER
The Design and Construct Contractor or the successful Tenderer will be required to
become a Subcontractor to the Builder. In which case the appointed Tenderer/Contractor
shall abide by the subcontract conditions determined by the Builder.
1.5 DEFINITIONS
The following definitions shall apply in the interpretation of this Specification.
Woolworths Woolworths Limited including:
• Woolworths Supermarkets
• Woolworths Liquor
• Dan Murphys
• BWS
• Dick Smith
• Progressive Enterprises (NZ)
Designer The Consulting Engineer or Design and Construct Contractor responsible
for the preparation of a complete design based on this Design
Specification.
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Contractor The successful tenderer selected to perform the works described in the
Consulting Engineers specification or the selected Design and Construct
Contactor.
Builder The person or company responsible for carrying out the general building
works and who shall also determine subcontractor conditions for the
Contractor, if required.
Developer The person or company developing the site.
Site The actual site where the project is being erected.
Approved Shall mean approved in writing by Woolworths.
1.6 EXTENT OF HVAC SYSTEMS
This section summarises the HVAC requirements for each of the different areas within
the store. These are a minimum requirement and do not override or replace any
additional code, standard or regulatory requirements.
1.6.1 TRADING FLOOR
It is a requirement that the entire trading floor area be provided with conditioned air
to ensure adequate cooling in summer and heating in winter. The type of airconditioning
system used to serve this area is defined later in this specification.
Particular care needs to be taken in areas where refrigerated cases are present, to
ensure that there are no draughts blowing into the refrigerated cases.
The air conditioning system serving area where fresh food is displayed also
requires specific requirements to be incorporated into the design to ensure the
required humidity levels are maintained.
1.6.2 BACK-OF-HOUSE OFFICE AREAS
Air conditioning systems shall be supplied and installed to serve the following
areas:
• Systems office.
• Cashiers office.
• General office.
• Communications Room. (Cooling only required)
• Staff Training.
• Staff dining and lounge areas.
• Female Locker Room.
• Male Locker Room.
• Managers Office.
• Any other back-of-house similar area shown on the drawings.
For any other areas that are not specifically mentioned in the previous sections,
the contractor is to highlight this and bring it to the attention of the Woolworths
Senior Mechanical Engineer.
1.6.3 GENERAL GUIDANCE
If a central air conditioning plant is used, it is usual for the following areas to be
served from this unit.
For Supermarkets:
• Trading areas
• Deli preparation area
• Dairy or Service Deli area
• F&V preparation area - spot cooling if open area
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• Bakery and cake wrap (where applicable)
• Cold Aisle return air system to suit refrigeration cabinet layout
complete with fan
Generally:
• Security area (where applicable)
• Public toilet locker rooms (where applicable)
1.6.4 AREAS SPECIFIC TO SUPERMARKETS
1.6.4.1 MEAT PREP AREA
If this area is enclosed then this area shall be provided with a
fresh air supply (from main A/C or separate filtered O/A supply)
with temperature control (in the form of a wall mounted FCU) to
this area being provided by the Commercial Refrigeration
contractor.
1.6.4.2 PRODUCE PREP AREA
If this area is enclosed then area shall be air conditioned. Air
conditioning shall be provided from VRF condenser unit serving
offices. If this area is open to the stock room then no air
conditioning or mechanical ventilation is required.
1.6.4.3 KITCHEN EXHAUST SYSTEMS
Kitchen exhaust systems shall be supplied to all cooking and
kitchen equipment as required by AS 1668.2 including chicken
cookers, bakery ovens; donut cooker and dishwasher (refer to
Section 4.7.7).
1.6.4.4 FISH SERVERY & PREP AREA
Fish servery and preparation areas shall be provided with an
exhaust system (refer to Section 4.7.8)
1.6.5 LIQUOR AREA
A separate split ducted or packaged air conditioning unit shall be supplied and
installed to serve this area. The liquor cool room temperature control is by others.
1.6.6 TOILETS & CLEANERS ROOMS
An exhaust system shall be supplied and installed to serve this area (refer to
section 4.7.2).
1.6.7 MSB ROOM
An exhaust or air conditioning system shall be supplied and installed to serve this
area (refer to Section 4.7.4).
1.6.8 STOCK AREA
An exhaust system shall be supplied and installed to serve this area (refer to
Section 4.7.3).
1.6.9 SMOKE EXHAUST
Smoke Spill and/or Smoke Exhaust systems, Car Parking area and Loading Dock
exhaust or ventilation systems may be required by any statutory or regulating
authority. Refer to section 4.7.6 for details.
1.7 DESIGN
This design specification defines the quality and configuration of the required air
conditioning and mechanical ventilation equipment.
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Deviations from the quality and configuration specified and shown on the drawings will
not be accepted unless any such proposed deviations are submitted to Woolworths for
approval prior to acceptance of any tender. No deviations shall be carried out without
Woolworths’ approval.
1.8 WORK BY OTHERS
The following works associated with the air conditioning and mechanical ventilation
systems shall be carried out by others:
1.8.1 BY BUILDER
• Provision of combined services drawings for Woolworths approval.
• Provision of access to existing services necessary for the alteration
and/or extension of these services.
• Provision of openings and access hatches in the roof and plasterboard
ceilings.
• Provision of access doors in all plant room walls and service ducts.
• Provision of plantroom enclosures as shown on the drawings.
• Provision of acoustic sealing of all pipe, duct and cable penetrations
through acoustically significant walls, floors and ceilings.
• Provision of pipe droppers in walls and partitioning where required.
• Provision of temporary protection to all walls, panels, ceilings, floors,
doors and fittings during construction.
• Provision of temporary fire services during construction
• Provision of weatherproof and vermin proof outside air plant room
ventilation intake louvres complete with bird wire and burglar bars.
• Provision of independent roofing and structural steel arrangement over
the plant room to facilitate equipment entry in the plant room through the
roof.
• Provision of roof mounted structural supports for air conditioning units,
condensers and condensing units.
• Provision of access for truck and mobile crane to a point adjacent to the
building and plant location areas.
• Forming and/or cutting and making good of openings in roofs, ceilings,
slabs, beams, walls and partitions for the passage of ducts, pipes and
conduits and for the installation of fans, outlets and grilles.
• Installation only of door air transfer grilles in offices and amenities areas.
(All air transfer grilles to be provided by the Contractor) in locations
required in the design.
• Provision of roof up-stands and under-flashing of roof penetrations.
• Painting of exposed ductwork and equipment other than those in plant
rooms and outside the building.
• Provision of toilet facilities and temporary power for hand tools and
lighting, during the construction period.
• Provision of roof insulation complete with a continuous, sealed, vapour
barrier on the warm side of all air-conditioned spaces in accordance with
the Architects’ Specification.
• Making good of fire wall or floor penetrations including 'fire rated' packing
material having a fire rating not less than the fire rating of the walls or
floor, except for fire dampers.
• Provision and installation of refrigeration equipment plant room supply
and exhaust ventilation fans. Burglar bars are to be fitted to plant room
ventilation fans and safety mesh.
• 75 mm deep return air plenum shall be provided by refrigeration
contractor between each multi-tiered cabinet line-up in centre of store.
1.8.2 BY HYDRAULICS CONTRACTOR
• Provision of cold water supply and waste to chilled water and heating hot
water plant.
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• Provision of one (1) 25 mm valved cold water supply and condensate
tundish outside of AHU and two (2) 100 mm floor wastes in the air
conditioning plant room. The floor waste must be located outside of the
air handling plant. The floor of the plantroom shall be graded so that all
water drains to the floor wastes provided.
• Wall mounted condensate tundish adjacent to separate offices ceiling fan
coil units (if required)
• Wall mounted condensate tundish adjacent to separate MSB /
Communications room wall mounted fan coil units.
• Provision of one (1) 19 mm valved cold water supply adjacent the
condenser deck.
1.8.3 BY SPRINKLER & FIRE ALARM CONTRACTOR
• Provision of sprinkler fire alarm wiring to mechanical services
switchboard for system fan or natural gas shut-off.
• Provision of 'Fire Trip' control wiring (via sprinkler protection/smoke
detection/thermal detection systems, singularly (when one system is
installed) or in conjunction with each other where more than one system
is installed.) connected to the air conditioning switchboard by the Fire
Protection /Electrical contractors (as appropriate).
• Wiring to smoke exhaust fans ESP from Centre mains
1.8.4 BY ELECTRICAL CONTRACTOR
• Provision of incoming 415V, 3 phase, 50 Hz 4 wire sub-main cables of
adequate capacity to new mechanical switchboards.
• Provision and connection of labelled on-off switches for all (bakery,
donut, chicken cooker & dishwasher) exhaust and make up air fans.
Isolator IP56 3 phase to be provided for chicken exhaust fan.
• Interlock between the operations of the bakery and chicken ovens and
their respective and exhaust and make up fans.
• Electrical Switchboard with Fire Rated sub main.
• Electrical contractor to supply and install relay box at a/c board & wire to
engraved light switch in Fish area for fish prep exhaust system.
• Doughnut, dishwasher, bakery and chicken hood wall mounted control
switch to be provided and wired by the electrical contractor. Mechanical
contractor to provide cabling to be wired.
1.8.5 BY REFRIGERATION CONTRACTOR
• Provision and control of refrigeration plantroom ventilation fans.
• Provision of general office interface PC
• Provision of control system communication ’hub’.
1.9 DEFECTS LIABILITY PERIOD
Defects Liability Period for the air conditioning and mechanical ventilation installation
shall be sixty (60) weeks from the date of practical completion or the date on which the
plant is put into commercial operation, whichever is earlier. In any event, the Defects
Liability Period will expire fifty two (52) weeks from the date of store opening.
1.10 MAINTENANCE DURING DEFECTS LIABILITY PERIOD
During the Defects Liability Period the Contractor shall, in addition to attending to any
operational defects and breakdown fully maintain the plants and carry out twelve (12)
preventative maintenance services on the installed equipment fully complying with
Manufacturers’ recommendation and requirements and all relevant regulations. The
maintenance service work may be carried out by an agent appointed by the Contractor,
subject to prior approval by Woolworths.
Note: Maintenance shall include cleaning of all filters including exhaust hood filters.
Page 10 of 157 10

Warranty service to include 24 hours per day, 7 days per week emergency service.
Contractor to provide 24 hr contact details to Woolworths EMS Dept.
Provide maintenance performance sheets detailing all activities and frequency when
activities will be carried out. The proposed schedule shall be approved by Woolworths.
Completed monthly maintenance sheet must be signed by the Store Manager. The
original must be left with the Store manager, with a copy forwarded to the relevant
Woolworths State Asset Services Manager for record.
1.11 TECHNICAL DOCUMENTS
Electronic copies of the operating and maintenance instructions, built drawings (including
schematic electrical drawings) & Camel heat load data/calculations shall be forwarded to
Woolworths Senior Mechanical Engineer at the hand-over of the project.
In addition, copies of schematic electrical and control drawings encased in clear plastic
folders shall be mounted on the air conditioning plantroom wall.
1.12 GUARANTEES
The Contractor shall guarantee the performance of the installation and in addition provide
a separate guarantee stating that:
The refrigerant saturated suction temperature at full load conditions will not be less than
the design value(s) shown in the documentation submitted and as approved by
Woolworths.
In the event of the design values, so stated, not being achieved the Contractor shall
make all necessary alterations to obtain the conditions as approved. All costs, including
design and consultancy fee associated with any modifications required to achieve the
design values are to be borne by the developer or contractor(s).
The contractor shall have a QA system in place. Details to be submitted to Woolworths
for record. This system shall be consistent with the builder.
1.13 REGULATIONS
The Contractor shall, throughout the execution of the works, comply with the
requirements of all Statutory Regulations, Local Government By-Laws, Workplace Health
& Safety Acts and Regulations, as appropriate, The Building Code of Australia, National
Standard for Plant and all Authorities having jurisdiction at the site.
The Contractor shall exercise Duty of Care throughout the Works and shall carry out a
Risk Assessment and identify all hazards.
In addition the Designer shall ensure that all moving parts are adequately protected in
accordance with the Regulations and for the prevention of reasonably foreseeable harm.
The Contractor shall also comply with the requirements of all relevant Australian
Standards and Codes of Practice applicable to the works.
The Contractor shall obtain all certificates, pay all fees and obtain all approvals, including
Registration of Plant and Design Registration necessary to enable the work to proceed.
Certificates of ownership, when required shall be completed by the Contractor.
Copies of all approvals and certificates shall be forwarded to Woolworths, for record
purposes.
A Certificate of Practical Completion will be withheld pending receipt of all certificates and
approvals.
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1.14 OCCUPATIONAL HEALTH AND SAFETY
At all times, the contractor shall comply with Woolworths’ Occupational Health and Safety
(OHS) programs, state based OHS Regulations and Legislative Requirements. This is
described in the Woolworths Code of Conduct. All Contractors shall have completed the
Woolworths Pegasus safety requirements and be registered as a preferred contractors to
Woolworths.
At all times the contractor shall comply with any directions given by a Woolworths
representative, make available any relevant paperwork or documentation and assist in
reviews and investigations as requested.
The Contractor shall assume a Duty of Care to prevent foreseeable harm resulting from
or associated with the plant or any activity undertaken. The Contractor shall comply with
the requirements of the national standard for plant (NOHSC:1010), all state based
Occupational Health and Safety Acts, Regulations, Codes of Practice Safety Handbooks
for Construction as well as other legislative requirements and shall apply the principles of
Risk Management defined therein to all phases of the work executed under the Contract.
1.14.1 GENERAL WORKPLACE INDUCTIONS
It is expected all personnel (whether management, supervisory, tradespersons,
etc) entering any Woolworths project site (regardless of the type of site) have
attended an OHS General Health & Safety Induction Training Course and receive
certification of their attendance and successful completion required by local
authority (e.g. Green Card, Blue Card, Red Card, etc).
All personnel are required to produce certification of aforementioned course when
requested by Woolworths Representative (which also includes the Woolworths
nominated Principal Contractor) and may be asked to leave site should they be
unable to produce acceptable certification.
1.14.2 SITE SPECIFIC INDUCTIONS
All personnel shall undertake a site specific safety induction as directed by
principal contractor and landlord. The contractor shall allow for any costs
associated with personnel attending site inductions within their submission.
1.14.3 TOOLBOX TALKS
It is expected contractors undertake a program of task specific toolbox talks at
regular intervals throughout each project. Records of attendance at toolbox talks,
topics discussed and signatures of all attendees shall be kept on site and be made
available to Woolworths’ personnel upon request.
1.14.4 DOCUMENTATION & SAFETY PLANS
Before the date of the first site meeting, the contractor (and selected subcontractors)
shall submit as follows, Site Specific Safety Plan (SSSP) and
associated documentation.
Principal Contractor: 2 x hard copies + electronic copy
Woolworths Project Manager & Refrigeration Engineer: electronic copy
The SSSP shall outline the contractors’ own safety program and include all Safe
Work Method statements (SWMS), Job Safety Analysis (JSA), Safe Work
Procedure (SWP) and certificates of currency.
1.14.5 PERSONAL PROTECTIVE EQUIPMENT (PPE)
It is Woolworths policy for all personnel entering a Woolworths project site
(regardless of the type of site) to wear PPE as follows:
• Hard Hat
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• ‘High Vis’ shirt or vest
• Safety Goggles (Standard prescription eyewear are not deemed
safety glasses)
• Steel Capped Safety Footwear (covered shoes/boots not thongs
or sports shoes)
• Gloves.
Note: Project Managers, visitors, suppliers and guests are not required to wear
gloves if their attendance is for observation only and no manual tasks are being
undertaken.
1.14.6 LICENSES
Personnel shall not operate any plant or equipment unless training has been
completed and the operator holds (and is in possession of) the appropriate
certification.
Copies of current and valid licences are to be made available to the Site
Manager/Supervisor or Woolworths Project Manager and or nominated
representatives upon request, at any time including:
Work Permits
• Plumbing
• Gas fitting
• Electrical work (A Grade Licence)
• Structural Maintenance work (Builders Licence)
• Carpentry/minor maintenance (Carpenters Trade Qualification)
• Refrigeration and Air Conditioning
• Forklift
• Elevated Work Platform
• The following work permits are in use at Woolworths:
• Hot Work Permit
• Working at Heights Permit
• Electrical Work Permit
• Gas Work Permit
• Fire Impairment Permit
• Confined Space Entry Permit (Contractor to supply and complete),
and
• Restricted Access Permit
All permits must be authorised by the Principal Contractor or Main Contractors Site
Manager, or Site Supervisor prior to the commencement of any work. A Permit to
Work can be obtained from the Site Manager or Site Supervisor and are only valid
for a 12 hour period.
1.14.7 HOT WORKS PERMIT (HWP)
When undertaking any activity that may be classified as hot works, the Contractor
shall apply to the Woolworths Limited FM Global Hot Works Permit requirements.
Hot work is defined as grinding, welding, soldering, thermal cutting, oxygen cutting
or heating and other related heat producing or spark producing operations. A hot
work area is defined as anywhere within a 15-metre radius of the ignition
source(s). A Hot Work Permit form will be completed by the contractor and Site
Manager / Supervisor / Store Manager (when undertaking works outside of
Construction Period), detailing the hazard controls to be implemented according to
the work to be done and prior to any work commencing. The person conducting
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the hot work must be informed of the location of the fire fighting equipment and be
competent in its operation.
A four (4) hour fire watch must be maintained after the work is completed (1 hour
by Contractor; further 3 hours by Site Manager / Supervisor / Store Manager).
The following actions are required when conducting hot work on Woolworths’
premises:
Isolate the following:
• Within a 4 metre radius around the source - floors swept; removal
of pallets; wall & floor openings covered; shields in place; etc
• Within an 11-metre radius around the source - relocate any
flammable liquids & aerosols;
• Within a 15-metre radius around the source - relocate dangerous
goods and combustible materials.
• Coordinate with the Store/Duty Manager to relocate Woolworths
owned gas powered forklifts and gas cylinders away from the
source.
• Coordinate with the Store/Duty Manager that no recharging of
batteries is to take place whilst hot work is in progress.
• The ignition source(s) are to be screened using fire-resistant
materials.
• Approved barricades and signage indicating the hot work area are
to be erected.
• The work area is to be adequately ventilated. This may require
opening of doors/ roller doors, or conducting the works outside.
• The work area must have safe entry and exit areas, and these are
to be documented on the Permit to Work.
• Within a 10 metres radius of the source suitable fire extinguishers
should be available for emergency situations.
• Contractor's LPG and Acetylene gas cylinders are to be stored
upright and chained to a mobile trolley equipped with a personal
fire extinguisher for fall prevention and emergency situations.
• Where available, Automatic Fire Protection must be in-service.
• If Automatic Fire Protection Service has been isolated the Site
Manager/Supervisor must notify the Store/Duty Manager prior to
any Hot Works commencing on site.
Personal Protective Equipment will be provided by the Contractor performing the
work which will include some or all of the following as per the control measures
outlined in their SWMS:
• Non flammable clothing
• Mask
• Apron
• Safety boots
• Gloves
• Eye protection
• Hearing protection
• Protective overalls.
It is the Site Managers/ Supervisors responsibility to inform all relevant
Woolworths Site/Duty Managers and staff of any work impacting their areas of
responsibility.
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1.14.8 ELECTRICAL SAFETY
1.14.8.1 GENERAL
• All contractors shall inspect their electrical equipment including
portable leads before use.
• Inspection tags must be fitted on all leads and tools.
• When connecting or disconnecting power, make sure the power
switch is OFF before inserting or pulling out a power cord.
• Only authorised people are permitted to open electrical
•
enclosures.
Working on live electrical equipment must only be considered for
testing and commissioning, and then only when an adequate,
documented risk assessment has been undertaken by the
Contractor.
• A Permit to Work form shall be completed by the Site
Manager/Supervisor and the Contractor detailing the hazard
controls to be implemented according to the work to be done and
prior to commencement of work.
• The circuit may only be re-energised by the person who
performed the isolation.
• All ladders used on site are to be constructed of non-conductive
material.
• It is the contractors’ responsibility to ensure that all portable
equipment and leads used on site by the store, his employees and
Sub-Contractors are tested and tagged in accordance with AS
3760 and all the applicable workplace Occupational Health and
Safety authorities’ requirements.
• Prior to the Contractor commencing work on site he shall submit a
signed copy of his own company’s site and trade specific
workplace Occupational Health and Safety Plan to the Builder and
Project Manager for approval.
• The Contractor shall carry out the installation works strictly in
accordance with Woolworths Limited Requirements for Health and
Safety – Major Works.
• The contractor is not to work on a “Live” switchboard. If the
electrician must work under live conditions, safe procedures and
approval SHALL be obtained from site Principal and/or
•
Woolworths Engineer prior to the commencement of the works.
The contractor shall ensure that circuit breaker lock-out devices
are used when work on those specific circuits is carried. The
contractor shall provide circuit breaker lock out devices suitable
for circuit breakers specified by Woolworths Limited.
• When working on switchboards, warning notices shall be
positioned at the plantroom entry.
• Portable leads must be elevated off the ground and are not
permitted to run across walkways.
1.14.8.2 LOCKOUTS
The Refrigeration Electrical Contractor shall be deemed as
responsible for ensuring all electrical circuits are adequately
‘locked out’ when undertaking any work on electrical circuits
where upstream power may be present.
The only accepted method of electrical circuit lockout shall be by
key-lockable isolators. All lockouts shall be supplied by the
individual working on the circuit.
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1.14.9 WORKING AT HEIGHTS
1.14.9.1 LOCKOUTS
• Unless a risk assessment establishes an alternative safe work
practice, fall protection shall be provided for all persons exposed
to a fall of 2 metres (3 metres in New Zealand) or greater.
• The use of safety harnesses, lanyards and inertia reel equipment
is mandatory when working within 3 metres of any roof edge with
an edge to ground in excess of 2 metres (3 metres in New
Zealand).
• Prior to beginning any works involving work at heights, a Permit to
Work will be completed.
• Unless a risk assessment exists to the contrary, the following
works will require fall protection procedures and equipment:
• Work near unprotected open edges of floors and roofs
• Work near unprotected penetrations or openings in roofs, floors
and walls
• Work near unguarded shafts or excavations
• Work from unstable structures (temporary or permanent)
• Work on or near fragile or brittle surfaces (e.g. cement sheeting
roofs, fibreglass sheeting roofs and skylights)
• Areas below must be made safe by erecting barriers, men at work
signs etc.
• Materials and scrap must not be dropped to lower levels without
the area being made secure by erecting barricades, men at work
signs and a person posted on the lower level supervising the area.
1.14.9.2 LADDERS
Ladders are not a fall protection measure; they are a means of
providing access/egress to a work area. Ladders complying with
AS/NZ 1892 must only be used.
Ladders are only to be used where it can be shown that other risk
control measures are not practicable to remove or reduce the risk
of falling.
Where ladders are used in areas near pedestrians, forklifts, pallet
jacks etc permits should specify what system will be used to
prevent the ladder being knocked over.
For example:
• Safety Cones
• Approved barricade system
• Person to hold ladder and ensure access to area is restricted.
Contractors will not use Ladders:
• In access areas or within the arc of swinging doors;
• When the work involves restricted vision or hot work i.e. welding;
• On scaffolding to gain extra height;
• Where it is possible for the ladder or the user to come into contact
with electrical power lines;
• In very windy or wet conditions;
• Over other people
• Performing a task that requires over-reaching (belt buckle within the
stiles of the ladder);
• Allowing anyone else to be on the ladder at the same time;
• Placed near the edge of an open floor or penetration where, if the
ladder toppled, a person could fall over the edge.
Page 16 of 157 16

Contractors will use Ladders:
• Placed at a slope of 4 (vertical) to 1 (horizontal) & be secured at the
top;
• Supported on a firm, level, non-slip surface in the fully opened
position;
• Fitted with safety feet and tied off while in use and inspection tags
fitted;
• Perform all work facing the ladder;
• Placing their feet no higher than 900mm from the top of the ladder
(2 rungs from the top rule);
• Always having two hands free to ascend and descend the ladder,
transporting all material and tools which cannot be safely secured
to the worker's belt independently;
• Only using tools which are easily operated with one hand;
• Electrically approved for electrical work;
• Always maintaining 3 points of contact (2 hands & 1 leg OR 1 hand
& 2 legs).
1.14.9.3 FALL PROTECTION
Some engineering methods of fall protection include:
• Guard railing
• Working platforms
• Scaffold
• Elevated work platforms (cherry pickers, scissor lifts)
• Travel restriction devices (harnesses and lanyards)
• Fall arrest systems
• Catch platforms
• Safety nets
The Contractor should be providing one or more of these fall
protection methods if the Contractor's feet are more than 2 metres
(3 metres in New Zealand) from the ground. This is to be detailed
on the Permit to Work.
1.14.9.4 BARRICADES
When undertaking work at heights (i.e. on elevated work
platforms), the Contractor shall erect barricades in accordance
with Woolworths requirements. The use of safety tape shall not
be considered as an acceptable barricade.
1.15 DESIGNER RESPONSIBILITIES
This Design brief defines Woolworths requirements for air conditioning and mechanical
ventilation systems.
The Designer shall interpret these requirements and translate them into a complete
design.
The Designer will identify individual equipment selections making up the plant, their
design conditions and duty.
The Designer shall provide layout drawings showing the size and location of all air
distribution systems, plant and equipment, and co-ordinate with all other services on the
project. The Designer shall include a complete air conditioning refrigeration pipework
schematic, including all pipe sizes, valves and fittings.
The full electrical diagram showing all power and control wiring shall be prepared. The
Designer shall determine the Electrical Maximum Demand of each submain and identify
Page 17 of 157 17

equired submain capacities and minimum circuit breaker and HRC fuse ratings and
provide this information for inclusion in the Building Electrical Design.
The Designer shall provide mass, equipment locations and duct suspension loads for
inclusion in the structural design.
The Designer shall identify the location of any cold water supply and drain points required
for inclusion in the plumbing design.
The Designer shall coordinate the supply air ductwork, supply air grilles and return air
grilles to suit the trading area decor and lighting layout.
The designer shall provide details about any door grilles that need to be installed to the
builder so that door penetrations can be provided.
A/C refrigeration piping schematic diagram must be prepared and submitted (See also
Woolworths standard drawing SD 27).
The Designer shall liaise with the Commercial Refrigeration Contractor for a co-ordinated
common plant room and condenser deck layouts.
The Designer shall complete APPENDIX B - SCHEDULE OF TECHNICAL DATA at the
rear of this design specification and submit the completed form to Woolworths on
completion of design work and prior to accepting any tender
1.16 INSURANCE
The Designer must provide a copy of the current Professional Indemnity Insurance cover
to the value of $5,000,000 before commencing work.
The Designer must ensure that the following insurance policies are carried by the
Contractor and to provide certification of such policies on demand to Woolworths:
• Public Liability - not less than $20,000,000 cover.
• Contractors All Risks - total contract value covering materials in store, in transit
and on site.
• Workers Compensation - unlimited common law cover.
1.17 CONSTRUCTION PROGRAM
The Contractor shall ensure that the Construction Program is so arranged to ensure that
the air conditioning and mechanical ventilation systems are completed with a permanent
electrical supply connected to the switchboard(s) at handover.
1.18 CONSTRUCTION NOISE
The contractor shall take all due care to minimise the noise of installation. Restrictions
imposed by the builder with respect to noise levels and the time of use of particular
equipment must be observed. Note that this requirement will be particularly relevant
during after hours and weekends.
1.19 SITE ACCESS
Parking will be restricted to those areas nominated by the builder. The restrictions
regarding parking must be observed.
1.20 SITE INSPECTION
Designers are advised that an inspection of the site prior to the completion of the tender /
design is strongly recommended. No variation in the contract sum will be accepted for
additional work which could have been foreseen during a site inspection.
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1.21 PROVISION OF SAMPLES FOR APPROVAL
Samples of proposed ceiling outlets, door grilles and all other visible fittings shall be
provided for approval and acceptance to the senior Engineer or appointed representative,
prior to the installation of any fittings.
1.22 APPROVAL
The specification and drawings prepared by the Consulting Engineer (or Workshop
drawings prepared by the Design and Construct (D&C) contractor) shall be submitted to
Woolworths or appointed representative for approval at least two weeks prior to calling of
tenders (or ordering of equipment or commencement of manufacturing, if D&C contractor
is used). Contracts shall not be let prior to approval of the documentation.
Any comment or directive by Woolworths or their representative shall not relieve the
designer of the systems of any real or contractual obligation for providing a complete and
fully operational system.
1.23 QUALITY ASSURANCE
The installation of the mechanical services shall be performed at all times using skilled
and experienced tradesman. Commissioning and testing shall only be carried out by
appropriately trained and qualified persons.
1.24 NON CONFORMANCE TO THE SPECIFICATION
All works and equipment that are deemed by Woolworths not to comply with this
specification shall be corrected to Woolworths satisfaction by the Mechanical Contractor
at no cost to Woolworths. Corrective works shall not interfere with the proposed opening
date of the store or interrupt store trading (i.e. all works to be complete outside of the
stores trading hours). Woolworths reserves the right to peruse the mechanical contractor
for damages due to the non conformance that have a direct or indirect negative impact on
energy consumption, store sales or any extra cost borne by the store to conduct
business.
Page 19 of 157 19

2.0 DESIGN CONDITIONS
2.1 GENERAL
The design criteria shown below must be used as the basis for preparing the air
conditioning and mechanical ventilation systems design.
The occupancy level for the trading area shall be calculated using the gross store area
and the occupancy density shown in clause hereunder.
The use of exhaust ventilation in stock rooms is preferred. However, some regulatory
authorities may require an alternative form of ventilation. In any case the Designer shall
check with the local authority, at the earliest possible date, and obtain all approvals
necessary.
Direct relative humidity control (dehumidification only) shall be provided (55% RH Max).
Comfort heating in winter will not be required in stores in locations where the winter
outside design ambient condition is greater than 15° C, as defined herein. However, with
the need for RH control, provision for sub-cool and reheat to achieve the specified store
design conditions, heating using both heat re-claim via the Refrigeration system as well
as heating coils must be provided. Heating capacities designed to suit store design
heating loads. The Designer must advise the Refrigeration contractor the air flow, coil
size, handing and heating capacities so that the heat re-claim coil(s) can be supplied by
Refrigeration contractor, and installation of the same by the mechanical sub-contractor.
(Allow minimum 70kW of available heat reclaim).
Note: Humidity control only required for Supermarkets.
2.2 DESIGN CONDITIONS
2.2.1 INSIDE DESIGN CONDITIONS
2.2.1.1 FOOD & LIQUOR RETAIL STORES (i.e. Supermarkets, Liquor,
BWS & Dan Murphy’s)
Conditions are to be based on Critical Process (0800-1800) as published in AIRAH
DA09 application manual. For locations not included in DA09 approval of design
temperatures shall be sought from Woolworths Senior Mechanical Engineer.
Trading floor area
Summer 24°C DB (+/- 1 o C) 50% RH (Max)
Winter 21°C DB (+/- 1 o C) 55% RH (Max)
Note: Air moisture content shall not exceed 10g/Kg
The trading floor area requires particular attention to be paid to the humidity
control. This area does not only have simple comfort air-conditioning but requires
active humidity control to be incorporated into the air conditioning system design.
Back of house offices
Summer 23°C DB (+/- 1 o C) 60% RH
Winter 21°C DB (+/- 1 o C) 60% RH
These areas are classified as requiring comfort air-conditioning and no specific
humidity control needs to be included.
Loading dock
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No specific temperature control is required
Meat preparation area
If this area shall have temperature control provided by the commercial refrigeration
contractor with fresh air to be supplied by Mechanical Contractor.
Coolrooms, cold rooms and freezer rooms
These areas have temperature control provided by the commercial refrigeration
contractor.
2.2.1.2 GENERAL MERCHANDISE, HARDWARE & ELECTRONICS
RETAIL STORES (i.e. Dick Smiths)
Conditions are to be based on Comfort Process (0800-1800) as published in
AIRAH DA09 application manual. For locations not included in DA09 approval of
design temperatures shall be sought from Woolworths Senior Mechanical
Engineer.
Trading floor area
Summer 24°C DB (+/- 1 o C) 60% RH (Max)
Winter 21°C DB (+/- 1 o C)
Back of house offices
Summer 24°C DB (+/- 1 o C) 60% RH
Winter 21°C DB (+/- 1 o C) 60% RH
Loading dock
No specific temperature control is required
2.2.2 LIGHTING
All areas - 22 W/m²
2.2.3 ELECTRICAL EQUIPMENT
Refer to control plan indicating location and quantity of equipment.
Computer heat load = n x 700w
Printer head load = n x 300w
TV heat load = n x 600w
Note: n = to quantity of units (refer to Control Plan)
Where other miscellaneous equipment is shown on the control plan, heat load
shall be acquired from the nominated electrical engineer.
2.2.4 OCCUPANCY DENSITY
Trading area (Gross area) 7.0m²/person
Offices 7.5m²/person
Lunch Room 1.5m²/person
2.2.5 OUTSIDE AIR RATE
Trading Areas
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Fresh air rate shall be the greater of:
- Minimum fresh air as determined by maximum allowable CO2 level for
a habitable space. For design purposes Woolworths has determined
that this level is 600 ppm.
- Fresh air rate shall be greater than the sum of the exhaust systems
and lost air plus half an air change per hour, that is ½ the air
conditioned volume changed per hour.
Office and Amenities areas
- Outside air as determined by AS 1668.2
2.2.6 INFILTRATION ALLOWANCE
An infiltration load shall not be allowed. Infiltration shall be offset by the half air
change per hour.
2.2.7 ROOF/CEILING HEAT TRANSFER COEFFICIENT
Refer to Architectural Drawings.
2.2.8 REFRIGERATION CABINETS
The indicative cooling allowance for a typical store is as indicated below. Actual
cooling load allowance should be confirmed with refrigeration Engineer for each
specific store as quantity of refrigeration varies between stores.
2.3 NOISE LEVELS
Model Store Sensible
Latent
kW
kW
2000 12 10
2500 15 13
3200 19 16
3800 23 18
4200 25 20
4800 28 22
2.3.1 GENERAL
Noise levels within the air conditioned spaces shall not exceed NR45 (50dB(A)).
Noise levels in ventilated occupied spaces (i.e. Stock Area) shall not exceed NR50
(55dB(A)), taking into consideration noise levels from exhaust systems.
All measurements shall be taken 1.5 metres above the floor level and 1.5 metres
away from hoods or other equipment.
In any event the noise level measured adjacent to each of the cooking hoods must
not be greater than 5dB (A) above background noise level. The background level
shall be established by measurement at the centre of Trading Area with only airconditioning
plant operating and all hood exhausts switched off.
It is required that the air conditioning and all mechanical ventilation systems be
designed and installed to ensure that noise transmitted to the outside of the
building at boundaries be kept within the limits specified by the appropriate SAA
code and/or as directed by the Local Authorities.
Page 22 of 157 22

Designer to pay particular attention to duct borne noise and duct break out
noise in areas close to equipment.
2.3.2 EQUIPMENT EXTERNAL NOISE MEASUREMENT
Sound Pressure levels shall be the maximum of any measurement made one
meter away from any face of the unit under semi free filed conditions and worst
case operating conditions.
2.3.3 DOWN DUCT NOISE
All equipment shall produce no objectionable pure tones within the occupied areas
and no atypical noise levels in the frequency bands outside those specified.
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3.0 GENERAL DESIGN REQUIREMENTS
3.1 AIR DISTRIBUTION SYSTEM
The air distribution system must be designed so that the total system losses do not
exceed 550 Pa (dirty). The Store must be positively pressurised relative to the ambient.
(I.e. Total outside air supply in the store must be greater that total exhaust air by at least
5%).
3.2 REFRIGERATION CABINETS
No air is to be supplied or aimed directly onto the refrigeration cabinets. Cold aisle return
air shall be provided via void underneath and behind refrigerated cabinets (only open
multi deck type) that form aisle configuration.
3.3 ACTIVE HUMIDITY CONTROL (SUPERMARKETS ONLY)
The system shall incorporate active humidity control to maintain the maximum space
relative humidity.
The system shall not actively reheat a cooled air path by more than 7°K as per
requirements outlined in the BCA Section J.
Mechanical dehumidification shall be controlled by the humidistat sensor energising steps
of cooling to bring the air below dew point then reheated via heat reclaim coils first then
heating coils (gas fired hot water coils or heat pump) to increase the dry bulb
temperature.
The use of desiccant wheel technology may be used as an alternate method of
dehumidification with the written approval of Woolworths Senior Mechanical Engineer.
3.4 HEATING
3.4.1 GENERAL
Heating shall be provided for both comfort and RH control.
The heating capacity shall be designed for an early morning warm-up period of 2
hours without the assistance of lighting and equipment.
Comfort heating in winter is not required in stores in locations where the winter
outside design ambient condition is greater than 15° C, as defined in the design
conditions.
For Supermarkets the heat reclaim coil shall not provide greater than 50% of the
total building comfort heating requirement and the heating capacity must be
designed assuming no heat reclaim is available. Heating other than heat reclaim
from the refrigeration system shall not be engaged outside of store trading hours
with the exception of morning warming.
3.4.2 HEAT RECLAIM
The Designer must advise the Refrigeration contractor of the air flow, dimensions
and heating capacities so that the heat re-claim coil(s) can be supplied by the
Refrigeration contractor and installation of the same by the mechanical contractor.
(Allow minimum available heat reclaim of 70kW for stores greater than 3500 m 2
and 45kW for stores less than 3500m 2 .
A static pressure allowance of 70 Pa shall be made for the refrigeration heat
reclaim coils.
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3.4.3 STRATIFICATION
The air distribution system shall be designed so that stratification of air during
heating mode is minimised. Methods to reduce stratification include but are not
limited to:
• Use of swirl type diffusers.
• Low level return air if space/design permits
• Use of jet diffusers that are engaged during heating mode
3.5 OUTSIDE AIR CONTROL
The outside air supplied to the store shall comply with requirements outlined in AS1668.2
(refer to version in current BCA). A performance approach (ref AS1668.2 1991 Section
G) to outside air control is required where the maximum level of CO2 is limited to 600
ppm.
The system shall be designed to monitor the operation of the exhaust hoods, sum the
exhaust air quantities (less make up air) and set the minimum outside air (low level limit)
at the total exhaust rate plus at least 5% ensuring positive pressure within the store.
Note: Also refer to section 9.3.2 regarding air distribution strategy
3.6 ECONOMY CYCLE
An economy cycle shall be provided on all air conditioning systems as outlined in the
BCA Section J. The exclusion of the economy cycle from the design may be approved by
the Woolworths Mechanical Engineer where it can be demonstrated that the economy
cycle will provide “no psychometric benefit” (thus no savings in energy), based on
standard 24 hour weather data for the location.
Note: Also refer to section 9.3.2 regarding air distribution strategy.
3.7 COLD AISLE RETURN AIR (SUPERMARKETS ONLY)
Cold air from the ‘Cold Aisle’ shall be returned to the return air system via linear vent at
base of refrigerated case (supplied by case manufacturer); void underneath and behind
refrigerated case and connecting duct work.
Return air rate shall be 50l/s per linear metre of refrigerated case and shall apply to all
open deck cases that form an aisle (back to back configuration).
Total cold aisle return air shall not be greater than 50% of the total system supply air
volume.
All exposed duct work shall be of the same dimension and shall be equi-spaced along the
length of the case run. The cold isle return duct shall be boxed in and painted (refer to
finishes schedule) by others.
All plenums and duct work above shall be internally insulated (minimum 50 mm) so to
prevent any condensation forming internally or externally to duct.
In BCA climate Zones 1 & 2 additional 50 mm of external insulation shall be applied to all
duct work above within the ceiling space.
Design Note:
Air within cold aisle return air system shall always be above dew point. RA from the
general store space shall be mixed with the cold aisle return air such that the temperature
of the mixed air is always above dew point.
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4.0 SYSTEM FORMS
4.1 GENERAL
Depending on the store location, design and layout, a number of different forms of airconditioning
system may be allowed.
� Central Pant – (Plant Room Required)
� Custom Package Units - (Roof Top Mounted)
� Roof Top Package Units (Reverse Cycle)
� VRF (VRV) Systems
� Multi Head Polyvalent System (Reverse Cycle Chilled Water)
Note: The standard air conditioning layout drawing shows the typical routing of the supply
and return air ductwork. This typical layout may vary due to architectural and/or structural
limitations on each installation.
The Designer shall check the working drawings in each case and allow for any variation.
The ductwork configuration shown for the trading area is the typical ductwork arrangement
and shall not be altered significantly without the express approval of Woolworths.
The actual position of each duct run, however, shall be coordinated with the trading area
decor, refrigerated cases (from return air system), gondola layout, lighting, signage, fire,
refrigeration and electrical services, in every case.
4.2 CENTRAL PLANT (PLANTROOM)
This air conditioning plant shall be a single zone draw through conditioner located in the
plant room, either direct expansion or chilled water cooling coils, heat reclaim coils, hot
water coils, dry media deep bed filters, ‘scroll’ or ‘plug’ type supply air fan and a low
pressure ductwork system.
Fresh air shall be ducted from outside the building and be free from contamination
including condenser discharge air; minimum 6 metres separation from any exhaust or
objectionable discharge as per AS 1668.2
Central main plant generally comprises the following:
1. Walk in air handler unit housing pre assembled and located on condenser deck (or
assembled on site, within the plantroom), and containing the following
components.
a. Insulated Panels
b. Cooling coils.
c. Heating coils. A single hot water heating coil shall be provided. (or Heat
Pump condenser coil in air handler)
d. Heat reclaim coil(s). Heat reclaim coil(s) shall be provided by the
refrigeration contractor but shall be installed within the AHU by the
mechanical contractor. All refrigerant piping from this coil to the
refrigeration system shall be by the refrigeration contractor. This coil shall
always be installed upstream of the main heating coils.
e. Filters.
f. Supply air fan.
g. Motorised outside air damper for economy cycle and CO2 Outside air
volume control.
h. Lighting
Page 26 of 157 26

2. Mechanical services switchboard including controller.
Depending on the cooling and heating options, the following may also be included:
3. Air cooled condensers located on the condenser deck
4. Chilled water unit located on the condenser deck
5. Reverse cycle chilled water unit located on the condenser deck
6. Hot water boiler located in the plant room or on condenser deck.
7. Compressors either located within the plantroom or as an integral part of
condenser set.
4.2.1 DIRECT EXPANSION
The following two types of systems shall apply:
− Cooling only DX with hot water heating and refrigeration system
reheat
Compressors: shall be of either semi hermetic (screw or reciprocating) or
hermetic scroll design. Generally screw compressors should only be used
where the compressor cooling capacity is greater than 250kW. Below
250kW, reciprocating or scroll compressors should be used.
Each installation shall have a minimum of two compressors which may be
combined onto one refrigeration circuit, preference. The compressor sets
must be mounted in the plant room outside of the AHU.
See also section 6.8
Condensers: Either one or two air cooled condensers shall be sized for
compressor duty. These shall be located on the condenser deck.
See also section 6.9
Heating: The first stages of heating shall be made available from a heat
reclaim coil providing waste heat from the stores refrigeration plant, Coil
shall be located upstream from additional heating coils.
The final stage of heating shall be provided by gas fired boilers where
town mains gas is available. Where no gas is available a heat pump or hot
water from reverse cycle chiller. These may be located in either the plant
room or on the condenser deck depending on site conditions.
− Reverse Cycle
Compressors: Each installation shall have a minimum of four scroll (410a)
compressors with each compressor having a separate refrigerant circuit.
The compressors shall be sized so that at two compressors are dedicated
for cooling, one compressor reverse cycle and the remaining compressor
dedicated for heating.
Evaporators: The ‘cooling only’ and reverse cycle evaporators shall be
installed in parallel configuration forming a bank of coils. The ‘heating only’
and refrigeration heat reclaim shall form a coil bank being in a parallel
configuration. The ‘cooling only’ and reverse cycle coil bank shall be
upstream from the ‘heating only’/ heat reclaim coil bank.
Condensers: A minimum of two air cooled condensers shall be provided.
These shall be either ‘V Block’ or horizontal configuration located on the
Page 27 of 157 27

condenser deck. Compressors shall be incorporated into the condensing
unit.
Heating: Heating shall be achieved by reverse cycle operation of the
system. In addition a heat reclaim coils shall be provided from the
dedicated cooling system. This heat reclaim shall be used when heating is
required for dehumidification.
Note: The system shall be capable of both simultaneous heating and
cooling to ensure adequate humidity control is achieved.
4.2.2 CHILLED WATER COOLING
If the cooling is provided by a chilled water source then the following applies.
a) Chilled water supplied by others:
General: A source of chilled water will be made available ‘by others’ at the
plantroom. Flow and return chilled water lines shall be terminated at the
plantroom ‘by other’ with shut off valve, including flow and return
thermometer wells and flow measurement device. The mechanical
contractor shall provide all necessary piping to connect the AHU coils to
this piping.
Cooling: Minimum of two chilled water coils shall be installed in parallel
complete with modulating by-pass control by-pass valves.
Heating: The first stage of heating shall be made available from a heat
reclaim coil from the stores refrigeration plant. This coil shall be located
upstream from additional heating coils.
The second stage of heating shall be provided by gas fired boilers where
town mains gas is available or a heat pump where no gas is available.
These may be located in either the plant room or on the condenser deck
depending on site conditions.
b) Chilled & Hot water supplied by mechanical contractor
i. Chiller and Gas Boiler: If town mains gas is available then the
chilled water shall be provided by an air cooled chiller located on
either the condenser deck or in a plantroom and heating shall be
provided by a gas fired boiler.
Cooling: Minimum of two chilled water coils shall be installed in
parallel complete with modulating control valves.
Heating: The first stage of heating shall be made available from a
heat reclaim coil from the stores refrigeration plant. This coil shall
be located upstream from additional heating coils.
The second stage of heating shall be provided by gas fired boilers
where town mains gas is available or a heat pump where no gas
is available. These may be located in either the plant room or on
the condenser deck depending on site conditions.
Condensers: Condensers shall be air cooled and located on the
condenser deck.
Note: If there is an existing condenser water loop available within
the centre, then the option of using a water cooled chiller shall be
allowed.
Page 28 of 157 28

4.3 CUSTOM PACKAGE UNITS
ii. Reverse Cycle Chiller: If no town mains gas is available, then
both chilled water and hot water shall be supplied by an air cooled
reverse cycle chiller located either on the condenser deck or
within a plantroom. This shall be a four pipe system capable of
simultaneous heating and cooling.
Cooling: Minimum of two chilled water coils shall be installed in
parallel complete with VSD modulated pumps.
Heating: The first stage of heating shall be made available from a
heat reclaim coil from the stores refrigeration plant this coil shall
be located upstream from additional heating coils.
The second stage of heating shall be provided by heated water
from the reverse cycle chiller to the heating coil.
Chillers: Compressors, controls, and pumps shall be incorporated
into the one packaged unit located on the condenser deck.
Note: If there is an existing condenser water loop available within
the centre, then the option of using a water cooled chiller shall be
allowed.
4.3.1 GENERAL
This unit shall be a complete factory assembled unit, including air handling unit,
MSSB, compressors and condensers. The larger cooling capacity (greater than 200
kW) units shall be a walk in modular unit whilst the smaller cooling capacity units
(less than 200kW) may be modular with access doors into the various modules of
the unit.
The system shall comprise a single zone draw through air handling unit with either
direct expansion or chilled water cooling coils, heat reclaim coils, hot water coils, dry
media deep bed filters and backward curved centrifugal or ‘plug’ type supply air fan.
Fresh air louvres may be part of the AHU.
Specifically the unit shall include:
a. Weather proof insulated panel housing with suitable access doors.
b. Cooling coils.
c. Heating coils.
d. Heat reclaim coil. A single heat reclaim coil shall be provided by the
refrigeration contractor but shall be installed within the AHU by the
mechanical contractor. All refrigerant piping from this coil to the
refrigeration system shall be by the refrigeration contractor.
e. Filters.
f. Supply air fan.
g. Mechanical Services Switch Board (MSSB).
h. Motorised outside air damper for economy cycle and CO2 Outside air
volume control.
4.3.2 DIRECT EXPANSION COOLING
Refer to section 4.2.1
4.3.3 CHILLED WATER COOLING
Refer to section 4.2.2
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4.4 ROOF TOP PACKAGE SYSTEMS
General: This system shall comprise of a roof top package (RTP) unit with dedicated
supply and return duct work incorporating fresh air supply to a filter plenum box which is
separate to the RTP. Unit shall be mounted on a platform built to the same specification
as the condenser platform.
Energy Rating: RTP shall be tested for energy efficiency with the declaration of the units
EER. If required by legislation a MEPS rating shall also be provided.
Approve Manufactures: shall be as nominated in section 17.8 or equivalent approved by
Woolworths Senior Mechanical Engineer.
Controls: Unit controls shall be interfaced with the main CPC controller which shall be
located in the MSSB. Controls shall include:
− Compressor Start/Stop/Fault
− Reversing valve control
− O/A damper control
− S/A fan control/fault
− Condenser fan control
MSSB: Submains for RTP shall be feed from MSSB located in the main plantroom
Compressors: shall be scroll (410a) type of a Woolworths approved manufacture. A
minimum of 3 compressors shall be used per unit with the lead compressor being
complete with variable speed control.
Condenser Fans: shall be EC type of either EBM Papst or Ziehl Abegg make (or
equivalent approved by Woolworths Senior Mechanical Engineer).
Supply Air Fan: shall be a Plug type fan of Ziehl Abegg make (or equivalent approved by
Woolworths Senior Mechanical Engineer).
Heating: The first stage of heating shall be made available from a heat reclaim coil from
the stores refrigeration plant this coil shall be located upstream from the heating and
cooling coils in the filter box plenum (down-stream of the filter bank). The second stage of
heating shall be achieved by reverse cycle. Where the RTP is an excessive distance from
the refrigeration plantroom an alternate design for incorporating heat reclaim may be
submitted to the Woolworths Senior Mechanical Engineer for approval.
Dehumidification: If the RTP system is unable to achieve the required humidity level
(given the sensible load) in the space then additional mechanical or desiccant systems
shall be used to condition the fresh and return air as required.
4.5 VRV / VRF SYSTEMS
MEPS and EER shall be provided for each system. This information shall be documented
with the required Mechanical documentation.
4.5.1 BACK OF HOUSE & OFFICE AREAS
Back of house office areas shall be air-conditioned using a variable refrigerant
volume system. This shall comprise a number of indoor units connected to one or
more reverse cycle external condenser units. The system shall be capable of
simultaneously providing heating and cooling to different indoor units.
Air Handling:
− The indoor units shall be either cassettes or in ceiling ducted units. Units shall be
supplied with filtered fresh air.
Page 30 of 157 30

− For in ceiling units, the location of the unit shall be such that it is easy to access
the unit for servicing. In set ceilings, the mechanical contractor shall ensure that a
suitable access panel is provided to service the unit.
− Where more than one cassette type unit serves the same area, multiple units shall
be controlled from one controller only.
4.5.2 TRADING AREAS
Trading area shall be air-conditioned using a variable refrigerant volume system.
This may comprise either a single or multiple of indoor units connected to one
reverse cycle external condenser unit. The system shall be capable of
simultaneously providing heating and cooling to different indoor units.
Air Handling: The indoor units shall be in ceiling ducted units. Units shall be
supplied with filtered fresh air. The location of the unit shall be such that it is easy
to access the unit for servicing. In set ceilings, the mechanical contractor shall
ensure that a suitable access panel is provided to service the unit.
Dehumidification: If dehumidification capability is required then one or more
dedicated fan coil units shall be configured to dehumidify. This shall be achieved
by using two FCU’s connected to the same supply air duct simultaneously heating
and cooling supply air.
Use of Heat-Reclaim from Refrigeration Plant: Additional hot water coils (from
refrigeration heat reclaim) may be installed to provide heating and dehumidification
capacities. Hot water shall be sourced from a heat reclaim plate heat exchanger
(supplied by the refrigeration contractor) sourcing waste heat from the stores
refrigeration system. Where heat reclaim is used it shall always be designated as
the first stage of heating with the polyvalent chiller providing the second stage of
heating.
Design Approval: Final design of the system to be submitted to the Woolworths
Senior Mechanical Engineer for approval.
4.6 POLYVALENT SYSTEM (REVERSE CYCLE CHILLED WATER)
Chilled/heated water shall be supplied by an approved reverse cycle chiller capable of
simultaneously providing chilled and hot water to the air handling unit (AHU) or fan coil
units (FCU). This unit shall be a complete factory assembled unit, including controls,
pumps, compressors and condensers.
Air Handling: The air handling system may comprise of a single AHU or multiple FCU’s.
Dehumidification: System shall be capable of dehumidification requirement if specified as
a system requirement (refer section 2.2.1). Dehumidification shall be achieved by first
cooling then reheating supply air facilitated by a FCU designed with both heating and
cooling coils. Simultaneous heating and cooling is acceptable provided that the warm and
cool air is adequately mixed before being distributed into conditioned space. In addition
outside air may be dehumidified by an approved mechanical dehumidifying unit.
Use of Heat-Reclaim from Refrigeration Plant: Additional hot water coils (from
refrigeration heat reclaim) may be installed to provide heating and dehumidification
capacities. Hot water shall be sourced from a heat reclaim plate heat exchanger
(supplied by the refrigeration contractor) sourcing waste heat from the stores refrigeration
system. Where heat reclaim is used it shall always be designated as the first stage of
heating with the polyvalent chiller providing the second stage of heating.
Design Approval: Final design of system (including heat load calculations) to be
submitted to the Woolworths Senior Mechanical Engineer for approval.
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4.7 MECHANICAL VENTILATION
4.7.1 GENERAL REQUIREMENTS
Exhaust systems shall be fitted with roof mounted, low profile, vertical discharge
centrifugal fans.
Fans shall be of Fantech, Heritage series construction; Ziehl Abegg, EBM Papst or
approved equal, fitted with bird-mesh protection.
Motors to be mounted out of air stream.
Where discharge is above roof, opening is to be fitted with ‘bird-mesh’ protection.
4.7.2 TOILETS & CLEANERS ROOMS
The staff toilets and cleaners rooms shall have an exhaust rate as required by AS
1668.2.
4.7.3 STOCK ROOM EXHAUST
For stores where the roof over the stock area is sheet metal, the stock room exhaust
ventilation system shall consist of not less than two roof mounted propeller type fans.
For stores where the stock area ventilation system has to be ducted, a single exhaust
fan will be allowed.
The fans shall be of sufficient capacity to provide a minimum of ten air changes per
hour based on the total space volume (Excluding the volume of the cool, freezer or
store rooms).
Provision of make-up air to the stock room exhaust ventilation system must be
considered (via perforated loading dock shutters or if not practical due to location, or
adjacent refuse bins, then low level louvres shall be installed into stockroom
perimeter wall).
4.7.4 MSB ROOM VENTILATION / CONDITIONING
Roof mounted exhaust fan shall be provided complete with bird wire mesh, and wall
mounted thermostat set at 28°C, with low level wall mounted air intake grille complete
with panel filter. Design for 10 ACH.
Note 1: Fire dampers may be required if fire rated walls and ceilings are required.
Note 2: In BCA climate zones 1 & 2 the MSB room shall be air conditioned using
VSV/R ducted system. Evaporator shall not be contained within or above room with
condensate tray/lines shall be external to room.
In stores where the exhaust is at roof level, a roof mounted exhaust fan shall be
provided. In other instances, an inline axial fan may be used.
4.7.5 GENERATOR ROOM
If a separate generator room is required then this room shall be provided with
sufficient natural or mechanical ventilation to maintain the generator within its
designed operating temperature. Note: Generator will be required to operate
continuously in an emergency situation
Page 32 of 157 32

4.7.6 SMOKE EXHAUST SYSTEM
Smoke Spill and/or Smoke Exhaust systems, Car Parking area and Loading Dock
exhaust or ventilation systems as required by any statutory or regulating authority are
not included within the scope of this design brief. All such systems, when and if
required, shall be provided by the developer to meet the requirements of and to the
approval of any authority having jurisdiction at the Site
The developer may submit a ‘Fire Engineered Solution’ to comply with the
performance based criteria of the BCA; all subject to the approval of the local
authority having jurisdiction over the works & Woolworths. The fire engineer engaged
for the project must be accredited and approved by the relevant authority having
jurisdiction over the works and Woolworths. A copy of the Fire Engineered report
must be submitted to Woolworths for information and record.
Smoke Spill and/or Smoke Exhaust system shall be roof mounted fans over the
trading area located in positions approximately as shown on the Standard
Woolworths Air Conditioning Layout Drawing No. 9. Details of alternative fan
locations must be submitted to Woolworths prior to the completion of the design work
and before the acceptance of any Tender.
Note:
Smoke spill and/or smoke exhaust systems shall operate and run independently of
any Air conditioning system and equipment.
The use of smoke barriers below the ceiling line in the trading area shall be avoided.
Where authorities require that smoke exhaust fans be installed, it is the developer’s
responsibility to have a separate fire rated submain (MIMS or Radox only) installed
from the Centre Main electrical switchboard to a separate essential services 'Smoke
Spill Fans' control panel located in the A/C Plantroom in a fire rated enclosure.
All wiring required for connection between essential services control panel (ESP) and
smoke exhaust fan and Fire Indicator Panel must be included in the above works.
Smoke exhaust fans Fire Brigade’s manual over ride switches on ESP shall be of the
'lockable type'.
Roof mounted smoke exhaust fans local isolating switches are to be locked in the
"on" position as per AS 1668.1 In any event.
4.7.7 KITCHEN EXHAUST - CHICKEN COOKER, DOUGHNUT, DISHWASHER &
BAKERY
Each exhaust/make up air system shall be separately ducted to outside. The joining
of any exhaust duct from any system to another will not be accepted.
Exhaust systems shall be interlocked to its make up air system and respective
kitchen equipment so that exhaust and make up systems only operate when kitchen
equipment is in operation. Current sensing relay may be used to detect if kitchen
equipment is operating (i.e. difference between standby and operating current). A
15min run on timer shall also be incorporated so that exhaust will continue to operate
15min after kitchen equipment is turned off.
When winter outside design ambient conditions are below 10°C make up air system
shall stop with additional fresh air supplied to main air handling unit.
Make-up air system fans shall be installed above the roof.
Each exhaust and make up air system shall be interlocked to the main air
conditioning plant so that when exhaust systems are not running the fresh air quantity
to the main A/C plant is balanced so to maintain design pressure within retail space.
Page 33 of 157 33

All exhaust hoods shall be welded construction manufactured from 1.2 mm thick
stainless steel, grade 304 having a No. 4 finish. All corners shall be radiused filled
and ground smooth.
Design hood face velocity shall not be less than 0.5 m/s for chicken cooker, doughnut
cooking unit and dishwasher and 0.3 m/s for bakery ovens. The Designer shall
comply with the requirements of the local authority and AS 1668.2.
The standard hood sizes shown on the detail drawings (refer to Section ) shall be
used. Alternative designs that provide improved energy savings may be considered
providing that approval is given by Woolworths Senior Mechanical Engineer, the
hoods comply with AS1668.2 and a Certificate of Conformity is provided.
Note: Approved alternate makes are Halton (available from Stoddart) and Britannia
(available from HRC Alliance)
a) The chicken cooker unit shall be fitted with an exhaust hood complete with
grease filters, fan and ductwork. A make up air supply system shall also be
installed complete with fan, ductwork and filters. Make up air to the hood
shall comprise of an internal jet that assist in capturing effluent and low
velocity outlet located in the front of the hood vertically (refer to sections
18.1.1 & 18.1.2).
Note: Make up are shall not interfere with air distribution within the deli area.
b) The doughnut cooking unit shall be fitted with an exhaust hood complete with
grease filters, fan and ductwork.
c) The bakery oven shall be fitted with an exhaust hood, fan and ductwork.
(Grease filters shall also be supplied and installed if required by the local
authorities). A make up air supply system shall also be installed complete
with fan, ductwork, filters and outlet registers adjacent and to the rear of the
exhaust hood.
When the bakery oven is gas fired additional provision shall be made within
or adjacent to the hood to accommodate gas flue. (Refer to oven
manufactures details)
Note: When winter outside design ambient conditions are below 10°C
make up air shall be turned off.
d) The dishwashing unit shall be fitted with an exhaust hood complete with fan
and ductwork.
4.7.8 FISH SERVICE & PREPARATION AREAS EXHAUST (IF APPLICABLE)
The fish preparation area shall be provided with a roof mounted fan system of
sufficient capacity to give an exhaust rate not less than 160L/sec each exhaust outlet
(3 off) or fifteen (15) air changes per hour of total volume, whichever is greater.
Page 34 of 157 34

5.0 SYSTEM APPLICATIONS
5.1 TRADING AREAS
This section describes under what conditions the various system designs are to be
considered.
The type of airconditioning system used is dependant on the size of the store and its
geographic location.
Store Type/Size 1
Tropical
Supermarket
(Greater than
3800m 2 )
Supermarket (2000-
3800 m 2 )
Supermarket (1500-
2000 m 2 )
Supermarket – Small
Format (Less than
1500 m 2 )
2 & 3
Sub Tropical
BCA Climate Regions
4
Arid
5 & 6
Warm
Temperate
7 & 8
Temperate
Central Plant Central Plant Central Plant Central Plant Central Plant
Custom Custom Custom Custom Custom
Package Unit Package Unit Package Unit Package Unit Package Unit
RTP Unit RTP Unit RTP Unit RTP Unit RTP Unit
VRF Unit or
Multi Head
Polyvalent
VRF Unit or
Multi Head
Polyvalent
VRF Unit or
Multi Head
Polyvalent
VRF Unit or
Multi Head
Polyvalent
VRF Unit or
Multi Head
Polyvalent
Dan Murphys RTP Unit RTP Unit RTP Unit RTP Unit RTP Unit
Wooloworths Liquor RTP Unit or RTP Unit or RTP Unit or RTP Unit or RTP Unit or
VRF Unit VRF Unit VRF Unit VRF Unit VRF Unit
BWS VRF Unit VRF Unit VRF Unit VRF Unit VRF Unit
Dick Smith (Greater
than 500 m 2 )
Dick Smith (Less
than 500m 2 )
RTP Unit RTP Unit RTP Unit RTP Unit RTP Unit
RTP Unit or
VRF Unit
RTP Unit or
VRF Unit
RTP Unit or
VRF Unit
RTP Unit or
VRF Unit
RTP Unit or
VRF Unit
Note: - Where chilled water is available RTP and VRF units are interchangeable with chilled water
FCU’s.
- All VRF units to be of ducted configuration.
- Climate Zones for New Zealand shall use equivalent to Australian zones.
5.2 OFFICE & AMENITIES AREAS AIR CONDITIONING SYSTEMS
Reverse cycle air cooled split air conditioning systems (Variable Refrigerant Flow/Volume
type only) shall be supplied and installed to serve the following areas:
Page 35 of 157 35

a) Systems Office
b) Cashiers Office
c) General Office
d) Communications Room
e) MSB Room ( BCA climate zones 1 & 2)
f) Staff Training
g) Staff dining and lounge areas
h) Female Locker Room
i) Male Locker Room
Note:
• All areas nominated above shall be controlled individually using wall mounted thermostat
located within each space.
• Ceiling mounted fan coil units must be isolated from the building elements and located to
ensure service access clearances are sufficient to allow unrestricted access to all
components within the fan coil unit, to filters, safety trays and condensate drains.
• All systems shall be supplied with fresh air as per AS 1668. Both return air and fresh air shall
be filtered as per AS 1668
• Noise levels of equipment must comply with section 2.3.
• All roof mounted air cooled condensers shall have passivated fins.
• Systems shall be wired from the MSSB located in the main plantroom.
• All systems shall be linked with the main air conditioning system controller (CPC) so
temperature set points and On/Off schedule can be controlled centrally.
• The capacity of each air conditioning unit shall be sufficient to meet the total of the building
load, outside air load, people occupancy load, light load and computer equipment loads as
above.
Page 36 of 157 36

6.0 EQUIPMENT
6.1 REFRIGERANTS
All air conditioning systems and all associated condensing units shall be designed to
operate using an environmentally friendly refrigerant such as R134a, R410a or approved
alternative.
Note:
• The use of CFC and HCFC Refrigerants shall not be permitted.
• The use of R407c & R22 is not permitted.
• All air conditioning systems shall be designed using air cooled heat rejection
equipment.
• THE USE OF OPEN ATMOSPHERIC WATER COOLING SYSTEMS SUCH AS
COOLING TOWERS AND EVAPORATIVE CONDENSERS WILL NOT BE
PERMITTED.
• As a minimum all equipment shall comply with the energy efficiency requirements
of the Building Code of Australia. Particular note should be taken of sections J5
and J7 as these sections are directly applicable to Air conditioning and
Ventilation systems.
6.2 CORROSION PROTECTION
The installation shall use materials which resist corrosion (i.e. 2000 hrs salt spray test). In
particular, care shall be taken with all equipment located externally to ensure maximum
corrosion protection.
The design and installation of the mechanical services shall take into account standard
acceptable procedures to minimise corrosion. As far as possible, dissimilar metals shall
not be in contact to avoid the possibility of electrolytic corrosion which may occur in such
cases.
Where unlike metals are in connected, those metals shall be in close proximity on the
galvanic series. Where fixings are used which may result in materials of lesser surface
area being in contact with parent materials of considerably larger surface area, the parent
material shall be lower on the galvanic series than the material of the fixing, in order to
avoid rapid failure of the fixing.
All steel items, including brackets and fixings (including screws, nuts and bolts) shall be
hot dip galvanised after fabrication. Non galvanised, painted steel items are not
acceptable on any part of the installation.
6.3 AIR HANDLER UNITS
6.3.1 BUILT UP AIR HANDLING UNIT (AHU) HOUSING
The air handling unit shall be fabricated from refrigeration type cold room
sandwich panels with a minimum of 75mm FM Global approved (PIR) core (i.e.
EPS is not approved) with 0.5 mm colour bond pressure bonded skins, on all sides
and with 75 mm ceiling and floor.
A separate walk in compartment shall be provided between the air filter and
cooling coils/ heat reclaimed coils as well as between outside air and return air
plenums and fan chamber. Fluorescent (T5) lighting must be provided in each of
the compartments as per AS 1677..
A separate 550mm x 1500mm hinged access door shall be provided to each
separate compartment. Access doors shall have chrome plated hardware with
quick release catches, and shall be ‘Bullock’ design or approved equal. Direction
of opening of doors shall be arranged to ensure that the door gasket is assisted in
closing against the pressure difference over the door.
Page 37 of 157 37

A stainless steel condensate tray shall be provided under each cooling coil with a
minimum 32mm diameter drain from each condensate tray. Fall to drain point shall
be a minimum of 1:100. Tray to extend to the heating coil bank.
A common condensate drain shall pass through the AHU unit housing, be suitably
trapped and be of sufficient height to overcome the systems pressure difference
and discharge with an air break into a floor waste outside the air handling unit.
Sufficient space shall be allowed within the housing to accommodate a hot water
coil and hot refrigerant gas heat reclaim coil (from the commercial refrigeration
installation). Heat reclaim coil to be supplied by the commercial refrigeration
contractor, installed by the mechanical sub-contractor.
All floors in walk in compartments shall be protected with stainless steel checker
plate flooring.
6.3.2 MODULAR CONSTRUCTION AIR HANDLING UNIT (AHU) HOUSING
Generally the type of AHU has the same specification as the ‘Built Up Plant’ AHU
(refer to section 6.3.1), except that this type of AHU is specifically designed to be
located external to the plantroom (i.e. on the condenser deck). The following
addition requirements shall apply.
• The AHU shall be completely weather proof.
• Roof of AHU shall have a fall of not less than 3 degrees.
• Roof Fall shall not be towards side of AHU with access panels
• A weather guard shall be installed 150mm above all access panels. Guard
shall protrude 50mm off vertical face of AHU and shall have a formed
safety edge on all edges.
• Switchboard shall be completely enclosed within the structure so that it is
not effected by weather.
6.3.3 SUPPLY AIR FAN & FILTERS
Refer to section 6.14.2
6.4 FAN-COIL UNITS
6.4.1 GENERAL
Return and outside air mixing plenums shall be installed on all fan-coil units. Filters
shall be provided and all gaps and spaces which allow air bypass around filters
shall be filled and sealed to prevent bypass.
6.4.2 FABRIC COUPLINGS
Supply and install on both supply and return air ducts, approved fabric couplings.
These couplings shall have a minimum extended dimension of 75mm and shall be
installed to ensure that they are air tight and free to function correctly without being
taut or restricting air flow. Where these couplings are exposed to the weather, they
shall be protected with appropriate covers.
6.5 VRV OR REVERSE CYCLE SPLIT DX SYSTEMS
This section describes the requirements for mid-wall, high-wall, ceiling cassette or small
in-ceiling fan-coil units for use in back of house areas.
The system shall generally comprise an air cooled condenser unit connected to a number
of indoor fan coil units. Each indoor unit shall be sized to meet the cooling or heating
requirements of the room being served.
Page 38 of 157 38

The system shall use inverter driven or digital scroll technology and be able to offer
simultaneous heating and cooling to different indoor units connected to the same outdoor
unit. There shall also be heat recovery operation possible.
The system shall have a minimum energy efficiency ratio that complies with Section J of
the latest version of the Building Code of Australia.
The outdoor unit shall be a factory assembled unit, housed in a sturdy weatherproof
casing constructed from rust proofed mild steel panels coated with a baked enamel finish.
The outdoor unit shall be modular in design and should be designed to allow for side by
side installation.
The noise levels for both the indoor and outdoor units shall meet the requirements as set
out in the noise level specification section.
All indoor units used shall be capable of accepting the outside air supply directly into the
return air of the unit.
Cassettes and mid wall units shall be provided with integral condensate pumps.
The refrigerant circuit shall include liquid gas shut off valves and a solenoid valve. The
system shall be fitted with all necessary safety devices to ensure safe operation of the
system.
Units shall be equipped with an oil recovery system to ensure stable operation with long
refrigerant pipe runs.
Each fan coil unit shall be of the ducted medium or high static type and be fitted with
appropriate filter. See filter section. The filters may be fitted in the return air duct.
The system shall incorporate a proprietary control system that can be controlled by a
single all-in-one unit located in the general office. It will be necessary for the proprietary
control system to be able to communicate with the Emerson mechanical control system.
All temperature set points and alarm notifications shall be accessible from the Emerson
system.
Approved brands are nominated in section 17.7 or equal approved by Woolworths Senior
Mechanical Engineer.
6.6 COOLING COILS
All coil configurations shall be designed to allow for condensate to flow away from the coil
easily without being drawn through the coil into the air stream or water logging the coil.
Coils shall be copper tube with aluminium fins, copper headers and aluminium casing.
Tube lengths and fins shall be free from joints. Coils shall be arranged in slide racks for
ease of removal. No non ferrous parts shall be in contact with any ferrous part.
All coils shall have ARI 410 certification for performance verification.
6.6.1 DIRECT EXPANSION
Coils shall be a minimum of six (6) rows deep and shall be parallel refrigerant - air
flow with loop back onto the air entering face.
For areas with design wet bulb temperatures equal or over 27°C WB; 8 row coils
shall be used.
Coil suction piping connections must be taken from the lowest point in each
suction header, with oil risers on each suction line.
Page 39 of 157 39

Coils shall be single circuit to maximise latent cooling and for multi-circuit systems,
there shall be an individual coil for each circuit.
If coils are installed one above the other a stainless steel condensate tray shall be
installed under each coil section.
Maximum Face Velocity: 2.50 m/s
Minimum SST: 6.0°C
Minimum Coil Superheat: 9K
Minimum Refrigerant Velocity: 5.0 m/s
Maximum Refrigerant Pressure Drop 80 kPa
Maximum Fin Density 400 f/m
6.6.2 CHILLED WATER
Coils shall be arranged no more than two coils high and a stainless steel
condensate tray shall be fitted under each coil.
Chilled water cooling coils shall have a minimum of six rows in direction of air flow.
Maximum Air Velocity 2.5 m/s
Designed Water Temp In 7°C
Designed Water Temp Out 12°C
Maximum Fin Density 400 fp/m
Coil Pressure Drop (Water Side) 25 kPa
6.6.3 REVERSE CYCLE DX COILS
All evaporator and condenser coil configurations shall be designed to allow for
condensate to flow away from the coil easily without being drawn through the coil
into the air stream or water logging the coil. This is particularly important in heating
mode when the “condenser coil” is acting as the evaporator. The condenser coils
shall be in a vertical or V-block configuration.
When a coil is in cooling mode, the coil specification shall meet the requirements
as set out in the direct expansion coil section above.
When the coil is in heating mode, the coils shall meet the above requirement plus
the following additional requirements.
Maximum coil refrigerant temperature difference: 10 °K
6.7 HEATING COILS
Heating coils shall be a minimum of two rows deep
6.7.1 DIRECT EXPANSION
Maximum Face Velocity: 2.50 m/s
Maximum Air Pressure Drop: 50 Pa
Maximum Refrigerant Pressure Drop 50 kPa
Maximum Fin Density 400 f/m
6.7.2 HOT WATER
Maximum Face Velocity: 2.50 m/s
Maximum Air Pressure Drop: 50 Pa
Maximum Pressure Drop 50 kPa
Maximum Fin Density 400 f/m
Page 40 of 157 40

6.7.3 REFRIGERATION HEAT RECLAIM COIL (BY OTHERS)
6.8 COMPRESSORS
6.8.1 GENERAL
Labels to be provided with compressor indicating type of refrigerant gas, charge,
date entered into service and type of lubrication oil to be used (in compliance with
the relevant Statutory/Regulatory requirements).
Reciprocating compressors shall have single stage compression and be selected
to match the design duty when operating at the evaporator and condensing
temperatures specified herein.
All electric driving motors shall be suitably protected against an overload condition
(by thermal overloads and phase failure protection) and shall include thermistor
protection.
All compressors shall be fitted with sufficient electrically controlled capacity control
steps to satisfy cooling load variations and shall have pressure lubrication, oil
strainer, suction discharge shut-off valves, discharge mufflers, suction
accumulator, vibration isolation mounts, pipework vibration eliminators, crank case
heaters, manual reset HP/LP and oil safety switches.
All control lines from compressor to ‘control manifold’ to be in approved
refrigeration flexible lines.
Note: Sump oil drain valve shall be fitted to semi hermetic compressors.
6.8.2 APPROVED COMPRESSORS
Refer to section 17.3
Note: All compressors may be the manufacturers’ standard unit provided that the
unit complies with all the requirements of this design brief.
6.9 AIR COOLED CONDENSERS
6.9.1 APPROVED CONDENSERS
Condensers shall be of the type and make nominated in section 17.4 (or as otherwise
approved in writing by the Woolworths Senior Mechanical Engineer) and shall comply
with the design conditions set out within this specification.
The nomination of any manufacturer's equipment shall not imply any preference or
order of selection of any brand.
6.9.2 LOCATION & POSITIONING
Unless otherwise indicated the condenser shall be mounted on galvanized steel deck
or structural supports provided by others.
All condensers shall be located so as to be above the compressor sets and liquid
receivers.
The Designer shall nominate the number of air cooled condensers required and
coordinate the positioning of the condenser(s) on the roof platform with the
commercial refrigeration contractor and the builder.
Location of condensers shall ensure adequate air flow across the condenser and
comply with acoustic requirements for the building site.
Page 41 of 157 41

6.9.3 CONDENSER FANS
Air cooled condensers shall be provided with air circulating fans of the propeller type.
Each condenser shall have not less than two (2) fans, offering three (3) stages of
capacity control (0 Fans/1 fan/2 fans). The fans shall be each direct coupled to totally
enclosed electric driving motors suitable for operation on three phase 50 cycles
electric supply.
Each fan motor shall be factory wired to individual isolation switches located in an
adequately protected terminal box with waterproof conduit entry. The terminal box
shall be made of UV stabilised material and be IP56 rated. The terminal box shall be
easily accessible by technicians with minimum free clearance of 600mm to allow
installation and servicing.
Electrical components for condensers shall be located in the main refrigeration
switchboard in the plantroom. No such components at the condenser will be
accepted.
6.9.3.1 AXIAL (AC) FAN MOTOR SELECTION
When selecting a condenser with standard AC motors, preference
shall be given to energy efficient 8-pole motors. The make of fans
shall be as nominated in section 17.4.1 or equivalent approved by
Woolworths Senior Engineer.
6.9.3.2 EC FAN SELECTION
When selecting a condenser with Electrically Commutated (EC)
fans, the make shall be as nominated in section 17.4.1 or
equivalent approved by Woolworths Senior Engineer.
Fans shall be capable of achieving 1080RPM operational speed.
Condensers shall be selected at standard 8-pole (high-speed)
condition. Fans shall be capable of achieving full speed operation
as required by the Electronic Alarm & Control system.
6.9.4 CONSTRUCTION
Condenser coil protection shall be by epoxy treatment of fins prior to manufacture of
condenser. The ‘dipping’ of condenser coil block shall not be accepted as a form of
corrosion protection. All condensers offered shall be subject to a 2000hr salt spray
test in accordance with ASTMB117 and ASDTMB287. Results of such testing shall
be made available to Woolworths upon request.
Condensers shall be constructed of copper pipe expanded into epoxy coated
aluminium fins. The fins shall be spaced at not more than 472 per metre and the
coils may incorporate a ‘floating ‘ coil arrangement or be expanded into galvanised
steel tube plates and assembled within a galvanised steel / aluminium casing
complete with supporting legs.
All air-cooled condensers shall be not less than four (4) rows deep in direction of air
flow. The condenser coils shall be arranged to enable cleaning of the coils.
Discharge and return lines to Condensers are not to be insulated, and shall be fixed
using pipe clamps and painted. Pipe clamps and fasteners shall be galvanized or
stainless steel separated from copper piping with insulating material.
All air-cooled condensers shall have a horizontal coil, with vertical air discharge
unless ‘V Block’ type condensers are used
At the time of commissioning all fins shall be demonstrably free of damage caused by
transporting, unloading and erecting the equipment.
Page 42 of 157 42

Any steel casing shall have a galvanised finish and shall be finished with first quality
powder coat finish to 80 micron thickness.
The condenser coils may be multi-circuited and suitably headed with brazed
connections.
The liquid outlet shall be not less than 300mm above the top of the liquid receiver.
6.9.5 CONDENSER SELECTION
The condensing temperature of all refrigeration systems shall not exceed
temperature differences above the ambient temperature as outlined in Section 2.2.
Air cooled condensers shall be selected to maintain a temperature difference
between the design ambient dry bulb and the condensing temperature, as follows:
Ambient °C Temp Diff °K Condensing °C
(SCT)
32 13 45
33 12 45
34 11 45
35 11 46
36 11 47
37 10 47
38 10 48
39 10 49
40 9 49
41 8 49
42 8 50
If a single condenser is selected to match the total heat rejection requirements then
the condenser shall incorporate two (2) separate refrigerant circuits.
In the case of two (2) condensers being selected to match the total heat rejection
requirements then each condenser shall form part of a separate refrigerant circuit.
6.10 DRY FLUID WATER COOLED CONDENSERS
May be considered for stores where the distance between the plantroom and condenser
deck is excessive and the resulting increased refrigerant charge presents an increased risk
to system integrity and operation.
This option shall be fitted with a mechanically cleanable shell and tube condenser and
condenser water pump connected with piping to a remote mounted dry (water-to-air) heat
exchanger.
In all instances the condenser water circuit shall be a closed circuit and not open to external
contamination at any point within the cycle.
Shell & Tube condensers shall be as nominated in section 17.5.1 or as otherwise approved
in writing by the Woolworths Senior Mechanical Engineer
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Shall be mechanically cleanable and designed into a system with fouling factor of 0.178
m²K/kW when meeting the system design total heat of rejection. Control of system head
pressure shall be by bypassing condenser water flor around shell and tube condenser via
the use of a 3-way modulating valve, controlled by the electronic control system. Condenser
water temperature to be maintained by switching (or speeding) of dry-cooler fans.
Components within the condenser water piping circuit shall be flanged to allow the removal
of the condenser end covers without disturbing the condenser mountings.
Ancillary equipment and detail to be Included when employing a water-cooled condenser
Installation as follows:
• Air Purge Ports:
Automatic air vents shall be provided at system high points complete with shut off valves
to clear pipework of air and to prevent air locks. Careful consideration shall be given to
the positioning of air vents to ensure satisfactory operation of the whole system.
• Chemical Water Treatment
The Mechanical contractor shall add corrosion and bacterial inhibitor to the water
system on initial charge and again at the end of Defects Liability Period. The Contractor
shall provide evidence and details of water dosing to Woolworths personnel at both
times.
• Condenser Water Circuit:
Water piping between the shell and tube condensers and the dry cooler shall be in
copper. The piping system shall include isolating valves to enable isolation of each
piece of equipment, balancing valves and control valves. The pipework shall be graded,
preferably in the direction of flow with air purge ports at each high point.
• Condenser Water Pumps:
Two (2) equally sized condenser water pumps shall be supplied with each capable of
delivering 100% duty. Pumps shall be installed in parallel and be automatically switched
every seven (7) days to equalise run-time or started if the other pump fails to operate.
An alarm shall be raised on pump run failure. A water flow switch shall be installed
immediately after each pump.
A mechanically cleanable strainer shall be incorporated in the water pipe prior to each
pump. Flexible couplings shall be installed at the inlet and outlet of each pump.
Each pump shall comply with the following specification:
• Globe Valves
• Make: As nominated in section 17.6 or equivalent approved.
• Type: End suction. Open drive centrifugal.
• Construction: Cast iron casing, bronze impeller, stainless steel shaft
and packed gland.
• Motor and Coupling: 4 pole high efficiency 1450rpm non overloading
- direct coupled.
Globe Valves for water flow balancing shall be installed with each shell & tube
condenser and also dry cooler to ensure accurate water balancing throughout the
system.
• Drip Wells
Page 44 of 157 44

A drip well shall be incorporated under the pump shaft gland. The well shall be drained
to the nearest floor waste in 15mm diameter copper pipe.
• Dry Fluid Cooler(s):
Shall be of similar construction to air-cooled condensers as per section 6.9. If multiple
dry-coolers are to be employed, these shall be identically sized and circuited to ensure
equal fluid flow.
• Flanged Connections:
Each piece of equipment shall be fitted with flanged type valves to allow its removal and
reinstatement without the need to introduce heat.
• Isolation Valves:
Immediately before and after each piece of equipment, the contractor shall install gate
type valve to isolate the flow of water so that the piece of equipment can be removed
and reinstated without the need to drain the entire condenser water circuit.
• Make-up Tank:
A make up tank shall be provided for the close water circuit. The tank shall be of 20
gauge copper sheet or stainless steel approx. 610 mm diameter by 457mm high with
removable lid and be complete with:
o 19 mm mains water stop valve connected to 19mm float valve.
o Rectangular 20 gauge copper or stainless steel drain pan 150 mm deep.
o 38 mm one flow to tray.
o 19 mm valved drain to tray.
o 32 mm copper drain pipe from tray to adjacent drain waste.
o 32 mm copper pipe connection to the condenser water pump suction pipe.
The tank shall be suitably supported in a convenient position adjacent to the fluid
coolers.
• Modulating Valves:
Shall be Siemens or Belimo manufacture and be selected so the speed of the
modulating actuator can be adjusted to achieve stable head pressure. Control shall be
via a 0-10V signal provided by the Electronic Control System.
• Operating Temperature:
The dry cooler shall be selected to maintain, in conjunction with the shell and tube
condenser, operating temperatures as follows:
• Thermometer Pockets
Ambient
Water Outlet
Temperature Temperature
Up to and
Ambient Temp
Including
34°C
+1 Deg C
Over 34°C Ambient Temp
+2 Deg C
Condensing
Temperature
Water Outlet +
7.5K
Water Outlet +
7.5K
Page 45 of 157 45

Thermometer pockets shall be provided in the flow and return lines at inlet and outlet of
dry-cooler for controller probes so accurate control of the water temperature can be
maintained.
6.11 VIBRATION ISOLATION AND FIXING
6.11.1 CONDENSERS
Condensers shall have a minimum of one layer of nominal 10mm thick waffle pad
installed between each foot and the surface in which it is being positioned. The
Contractor shall ensure the pad used is selected taking into account the actual
operational weight of the equipment.
Where condensers are located on a mesh deck, the Contractor shall supply a
2.0mm thick galvanized steel plate between the mesh and the waffle pad to protect
against damage when the weight of the condenser is applied to the waffle pad.
Regardless of the mounting surface, the Contractor shall ensure the condenser is
securely bolted down using minimum 12mm bolts at all ‘foot’ locations.
6.11.2 COMPRESERS
Compressors mounting frame shall have a vibration isolation mechanism that
eliminates vibration from compressor through to the plantroom floor. The design
should consist of one-piece (Embleton or otherwise approved in writing) anti vibration
mounts designed for the specific weight of the rack. A minimum of four (4) mounts
are required for each individual compressor rack frame. Mounts shall be spread
evenly across the base of each frame.
Waffle pads are not acceptable as vibration elimination devices for compressors..
The contractor shall ensure that all piping is isolated from vibration that would
otherwise cause fatigue or fracture.
6.12 LIQUID RECEIVERS
Each refrigeration circuit shall be fitted with a liquid receiver of sufficient capacity to hold
the entire pump down refrigerant charge plus twenty percent (20%) reserve capacity.
The liquid receiver shall be manufactured in accordance with the Australian Standard for
Refrigerating Systems and be fitted with a pressure relief device. The relief device shall
be vented externally to plant enclosure.
Note: A manufacturer’s certificate shall be provided in accordance with AS 3920.1.
The liquid receivers shall be mounted below the air cooled condenser liquid outlet. The
vertical distance between the condenser liquid outlet and the inlet to the receiver shall be
of sufficient height to overcome any line and valve pressure drop.
The liquid drain line from the condenser to the receiver shall be sized for a liquid velocity
not exceeding thirty metres per minute (30m/min) to allow gravity flow of the refrigerant
through the condensate line from the condenser outlet to the liquid receiver inlet. Note
this requirement applies whether or not the option is taken to valve the receiver out of the
normal refrigeration circuit.
The receiver shall be shaded from the direct effect of the sun and free from the effects of
any external heat source. Preferred location is within the plantroom.
Page 46 of 157 46

Connection to receiver shall match incoming pipe.
6.13 PUMPS
6.13.1 GENERAL
Pumps shall be selected with the characteristic curves having continuously rising
static head with decrease in water flow and be non overloading over the expected
operating range.
The pump and motor shall be selected to deliver the required water quantity
against the resistance of the system.
6.13.2 CHILLED, HOT AND CONDENSER WATER
6.14 FANS
Each pump shall comply with the following specification:
• Make: As nominated in section 17.6 or equivalent approved.
• Type: Open drive centrifugal, End suction
• Construction: Cast iron casing, bronze impeller, stainless steel shaft and
mechanical seal.
• Motor and Coupling: 4 pole high efficiency 1450rpm non overloading - direct
coupled.
Note: Ensure all water ways are finished to a smooth surface. Statically and
dynamically balance the impeller and shaft assembly. Provide flanged
connections for replaceable casings.
6.14.1 GENERAL
Select mechanical seals suitable for the application and the fluid being
pumped.
A mechanically cleanable strainer shall be incorporated in the water pipe prior
to each pump. Flexible couplings shall be installed at the inlet and outlet of
each pump.
Assemble pump and motor on a bedplate fabricated from rolled steel angle
on channel sections with accurately machined facings for the pump and
motor feet. Treat the bedplate with Dimet or Zincolate. Fully paint the
pump unit prior to delivery on site. Support the complete assembly from the
concrete plinth or inertia base and vibration isolators.
Provide chilled water pumps with an integral copper drip tray and copper
drain pipe running to nearest floor waste. Install tray to extend beyond
uninsulated pump flanges to capture all condensate drips.
Fans shall be selected for maximum efficiency, i.e., minimum kW input to meet the
required duty. Fans shall be capable of delivering the required air quantities
against the resistance of the system as installed while ensuring that space noise
levels are not exceeded.
Drives and motors shall be selected such that a 10% increase in duty is attainable
without changing the motor.
Fans shall be factory statically and dynamically balanced.
Page 47 of 157 47

Connect fans to ductwork with flexible connectors. Where fans are located within
the occupied space or in areas where the noise can be transmitted to the occupied
space, provide acoustic treatment to flexible connectors to minimise noise breakout.
All reference to speed controllers, motors and drives refer to the Electrical Section.
Fans designated as smoke spill fans shall comply with the requirements of
AS/NZS 1668 Part 1.
Bearings:
• SKF or as otherwise approved by Woolworths.
• All bearings shall be 100,000 hour with grease relief.
• All bearings shall be self aligning roller type.
• All bearing housings shall be dowelled and be fitted with grease pipes and
nipples mounted in an accessible position.
Electric Motor:
The motor shall be selected to satisfy the starting torque and full load duty of
the fan, with reserve capacity to allow for a 10% increase in air flow capacity
and corresponding increase in static pressure. The motor shall be three
phase, 24 rps TEFC suitable for continuous duty.
Motors to be High Efficiency type and compliant to the current MEPS at the
time of commissioning of fan.
Mounting:
The fan and motor shall be mounted on a fully welded steel base and the
whole assembly shall be supported on spring vibration isolators. The spring
isolators shall be sized for a vibration isolation efficiency of 95%.
The spring isolators shall be mounted on ribbed rubber pads and when loaded
they shall have a length approximately equal to their diameter.
When installing the fan on site each support point shall be shimmed to ensure
that the fan assembly is not distorted.
Fan Location:
Fan shall be located at a sufficient distance from the last coil so that an even
velocity is achieved over the entire coils face area.
6.14.2 CENTRIFUGAL TYPE
6.14.2.1 Fans with flow rate greater than 2000 l/s
Fans shall be as nominated in section 17.9.2 or equivalent
approved.
Large central plant fans shall generally be backward-curved
centrifugal airfoil DIDW and shall be supplied complete with an
approved VSD.
The fan shall be selected to suit the system resistance. In any
event the system static pressure shall not exceed 550Pa including
the dirty filter pressure drop
Page 48 of 157 48

6.14.2.2 Fans with flow rate less than or equal to 2000 l/s
Fans shall be as nominated in section 17.9.1 or equivalent
approved.
Fans shall generally be backward-curved centrifugal airfoil SISW,
however forward curved fans are acceptable.
The fan shall be selected to suit the system resistance. In any
event the system static pressure shall not exceed 400Pa including
the dirty filter pressure drop.
6.14.2.3 Construction
Fan housing shall be galvanised mild steel
Shaft - HT steel shafting.
Seal welded laminar impeller.
Provide a drain in the lowest point of the casing
Note: The fan and motor shall be mounted on a common steel
channel base with appropriate anti-vibration mounting.
6.14.2.4 V Belts:
Provide and fit matched sets of vee belts and correctly aligned
pulleys for all centrifugal fans except those which are direct
coupled.
Secure all pulleys attached to motor and fan shafts and all fan
impellers by means of a straight parallel key secured by a
setscrew.
"B" Section - selected for 150% of motor torque.
6.14.2.5 Safety
Safety guards to be fitted to fan blades/shafts and drives.
To each vee belt driven centrifugal fan provide and fit an approved
substantial drive guard generally as follows:
• 15 mm to 20 mm open wire mesh supported by angle iron
or round rod frame.
Provide an open bottom to facilitate removal and allow thrown or
broken belts to fall free of pulleys.
Provide apertures in the guard at the prolongation of shafts to
permit speed measurement.
Size the guard to permit full belt adjustment and attach by means
of wing nuts for quick removal.
Danger Sign to be on A.H.U access door as per Australian
Standards (i.e. Caution Moving Parts).
6.14.2.6 Supply Air Transition
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Supply air duct work connected to the AHU shall incorporate a
transition that shall minimise static pressure losses. Transition
shall start with a velocity of 3 m/s.
6.14.3 PLUG TYPE
6.14.3.1 General
Backward-curved centrifugal airfoil direct drive ‘Plug’ fan shall be
as nominated in section 17.9.5 equivalent approved by
Woolworths Senior Engineer.
The supply air fan shall be selected to suit the system resistance.
In any event the system static pressure shall not exceed 550Pa.
(Allow for 150Pa for dirty filter condition).
6.14.3.2 VSD / EC Motors
An approved VSD shall be used to operate the fan at the required
speed to achieve the design duty (refer to section 6.18). As an
alternative an EC motor may be used.
6.14.3.3 Safety:
A person entering the AHU shall not be able to come in contact
with the moving fan impeller. The may be achieved by:
6.14.3.4 Construction
a) Provision of an operation and maintenance manual for the
AHU including instruction for the safe operation. Testing and
maintenance.
b) Signage on AHU doors acceding the fan warning.
“DANGER ROTATING MACHINERY”
And either of the following c) or d):
c) - Lockable access handle to areas of the AHU that
have access to the fan.
- Electrical interlock circuits on AHU fan access
doors to trip the circuit breaker and isolate power
supply to fans.
d) Provision of galvanised wire fan guard.
• Plug fan wheels shall include the following
construction features as a minimum:
• Welded steel design.
• Surface protection by powder coating.
• Nameplate with indication of hub size, permissible
maximum speed and quality of balancing.
• Arrow showing direction of rotation.
• Balancing weights in steel / stainless steel.
• Impeller designed for continuous operation S1.
• Short dynamic profiled Inlet cones manufactured from
Zincalume steel and fitted with pressure tapping point
for measurement of volume flow.
Page 50 of 157 50

6.14.4 AXIAL FANS
All steel axial flow fans shall be as nominated in section 17.9.3 or equivalent
approved. All fans offered shall be of the same make for standardisation.
Casings shall be hot dip galvanised and fitted into adjoining ductwork using
matching angle flanges.
Provide bolted inspection opening in fan casing or alternately an inspection panel
incorporating sash fasteners in the adjoining ductwork.
Where axial fan motors require grease lubrication, extend grease lubrication nipple
to casing exterior. Motor terminal boxes shall be mounted externally on casing.
Impeller blades shall be of die cast aluminium.
Maximum fan speed shall not exceed 24 rps.
6.14.5 ROOF MOUNTED EXHAUST FANS
Fans shall be direct drive axial or centrifugal type. Make shall be as nominated in
section 17.9.7 or equivalent approved. All fans offered shall be of the same make
for standardisation.
Fan casing shall be hot dip galvanised construction. A bolted inspection opening
shall be provided to the housing.
Adjustable pitch impeller blades shall be aluminium.
Where axial fan motors require grease lubrication, extend grease lubrication nipple
to casing exterior. Motor terminal boxes shall be mounted externally on casing.
Roof mounted smoke exhaust fans housing shall be of galvanised steel
construction with powder coat finish and shall be fitted with butterfly shutters, and
vermin proof mesh.
6.14.6 KITCHEN HOOD EXHAUST FANS
Kitchen exhaust fan shall be direct drive vertical discharge axial or centrifugal type,
galvanised steel construction suitable for direct duct mounting.
Fan shall be as nominated in section 17.9.6 or equivalent approved.
6.14.7 IN-LINE CENTRIFUGAL FANS
In-line centrifugal fans shall be as nominated in section 17.9.1 and 17.9.2, or
equivalent approved, with spigots suitable for connection to ductwork.
Impeller shall be backward curved, direct coupled to an external rotor motor, with
sealed for life bearings.
6.14.8 IN-LINE MIXED FLOW FANS
In-line mixed flow fans shall be as nominated in section 17.9.4 or equivalent
approved equal. Casings shall be of epoxy coated steel or reinforced injected
moulded plastic.
6.14.9 AIR CURTAINS
Air curtains shall be as nominated in section 17.10 or equivalent approved by
Woolworths Senior Mechanical Engineer. Width of air curtain shall be greater or
equal to width of door way opening this may require more than one unit installed
Page 51 of 157 51

over a door way. Operation of the air curtains shall be limited to the trading hours
of the store being controlled by the CPC Emerson mechanical control system.
6.15 CHILLERS
The chiller set shall be as nominated in section 17.11. Chillers shall be air cooled unit, or
similar designed for external roof mounting and with two independent refrigerant circuits.
The chillers shall be a reverse cycle system with total heat recovery capable of
producing chilled and hot water simultaneously.
The unit shall be supplied, installed and connected with all necessary piping to make a
complete installation.
The unit selected shall have sufficient capacity to provide the designed cooling load under
the design ambient conditions specified herein while maintaining a temperature difference
between the design ambient and condensing temperature as noted in section 6.9.5.
6.16 PIPING, VALVES AND FITTINGS
6.16.1 SCOPE
This section sets out the requirements for the installation of piping, valves and
fittings and is concerned with materials and standards of construction for air
conditioning systems.
Piping must comply with:
• AS 1571 ‘Seamless copper tubes for use in refrigeration’;
• AS 4041 ‘Pressure Piping’
• AS/NZS 1571 ‘Copper - Seamless tubes for air conditioning and
refrigeration’
• AS 1677 pt 1 & 2 ‘ Refrigeration Systems”
• AS 1432- ‘Copper tubes for plumbing, gas fitting and drainage
applications’
6.16.2 GENERAL
All piping before delivery to site and pending erection shall be sealed against dirt
and moisture.
Before erection, pipes and fittings shall be cleaned of scale, burrs or other
obstructions.
Welded or brazed joints shall be made by experienced and fully qualified
tradesmen and in accordance with best trade practice. Dry nitrogen shall be used
in all instances.
Each part of the system of piping shall be complete in all detail and provided with
all control valves and fittings necessary for satisfactory operation.
The piping shall be accessible for repairs and provided with sufficient flanged
and/or flared fitting joints for disconnecting and removing equipment.
Where piping is exposed and liable to damage, it shall be suitably protected with
well braced 1.6mm zincanneal sheet metal covers or heavier section if necessary.
PVC pipes and fittings shall not be in direct contact with any surface whose
temperature is likely to exceed 50° C. Direct exposure to sunlight shall be avoided.
Page 52 of 157 52

Provision shall be made in the piping to minimise the effect of vibration and to
ensure no joints fatigue when the plant is put into operation.
The Contractor shall provide a certificate for liquid receiver issued by an
accredited Boiler Inspector. Certificates shall be framed under glass and fixed in
an approved location close to the pressure vessel.
Short radius elbows and very short straight sections after elbows, onto pump
connections will not be accepted under any circumstances.
6.16.3 PRESSURE AND VACUUM TESTING
After testing, as explained below, defective material shall be replaced and leaks
properly repaired. Caulking, taping or other temporary measures will not be
permitted.
The plant shall be tested for leaks 8 weeks after it has been passed for
commercial operation and again at the end of the maintenance period.
6.16.3.1 PRESSURE VESSELS
All pressure vessels shall be manufactured in accordance with the
AS/NZS1677:1998 (and subsequent amendments). Refrigeration
Code of Practice and to the satisfaction of the department having
jurisdiction to whom the design of all pressure vessels to be used
shall be submitted. The approved plans shall be filed by the
Contractor for reference by the Purchaser if required.
When utilising low pressure refrigerant (R134a), the pressure
vessel shall be designed, constructed and tested to a minimum
design pressure of 3000kPa.
The Contractor shall provide a certificate issued by a qualified
Boiler Inspector where applicable for each vessel after installation.
These certificates shall form part of the operation and
maintenance manuals.
6.16.3.2 PIPEWORK
All pipework before lagging is applied over joints, shall be
pressure and vacuum tested as specified in AS/NZS1677-1998.
Specified test pressures shall be maintained for 48 continuous
hours.
Approved vacuum and pressure gauges shall be used.
Note: The use of CFC’s as a trace element will not be permitted.
A double evacuation test to 500 microns shall then be carried out
and held for a minimum of 8 continuous hours.
The first evacuation shall be broken with nitrogen and the system
brought back to atmospheric pressure.
The second evacuation shall be broken with nitrogen and the
system charged. After charging, the system shall again be
checked for leaks.
The contractor shall retain records of pressure tests and supply
details of pressure tests to the Purchaser as requested. Copies of
pressure tests shall be included in the ‘As Built’ documentation.
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6.16.4 PIPE SIZING
Prepare a schematic layout of the system and refer to recognised industry
application data such as Carrier Piping Design Manual Part 3 to establish all pipe
sizes and configuration.
Refrigerant piping shall be such as to give no greater than the following pressure
drops including all valves and fittings.
Suction Lines Equivalent to 1.2°K temperature drop for the total length.
Discharge Lines maximum 35 kPa for total length except liquid lines from
condenser to a receiver which shall be sized for a maximum liquid velocity to 30
metres per minute.
Liquid Line maximum13 kPa (receiver to evaporator)
6.16.5 GRADING OF PIPES
6.16.5.1 Refrigerant Piping
Refrigerant piping shall be graded where necessary and in
accordance with recognised trade practice to provide satisfactory
operation of the refrigeration plant under all load conditions
Sufficient traps and equalising lines shall be provided and pipe
lines shall be selected to achieve the following conditions:
Refrigerant Oil shall not be returned to the compressor in such
quantities as to cause damage.
Refrigerant Oil shall not accumulate in the evaporator coils or
elsewhere in system. Suction pipework connection shall be taken
from the side of the coil suction header as close to the bottom of
the header as practicable with suction ‘P’ traps at base of suction
riser.
Effective drainage of the condenser coils to the liquid receiver
shall be provided.
Refrigerant Oil shall be returned in a proper manner to the
compressor(s) sump(s).
Discharge refrigerant piping from compressors to remote
condensers shall be sloped away from the oil separator and shall
be either trapped adjacent to it and an inverted trap installed at the
top of the riser.
Careful sizing of vertical discharge risers is required with
compressors fitted with unloaders.
Size pipework on minimum compressor capacity step for a
minimum gas velocity of 5.5 m/s for vertical pipework and 2.8 m/s
for horizontal pipework. Do not exceed gas velocity of 20 m/s on
full capacity for noise and vibration control.
Liquid return piping from a remote condenser shall be sloped
towards the receiver and shall not incorporate any liquid traps.
Page 54 of 157 54

Where more than one evaporator is connected to the one
common suction, connection to the main suction pipe shall be
from above. Tee junctions shall sweep with the vapour flow and all
such joints shall be staggered.
6.16.5.2 Condensate Piping
All pipe work shall be graded as required by the duty. Condensate
pipework shall be graded to ensure that condensate moves
towards the appropriate trap. Heating hot water lines shall be
graded to ensure that pocketing does not occur and to facilitate
venting. Drain lines shall be graded to waste. Suitable traps shall
be installed at all air handling units sized to maintain a water seal
under operating pressures.
6.16.6 FLOOD BACK PROTECTION
6.16.6.1 Refrigerant Piping
Prevention of liquid flood back must be ensured by the following:
Proper setting of refrigerant expansion devices effectively sized to
limit refrigerant liquid from entering suction lines beyond the
evaporator outlet connection in addition to installation of liquid line
solenoid valves.
Note: Minimum superheat of 6 o K required.
Where the adjustment of the TX valve effectively reduces the
ability to utilise the complete coil surface area or where suction
line length is less than 10m overall from evaporator outlet to
compressor inlet, additional flood back protection shall be
provided by the use of a suitably sized suction accumulator.
Suction piping shall be sized so that the gas velocity shall not be
less than 2.8m/sec in horizontal lines and not less than 5.5m/sec
in vertical lines. An oil trap loop shall be installed at the bottom of
all vertical risers and horizontal lines shall be sloped towards the
direction of the compressor.
Particular care shall be taken in systems employing any form of
capacity reduction to ensure that suction gas velocities are
maintained at all times commensurate with restrictions within the
nominated line pressure drop. Where difficulties are discovered in
this regard double pipe vertical risers shall be installed.
6.16.7 PIPEWORK INSULATION
6.16.7.1 GENERAL
This section sets out the requirements for lagging of pipelines and
fittings and the treatment of pipe and conduit penetrations in cool
room.
6.16.7.2 DEFINITION
Insulation is required to all refrigerant pipe work in accordance
with the following guidelines. Refrigerant lines shall be defined
and grouped as follows:
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All suction lines shall be insulated and vapour sealed for the full
length of pipe.
Other forms of insulating may also be used at the approval of the
Woolworths Senior Refrigeration Engineer. In any event the
thickness and insulating values of any insulation shall be taken
into account to ensure sweating does not occur. Insulation shall
be applied to all suction lines fittings and valves regardless of
location.
6.16.7.3 INSULATION TYPES
TYPE A : EXPANDED RUBBER
Pipes shall be encased with proprietary closed cell expanded
rubber, sized to fit pipe diameter with wall thickness as outlined
below.
Insulation shall be self extinguishing with and subjected to the
tests as specified in AS1530.3-1999. Results of testing as
determined in the aforementioned document shall comply with the
following requirements:
Ignitability 0
Flame Propagation 0
Heat Evolved 0
Smoke Developed 3
Application BCA BCA
Regions 1-3 Regions 4-8
Sub Cooled Liquid 25mm 25mm
Suction Gas 19mm 19mm
Discharge Pipework
(Oil Separator to Heat Reclaim Coil)
13mm 13mm
Fix according to manufacturer’s instructions, being glued with
taped joints. All joints shall be sealed to maintain a continuous
vapour barrier on the outside of the insulation. The ends of the
insulation shall be sealed to the pipe.
Wherever possible, the insulation shall be applied without
‘splitting’ along the length of the tube. Where insulation is ‘split’,
the installer shall ensure that, along the length of the insulation,
the vapour barrier is restored by application of glue and rubber
tape in accordance with the manufacturers’ guidelines. Installers
shall pay particular care to the type of glue used so that the
aforementioned smoke fire indices are not compromised.
Type A insulation may only be used if sweating is not likely to be a
problem. It shall be the responsibility of the Contractor to ensure
that insulation does not condensate.
Insulation is not to be crushed and must have sleeves installed.
Where type ‘A’ insulation is installed outside of the building
structure, the insulation shall be protected from UV degradation
and bird attack with metal sheathing or similar.
TYPE B: BARE COPPER
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Type B installation shall be for pipe work that has no chance of
condensation forming. Discharge (other than lines between oil
separator and heat reclaim coil), Liquid Return and non-subcooled
liquid pies are applicable for this application.
6.16.7.4 Chilled water piping
Insulation shall be of FM Global approved material, of a thickness
to meet the requirements of the Building Code of Australia 2009.
Where
6.16.7.5 Hot water piping
Insulation shall be fibreglass with external lagging, of a thickness
to meet the requirements of the Building Code of Australia 2009.
6.16.8 LP GAS PIPES
By others
6.16.9 VALVES AND FITTINGS
6.16.9.1 General
Refrigerant piping, fitting and valves shall be in accordance with
AS/NZS 1677-Parts 1&2 and all the amendments current at the
date of tendering.
Under no circumstances shall a hand operated stop valve be fitted
in any main liquid line (or any section of the plant) which could
cause any section of the system to be isolated. Reductions in
piping, tee joints, 90° and bends shall only be commercially
available fittings.
Schwaged joints shall not be used in a non accessible position.
Compressor pipework shall be such that only 90° elbows are used
as the first fitting.
Balancing and throttling valves shall be Tour and Anderson STA-T
or STA-F or equal approved.
Water valves and fittings up to and including 50mm in diameter
may use screwed connections using appropriate components and
a sealing agent and Teflon tape as appropriate. Valves and fittings
over 50mm in diameter shall use approved machined flanges of
the correct material. Flanges shall generally be to AS 2129.
6.16.9.2 Piping and Fittings
The piping shall be securely fixed with saddle clamps (or
equivalent approved) to Unistrut, which shall be fixed to ceilings or
walls. Saddle clamps and fasteners shall be either galvanised or
stainless steel.
6.16.9.3 Valves
All valves shall be of globe type, key operated c/w sealed caps.
Where valves do not have direct capillary joint to the pipe, care
shall be taken to prevent distortion of the valve or power element
by heat.
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Valves in pipelines smaller than 25 mm shall be supported
independently of the line.
6.16.9.4 Sight Glass & Dryer
A Sporlon "Catch-All" dryer or as approved, and "See-All"
moisture and flow indicator with isolating stop valves shall be
installed in the liquid line from and adjacent to each liquid receiver.
6.16.9.5 Charging Valve
A charging valve shall be fitted between the receiver and liquid
line dryer.
6.16.9.6 Thermostatic Expansion Valve
An Emerson EX type (or equivalent approved) electronic
thermostatic expansion valve shall be installed into the
refrigeration circuit prior to each evaporator. Valve shall be
selected to match the evaporator design capacity.
Emerson EC3 superheat controller shall be installed in conjunction
with each EX valve. EC3 shall be wired in such a manner to
ensure valve automatically closes in event of power or control
failure. Pressure transducer, temperature probes shall be
installed on each refrigerant circuit to ensure correct operation of
valve at all load conditions.
6.16.9.7 Pressure Tappings
To ensure that liquid suction lines pressure drop maybe
adequately measured suitable pressure tapping points shall be
installed as follows;
� Liquid line after liquid receiver in the Plant Room
� Suction line adjacent to each evaporator coil
� Compressor suction and discharge service valves
� Discharge line at each condenser consisting of packed
and capped valve.
Note: Schrader valve shall not be used.
6.16.10 PIPE SLEEVES
Sleeves shall be placed in floors and walls (uninsulated) through which pipe lines
pass and extend 25 mm on each side. They shall provide a minimum clearance of
6 mm around the pipe or insulation.
Sleeves may be of pipe or formed from 1.6 mm gauge zincanneal sheet metal.
6.16.11 DRAIN PIPES
Drain pipes shall be run in copper tube or rigid P.V.C. from all equipment to floor
wastes provided by others. They shall be sized for their particular application but in
no case shall they be less than 32 mm.
Drains crossing floors shall be cast in the floor where applicable or chased in the
floor.
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6.16.12 PIPE IDENTIFICATION
Pipework and valves shall be clearly labelled and identified to AS 1345-1995.
Lettering on piping 50 mm in diameter, and smaller, shall be 13 mm high, and all
lettering on larger diameter piping shall be 20 mm high. Direction of flow shall be
clearly marked below each pipe label.
6.16.13 PIPE PRESSURE TESTING
Water and Gas Pipes
Pipework shall be tested as the project requires to ensure that no section
becomes inaccessible prior to a satisfactory test. All pipework shall be
hydrostatically tested unless otherwise specified. Hydrostatic testing shall be
carried out at 2.5 times the nominal operating pressure, or to 200 kPa. The
pressure set out shall be maintained for a minimum period of 24 hours, allowing a
tolerance for temperature fluctuations as necessary.
6.17 DAMPERS
At the end of the test, the piping shall be thoroughly drained and purged.
Refrigerant Pipes
After testing, as explained below, defective material shall be replaced and leaks
properly repaired. Caulking, taping or other temporary measures will not be
permitted.
The plant shall be tested for leaks 8 weeks after it has been passed for
commercial operation and again at the end of the maintenance period.
6.17.1 VOLUME DAMPERS
Volume dampers shall be fitted to all branches, take-offs and where shown on the
drawings for proper balancing of supply, return and exhaust air systems.
Single Blade Volume Dampers:
Volume dampers in ducts up to 350 mm deep shall be of single blade butterfly
type.
Construction of single blade dampers shall conform to latest edition of SMACNA
Duct Construction Standards.
Multiblade Volume Dampers:
Volume dampers in ducts over 350 mm deep shall be of the opposed blade type.
Dampers shall be manufactured from extruded marine grade aluminium, and shall
be suitable for velocity and pressure classification of ductwork systems.
6.17.2 NON RETURN DAMPERS
Non return dampers shall be manufactured from marine grade aluminium
complete with sealing strips, and shall be designed for rattle-free operation.
6.17.3 FIRE DAMPERS
Provide and fit fire dampers as required by all authorities having jurisdiction over
the works. Unless otherwise indicated fire dampers shall be minimum two hours
rated.
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The construction and fixing of fire dampers are to comply with AS 1682 and
AS/NZS 1668 Part 1.
Provide evidence that the prototype of the proposed fire damper has been tested
to the requirements of Section 5 “Testing” of AS 1682, Part 1.
Provide a thermally released link set for fire dampers to operate at 68°C and
located in accordance with AS 1682. Ensure easy access to the link for resetting.
Damper shall close in the direction of airflow.
6.17.4 BUTTERFLY VALVES
Butterfly valves used in air handling ductwork shall be lugged type with cast iron
body, stainless steel stem and disc, and EPDM liner and nylon bushing.
6.17.5 MOTORISED DAMPERS
Motorised damper motors shall be Belimo or equal approved by Woolworths
Senior mechanical Engineer
6.18 VARIABLE SPEED DRIVES
6.18.1 GENERAL
Variable speed drives shall be as nominated in section 17.12 or approved equal
specifically designed for HVAC pump and fan applications.
All variable speed drives shall be fitted with suitable chokes and / or sinusoidal
wave filters to suppress RFI / electrical “noise” and be capable of suppressing the
electrical “noise” generated within the fans.
The units shall be suited for modulating control of the rotary speed for pumps and
fans driven by standard asynchronous three-phase current motors.
Variable speed drive controllers shall be of the electronic variable frequency type
suitable for the control of three phase squirrel cage induction motors, having
operating characteristics compatible with the motor application.
The output shall be variable frequency of 1 to 50 Hz proportional to input signal to
an accuracy of 1%. The voltage/frequency ratio shall provide the highest efficiency
possible for a centrifugal load.
When operating at 50 Hz controller efficiency shall not be less than 95% and shall
not cause an increase in motor losses of more than 1.5%.
Wiring associated with the variable speed drives shall be steel wired armoured
cable.
Controllers shall be capable of operating at 50ºC and 90% RH (non condensing).
Radio interference of starters and generated supply power harmonics shall not
exceed limits allowed by the relevant authorities.
Controllers or associated contactors shall accept an input signal for thermistor
protection of the motor.
The following features shall be provided:
• Semi-conductor fuse protection (including spare fuses)
• Over temperature trip
Page 60 of 157 60

• Phase loss trip
• Power interruption (or power restoration) shall not damage the starter
• Controllers shall be capable of starting motors which are rotating
• LED indicators shall be provided for ON and RUN and for each type of trip
incorporated
• Motor current protection
• Over voltage trip
• Under voltage trip
• Remote trip through volt free contacts
• Speed control inputs through either 4 - 20 mA or 0 - 10V signals
Acceleration and deceleration times shall be adjustable between 1 to 150
seconds.
Where specified in the site specific scope of works, variable speed drives shall be
incorporated into system design. Drives shall be capable of full connectivity to
refrigeration controller via inbuilt communication protocol (MODBUS / 485 network
etc) including the following functionality as a minimum:
• Programming;
• Status (including fault, run, alarm, output etc);
• Control;
• Visibility through dial-in access;
Drives shall be installed into dedicated cubicles offering IP protection as specified
by the manufacturer of the drive. Additional components (contactors, overloads
etc) may be incorporated into the VSD cubicle at the discretion of the installing
contractor, however, the extent of this shall be at the approval of the Woolworths
Engineer.
6.18.2 WIRING
Refer to Section 8.8
6.19 ELECTRIC DUCT HEATERS
The use of electric duct heaters will not be permitted.
6.20 BASES AND PLINTHS
Bases shall be provided for all vibration-isolated equipment.
Bases shall:
• Have a rolled steel section frame.
• Have sole plates welded to the frame.
• Extend at least 100mm beyond the extremities of the equipment support pedestals.
• Be supported by vibration isolating mountings.
Concrete shall have a steel trowelled finish. Drilling of structural concrete for fixings shall
comply with the structural engineers directions.
6.21 EQUIPMENT EXTERNAL NOISE MEASUREMENT
Sound Pressure levels shall be the maximum of any measurement made one meter away
from any face of the unit under semi free filed conditions and worst case operating
conditions.
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6.22 DOWN DUCT NOISE
All equipment shall produce no objectionable pure tones within the occupied areas and
no atypical noise levels in the frequency bands outside those specified.
6.23 BOILERS
6.23.1 GENERAL
This section covers the supply and installation of a new heating hot water system
to serve air conditioning system appliances, comprising:
• All new piping, valves and fittings to reticulate heating water to heating
coils in air handling plant, as appropriate.
• New heating water circulation pump.
• Expansion tank and auto refill unit
• Venting of the system and individual components to atmosphere where
required or necessary.
• Automatic controls and electrics.
• Any other component or system necessary to ensure the safe proper and
efficient operation of both new and existing systems.
• Boiler to be located on condenser deck if external type unit
6.23.2 HHW BOILER – INTERNAL / EXTERNAL
HHW boiler shall be as nominated in section 17.14 or equivalent equal approved
complete with:
• Electronic modulating control
• Bronze headers
• Copper tubes
• Pressure and temperature gauges
• All necessary pressure and temperature safety controls including high limit
thermostat
• Valved drain
• Insulated casing
• Draft diverter
6.23.2.1 Efficiency
Boiler efficiency shall be not less than:
Rated capacity (kWheating) Minimum gross thermal
efficiency (%)
Less than 90 75
Greater than 90 80
6.23.3 BOILER FLUE – ATMOSPHERIC
Supply and install stainless steel grade 304 boiler flue 1 mm thick for the internal
HHW boiler. Provide a discharge cowl in accordance with Gas Authority
requirements.
The flue shall be thermally insulated with 25 mm thick high-temperature glasswool
insulation and be externally sheathed with 1 mm thick aluminium.
Provide all necessary flue supports, strays and fixings and weatherproof flashing
collar at penetration through roof.
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6.23.4 EXPANSION TANK AND AUTO REFILL UNIT - CLOSED
Supply and install a closed cell expansion tank of "Pneumatex" or equal approved
make adjacent to the pump. Tank capacity shall be sized for the total expansion
of the system installed, between mean operating temperature and 15°C, with a 5%
safety margin.
The tank shall be flexibly supported.
Supply and install a back flow prevention and refill unit of "Autoheet" manufacture
adjacent to the expansion tank to provide isolation of chemically treated water
from the domestic cold water system. The unit shall be installed and piped strictly
in accordance with Local Water regulations.
6.23.5 HHW EXPANSION VESSEL
All closed loop heating hot water loops shall be fitted with a closed steel expansion
vessel, factory sealed, with a butyl rubber liner and be Pneumatex, Zilmet or
approved equivalent. The vessel shall be installed complete with insulated makeup
water line, air vent, isolating valve, check valve, pressure relief valve, strainer, air
bleed and drain line.
6.24 FILTERS
6.24.1 GENERAL
Design of filters shall be in accordance with AS 1324 Part 1. Testing of filters shall
comply with AS 1324 Part 2. NATA certified test results shall be supplied for all filters
offered.
Attention is drawn to the requirement in the Maintenance Section for the provision of
spare filter media for replacement purposes during the currency of the maintenance
period.
Select the cell bank frame dimensions to suit the equipment or ductwork in which the
unit is to be fitted and provide an airtight sheet steel diaphragm where necessary.
Provide filter gauges across each set of filters, Filter Gauges shall be manual read
type with a range of 0 to 250 Pa or 0 to 500 Pa depending on required duty. These
shall be Magnahelic or equal. These shall have a digital output that is proportional to
the pressure drop and shall be connected to the control system for central monitoring.
Filter banks shall be made up of even filter panel numbers, in banks of 2 x 1, 2 x 2,
3 x 2, 3 x 3, 3 x 4 etc. Where uneven numbers of panels occur, provide an additional
panel.
Housings shall be installed in the air handler such that no air bypasses the filter.
Filter frames shall be epoxy coated to resist corrosion and to protect media from
snagging when being replaced during maintenance.
Note: Panel filters shall be provided to the outside air and return air ductwork.
The filters must be located in the AHU for ease of service and maintenance.
Filter media shall be:
• Moisture resistant up to 100% relative humidity.
• Fire Class F1 (self extinguishing) to DIN 53438 (or equivalent).
• Supported to prevent collapse.
• Replaceable without the use of special tools.
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• Resistant to fungal and bacterial attack
• Made so that it does not shed fibres into the air stream
Fibreglass media is not acceptable.
Each filter shall be sized so that they are capable of filtering the design air quantity at
the maximum effective face velocity specified and its performance characteristics
shall meet the requirements specified hereafter for the specific filter type.
Filters shall be installed in accordance with manufacturer's recommendations
complete with all accessories necessary for their proper performance. All filter
connections to adjoining equipment, panelling or support framing shall be sealed
airtight to prevent any air bypassing the filter media.
Filters shall be provided with front or rear access holding frames where insufficient
side access is available. Where more than two filters are required to be positioned
side by side in a filter bank a sliding channel may be provided only where the above
criteria does not apply.
Where possible filters should be “Sucked” onto the support frame to improve the seal
between filter and support frame.
6.24.1.1 TYPE 1 FILTERS
(Pleated type for specified Roof Top Packaged Air Conditioning
Unit, Air Handling Unit & Duct-Mounted Filters)
Filter banks shall achieve the following criteria when handling the
design air quantity:
• Initial resistance not greater than 50 Pa, measured across
the filter bank as installed (i.e. including the effects of any
surrounding blanking plates).
• Filter bank face velocity not greater than 2.5 m/s.
• Minimum average efficiency 40% F5(EN779).
• Minimum dust holding capacity at 125 Pa: 300g per
600mm square module.
6.24.1.2 TYPE 2 FILTERS
(Deep bed type for specified Air Handling Units)
Filters shall be extended surface disposable dry media selfsupporting
wedge shaped pocket type (i.e. without wire media
supports). The filter media shall be sealed effectively to the filter
frame.
Filters shall be supplied complete with a two piece stainless steel
or equivalent corrosion-resistant holding frame.
600 MM DEEP, MEDIUM EFFICIENCY
Filter banks shall achieve the following criteria when handling the
design air quantity:
• Initial resistance not greater than 50 Pa, measured across
the filter bank as installed (i.e. including the effect of any
surrounding blanking plate).
• Filter bank face velocity not greater than 2.5 m/s.
• Minimum average efficiency 60% or F6 (EN 779).
• Minimum dust holding capacity at 125 Pa: 800 g per 600
mm square module.
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6.24.1.3 TYPE 3 FILTERS
(Metal Viscous - Kitchen Extract)
Filters shall be modular, in frames complete with handles, to allow
easy removal for cleaning.
Grease filter banks shall achieve the following criteria when
handling the design air quantity:
• Initial resistance not greater than 30 Pa.
• Filter face velocity not greater than 2.5 m/s.
• Final resistance: 40 Pa.
6.24.1.4 TEMPORARY FILTERS
Provide temporary filter material over all filter banks to protect
permanent filters from soiling during construction and simulate
dirty filter condition during commissioning.
6.24.2 FILTER PERFORMANCE
All air-conditioning units shall be fitted with filters to remove particulate matter from
the air stream. The performance of the filters shall meet the following minimum
requirements.
6.24.2.1 Built up AHU’s
All units shall be fitted with Type 2 filters.
6.24.2.2 Package and Fan Coil units
All units shall be fitted with Type 1 filters.
6.24.3 PRE FILTERS
20mm roll-media or similar pre-filters shall be installed to protect the main filters
during construction. These shall be removed when all construction and external
site works are completed.
The pre filter shall have a performance rating equivalent to the old F4 (AS 1324.1).
Page 65 of 157 65

7.0 DUCTWORK
7.1 SCOPE
All air handling system including ductwork, acoustic and thermal insulation and fire
dampers, shall comply with AS/NZS 1668 and all applicable statutory requirements.
As a general rule ductwork shall NOT be painted internally, where visible through grilles
paint matt black internally.
All ductwork systems shall be complete with transitions, bends, tees, supports, dampers, ofsets,
flexible connections, take-offs and similar fittings necessary for the balancing and full
operation of the air distribution system.
The ductwork shall be designed to ensure the overall static pressure of the system and its
components does not exceed 550Pa at the main supply air fan.
7.2 DUCTWORK CONSTRUCTION AND INSTALLATION
7.2.1 GENERAL
Construction and installation of ductwork shall comply with AS 4254 - ‘Ductwork
for Air-handling Systems in Buildings’.
Duct velocity for supply, return and minor exhaust air:
3m/s behind side blow registers on exposed ductwork, the greater of;
7.5m/s and 1.0 Pa/m for riser ducts,
6m/s and 1.0 Pa/m for branch ducts
4m/s and 1.0 Pa/m for small take-off ducts mounted within the ceiling.
Duct velocity for kitchen exhaust: 9 to 10m/s.
Insulating locations of ductwork:
Insulation shall generally be as per BCA section J deemed to satisfy requirements.
Additional insulation shall be required cold aisle return air.
7.2.2 MATERIAL
Unless specified otherwise (for special systems) ductwork material shall be prime
quality lock forming galvanised steel, Grade G2 or G3 to AS 2338 with Z275
coating to AS 1397.
All sheet metal ductwork shall be manufactured from lock forming quality Lysaght
Galvabond sheet steel or equal. Galvanising shall be: 380gms/m2.
7.2.3 DUCT SEALING
Unless specified otherwise, ducts shall be sealed in accordance with Table 2.2.1
of AS 4254.
Ductwork below 500 Pa classification shall also meet Seal Class C.
Leakage rates of unsealed ducts shall not exceed the rates indicated in Table
2.2.2 of AS 4254.
Ductwork systems at Pressure Class 750 and less shall be leak tested by hand
feel and audio checking of all joints. All obvious leaks shall be sealed with
appropriate and approved sealant.
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7.2.4 DUCTS EXPOSED TO WEATHER
Ducts exposed to weather shall be fabricated using the next metal thickness.
Horizontal Exhaust ventilation ductwork exceeding 800 mm wide shall be crossbroken
each 1200 mm length to ensure the rain water does not collect on the top
surface of the duct. All circumferential and longitudinal joints to be sealed air and
water tight; using sealing compounds not affected by direct sunlight. Standing
flanged type circumferential joints are to have hat sections riveted over the top and
side joints and sealed as for the all the joints above.
Horizontal supply and return air conditioning ductworks (continued) exceeding 800
mm wide are to be internally insulated 25 mm thickness greater than specified for
within the ceiling space and covered on top and sides with separate G.I. cover
spaced 50 mm minimum from duct external face and pitched on the top cover from
centre of duct to edge to ensure water does not collect on top of cover. All
circumferential and longitudinal joints to be sealed air and water tight; using
sealing compounds not affected by direct sunlight.
Flexible connections shall be protected by weather covers.
7.2.5 ROUND DUCTS
Construction of round ducts shall be in accordance with Table 2.4 of AS 4254.
Unless otherwise indicated, all branch take-offs shall be 45° lateral fitting complete
with volume dampers, flexible duct connections shall be 90° tee fitting complete
with volume damper.
7.2.6 OVAL DUCTS
Construction of oval ducts shall be in accordance with Table 2.5 of AS 4254.
Exposed oval ducts shall have neat appearance with internal reinforcement.
7.2.7 VERTICAL DISCHARGE OR INTAKES
Vertical discharge or intake ducts that are exposed to the weather shall be
internally drained with a copper drain line to the nearest drain point.
All such ducts shall be graded to the drain point and shall have all joints and
seams sealed watertight.
7.2.8 KITCHEN/DISHWASHER EXHAUST DUCTS
Ductwork construction shall comply with AS/NZS 1668.
Unless otherwise indicated, duct material shall be minimum 1.2 mm thick
galvanised steel for kitchen exhaust ducts, 1.0 mm stainless steel for dishwasher
exhaust ducts.
Access panels shall be provided as per AS/NZS 1668.
7.2.9 TOILET EXHAUST DUCTWORK
Ductwork construction shall comply with AS/NZS 1668.
All toilet exhaust ductwork must be treated with a suitable sealing compound to
ensure that the duct is air tight and leak proof.
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7.2.10 DUCT HANGERS AND SUPPORTS
Duct hangers and support systems shall be in accordance with AS 4254. Where
required provide seismic restraints in accordance with AS 1170.4.
Hanger straps (only used where approved) shall be galvanised steel.
Hanger rods, trapeze angles, channels, brackets and fasteners shall be
galvanised steel.
Trapeze angles, channels and brackets shall be cut from full length sections.
Short lengths of sections welded together to form a longer length shall not be
used.
Exposed duct supports shall be treated and painted with an approved colour.
(Refer Painting Section of this specification).
Fixing the support systems to building structure shall be approved. Generally:
Fixing to structural steel shall be by beam clamps or similar fixing. No drilling or
welding is allowed.
Fixing to masonry or concrete shall be by masonry anchors.
Fixing materials shall be galvanised steel.
All exposed hangers and supports shall be manufactured corrosion resistant hot
dip galvanised sections.
7.2.11 FLEXIBLE DUCTS
Flexible ducts shall conform to AS 4254 and the BCA.
Unless otherwise indicated, flexible ducts shall have acoustic lining comprising
50 mm thick thermally bonded polyester with an R 1.0 rating (tested to AS 4859.1)
or equal internal insulation wrapped around block permeable fabric core and
covered with aluminium laminate. Insulation shall comply with the requirements of
section J of the Building Code of Australia.
Ducting shall have a fire test rating of 0,0,0,3 to AS 1530.3.
Flexible duct lengths shall not be more than 3 metres. Over 3 metres, galvanised
circular ductwork shall be inserted, with no more than 2 metres of flexible duct at
the end joining the galvanised circular duct to the terminal device (ceiling outlet,
intake etc.).
Connections of flexible ducting to spigots shall be held in place by duct ties applied
directly over the duct helix and under the insulation.
Flexible ducting shall be supported every 2 meters for ducts over 2 meters long
using 50mm wide strap hangers securely fixed.
Minimum bend radius shall be as per the manufacturers recommendation but in all
instances should not be less than twice the diameter.
7.2.12 DUCT THERMAL MOVEMENT AND VIBRATION
All ducts shall be carefully designed and provided with all necessary anchoring
and flexible connections to prevent damage to either the ducts or the building
structure due to thermal expansion and/or contraction of the ducts and to obviate
Page 68 of 157 68

transmission or vibration from any motive or noise generating equipment such as
fans, air handling units and mixing boxes.
All anchor points and flexible connections shall be shown on the shop drawings
and specific approval shall be obtained from appropriate authority before
proceeding with the installation of any anchors or fixings to the building structure.
7.2.13 FLEXIBLE CONNECTIONS
Flexible connections shall be air-tight, water-tight and comply with the
requirements of the relevant sections of AS/NZS 1668, Part 1, Fire Precautions in
Buildings with air-handling systems.
The flexible material shall be securely attached to galvanised strip for ease of
application.
Flexible connections shall be fitted to isolate vibrating equipment from ductwork.
The connections shall be arranged to permit the removal and replacement of the
connection without disturbing the ductwork or plant.
The metal parts of connected equipment shall be separated by not less than
100 mm and be installed with sufficient slack to compensate for free movement of
fans on spring vibration isolators.
7.2.14 CLEANING AND PROTECTION
All ductwork shall be fabricated under cover, delivered to site and stored in a
weatherproof and dry area. Open ends of duct sections shall be covered with
plastic sheet or tarpaulins until required for installation. Special care shall be given
to internally insulated ducts, silencers etc. for protection against dust and moisture.
Ductwork shall not be installed unless adequate cover and protection is available
to protect it from possible construction damage and the elements.
Prior to and during installation, ducts shall be thoroughly cleaned out and shall
have all ends covered in an approved manner to prevent ingress of dust and
general building debris.
7.2.15 PITOT TUBE OPENINGS
Provide test openings in the ducts in the following locations:
• Adjacent to the inlet and discharge of all fans.
• Downstream of all balancing dampers.
• Upstream and downstream of all heating coils
Locate the holes such that the air flow across the duct is sufficiently even to
enable accurate temperature and flow measurements to be taken to permit correct
balancing and adjustment.
Test holes shall be 25 mm dia. and be fitted with a rubber plug. Provide one spare
rubber plug for each test hole.
Where the duct is externally insulated ‘cone’ down the insulation around the test
hole. Where the insulation has a vapour barrier seal the barrier to the duct around
the test hole.
The number and positions of Pitot tube openings to be provided at each location
shall be as follows:
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For all ducts having diagonal dimensions or diameters up to 300 mm provide one
opening at the centre-line of the duct.
For all ducts having diagonal dimensions or diameters more than 300 mm but less
than 600 mm provide two openings at 1/4 points on either side of the duct centre
line.
For all ducts having diagonal dimensions or diameters 600 mm or larger, provide
four openings at 1/8 points on either side of the duct centre line and on each side
of the duct.
7.2.16 SEALING AND FLASHING
All ducts protruding through walls and floors and exposed to view shall be
provided with neat galvanised steel sealing frames fixed to ducts and walls or
floors as appropriate.
All external installations and roof penetrations shall conform to Section 3 of
AS 4254.
7.2.17 SMOKE DETECTORS
Refer to fire services drawings for location of duct mounted smoke detectors.
Cut openings in ductwork where required to facilitate installation of smoke
detectors to these units and seal openings afterwards.
Supply and install minimum 300 mm x 200 mm access panels in the ducts
adjacent to each smoke detector to facilitate future servicing.
7.2.18 DUCT ACCESS PANELS
No part of the panel shall project into airstream and when it is shut shall be flush
with the inside surface of the duct.
Access panels shall be provided where required for inspection and service
purposes. Access panels will be provided for but not limited to heating elements,
dampers, controls and for general maintenance and inspection purposes.
All access panels shall be clearly labelled to indicate services served.
7.2.19 ACCESS DOORS
Access doors shall be complete with hinges and handles.
Access doors shall be provided for air handling unit, including fan, plenums, filter
housing(s) and mixing sections and where shown on the drawings.
Provide doors with a minimum of three hinges and lockable quick release catches
with handles providing easy operation (sash catches, bolts, piano hinges or
catches requiring a screw driver for operation will be rejected)
Provide doors with air tight gasket seals. If lift-off panels are proposed, D-handles
shall be fitted to facilitate removal.
7.2.20 BURGLAR BARS AND BIRD SCREENS
Bird screens shall be fitted to all fresh air intake ducts, all louvres and all relief and
exhaust fan and air openings supplied under this Contract that occur in the
external fabric of the building.
The bird screen shall be 12 mm x 12 mm x 1.6 mm diameter galvanised woven
wire mesh in rigid galvanised frames or similar approved.
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In addition to the bird screens, burglar bars (by Builder) shall also be fitted to
external openings having a clear opening of 300 mm x 300 mm and larger.
On all exhaust and smoke exhaust fans, the burglar bars shall be located below
the fans to maintain service access.
The burglar bars shall be manufactured from 10 mm diameter galvanised rods
spaced at not more than 150 mm centres.
The burglar bars shall be welded into a support frame and be securely fixed to the
building fabric, either on inside face of wall or just below roof line.
7.2.21 PLENUM BOXES (CUSHION HEAD BOXES)
Unless otherwise indicated, all supply air diffusers shall be mounted on plenum
(cushion head) boxes or equal approved.
Where insulated plenum boxes or cushion heads are specified, raw edges of
insulation shall be fully sealed. Insulation shall be thermally bonded polyester
32 kg/m3 density (min) and shall be black faced with an R value to match the
supply air ducting insulation.
7.2.22 REFLECTIVE SURFACES
Reflective surfaces visible to view, behind supply air outlets, return air grilles and
the like shall be painted matt black.
7.2.23 INSULATION
All materials used in the installation of insulation shall have the following
resistance properties when tested to AS 1530 Part 3 "Test for Early Fire Hazard
Properties of Materials".
Ignitability Index 0
Spread of Flame Index 0
Heat Evolved Index 0
Smoke Developed Index 2
Where air mixing and filter plenums are accessible for filter changing, the plenum
floor insulation shall be covered with 1.2 mm thick galvanised steel sheet
sufficiently reinforced and supported for rigid construction. The plenum walls and
ceiling insulation shall be faced with perforated galvanised steel sheet.
Cold aisle return air duct work shall have a minimum of 50 mm internal insulation.
Where required additional external insulation shall be applied to ductwork located
within the ceiling space.
Ductwork insulation shall comply with Section J of the BCA.
7.3 DIFFUSERS, REGISTERS, GRILLES AND LOUVRES
Supply and install all diffusers, registers and grilles shown on the drawings.
All diffusers, registers and grilles shall be of extruded aluminium and shall have durable
powder coat finish, with the colour directed by Woolworths. All internal surfaces shall be
painted matt black.
Provide butterfly dampers with locking quadrants on duct take offs except for areas with
solid plasterboard ceilings.
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Provide face operated volume adjustment dampers on all diffusers except where a ductmounted
volume control damper is installed upstream of the individual diffuser or register.
Outlet velocity, net airway, and design of the diffusers shall be such as to give
satisfactory air distribution without draughts or noise nuisance.
Diffusers, registers and grilles shall be as noted on the drawings.
All diffusers, registers and grille sizes shown are based on the above manufacturer’s
data. Any alternative equipment offered should be checked against this data to ascertain
if the peculiarities of such equipment make them suitable for use.
Diffusers registers and grilles shall be as follows:
7.3.1 CEILING DIFFUSERS
Ceiling diffusers manufactured from extruded aluminium shall be installed, as
required, and may be 1 way, 2 way, 3 way or 4 way as appropriate and shall be
louvred core style to give required direction of blow as appropriate, with ‘draftless’
air distribution without noise.
Louvre faced type with OBD (when required) and insulated cushion heads above.
Note: ‘Swirl’ type diffusers may be used as an alternative to achieve improved
mixing of air in heating mode.
7.3.2 SIDE BLOW REGISTERS
All side blow registers, whether supply, return or exhaust shall be double
deflection type unless noted otherwise.
The register frame and core shall be such that no screw heads are visible on the
face or the register after fixing.
7.3.3 EXHAUST GRILLES
All exhaust grilles shall be aluminium egg crate type unless noted otherwise.
The grille frames and cores shall be such that no screw heads are visible on the
face or the grilles after fixing.
“Non-Rattling” balancing dampers shall be installed behind grilles as required.
7.3.4 RETURN AIR GRILLES ON VERTICAL SURFACES
All return air grilles mounted of vertical surfaces shall be ½-chevron blade type
unless noted otherwise.
The grille frames and cores shall be such that no screw heads are visible on the
face or the grilles after fixing.
7.3.5 RETURN AIR GRILLES ON HORIZONTAL SURFACES
All return air grilles on horizontal surfaces shall be egg crate type, unless noted
otherwise.
The grille frames and cores shall be such that no screw heads are visible on the
face or the grilles after fixing.
Details of all changes in size and type of outlet shall be noted on the tender
documents and stated in the tender submitted.
Where egg crate grilles are used on the return air of small in-ceiling fan coil units,
the egg crate grille shall be mounted in a hinged frame with the filter media fixed to
the back of the grille. This is to allow for easy filter cleaning during maintenance
without having to access the ceiling space.
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7.3.6 EXTERNAL AIR INTAKE & EXHAUST LOUVRES
Supply and install horizontal blade weatherproof air intake and exhaust louvres
where shown on the drawings. Louvres shall be single or two-stage type as
indicated on the drawings.
Louvres shall be manufactured from extruded aluminium with natural anodised
finish.
Intermediate supports and stiffeners shall be provided to prevent blades from
vibrating and from sagging.
Fix vermin proof corrosion resistant screens to the internal face of all air intake and
exhaust louvres.
7.3.7 LINEAR SLOT DIFFUSERS
Diffusers shall be Holyoake or approved equal. Each length shall be completed
with mitred corner end-caps and made up of active and inactive sections, butting
together with hairline cracks between sections. Inactive sections shall be blanked
off.
7.3.8 ROUND DIFFUSERS
Diffusers shall be Holyoake or approved equal.
Page 73 of 157 73

8.0 ELECTRICAL
8.1 GENERAL
This section covers the supply and installation of all necessary electrical equipment,
including starters, thermal overloads, circuit breakers, switches, control gear and all
wiring for the safe and satisfactory operation the electrical plant and equipment
associated with the air conditioning, ventilation, and mechanical services systems.
This section should be read in conjunction with the standard electrical drawings,
switchboard layouts and label schedule found in the appendix section of this
specification.
Any person or persons engaged on the electrical installation shall hold a current electrical
contractor's license, or an electrician's license under the Electrical Contractors and
Electricians Licensing Regulations.
8.2 REQUIREMENTS
All equipment supplied and all work done shall be in accordance with this specification
and the S.A.A. Wiring Rules and any other S.A.A. publications covering design,
manufacture or installation of electrical equipment and to the requirements of the local
Electricity Supply Authority. The latest issue or amendment of the relevant S.A.A.
publication shall be used.
All electric motors shall conform to the requirements of Australian or New Zealand
standards.
The switchboard manufacturers are to be selected from the approved list as outlined in
the section 8.6.5.
The switchboard manufacturer shall have a type test certificate in addition to Part Type
Test Assembly certificate from switchgear supplier to which the design, manufacture and
performance of the switchboard shall conform. The installation Contractor shall have an
Electrical Contractors license and employ only licensed electricians on Site.
Uniformity of type and manufacture of each item of equipment, fitting or accessory shall
be maintained throughout the plant.
The electrical contractor shall ensure that electrical loads are balanced across all supply
phases to within 5%.
8.3 INTERRUPTION TO SUPPLY
Should the work require shutting down of any part of the electrical equipment or the
whole plant, this shall be done at such times as are designated by the Purchaser.
8.4 DIAGRAMS
The electrical system shall be designed in line with the intent of the electrical drawings at
the rear of this specification. It shall be deemed as the responsibility of the contractor to
ensure the design of the electrical system is completed in a manner so the plant operates
to the requirement of Woolworths.
On completion of the installation a diagram of the complete installation and wiring circuit
shall be supplied to site as follows:
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• One (1) laminated copy to be mounted on the wall of the plantroom in a manner that
allows personnel to review the design. Drawings shall be A2 size;
• One (1) copy placed inside the door of the switchboard;
• One (1) copy included in the operating and maintenance manual;
• Electronic (PDF and DWG) copy supplied with the Mechanical ‘AS Built CD’;
8.5 INCOMING SUB-MAIN
Sub-mains of sufficient size shall be brought and connected directly to mechanical
switchboard.
‘Standard Kit’ circuit breaker at the Main Switchboard shall be sized as follows:
• 1 off 400A – 3 Phase
The Mechanical Services contractor shall confirm to the Woolworths Project Manager
within one week of being awarded the project, the required isolator size and the mains
size that shall be brought to the Main Distribution Board. Termination into the Main
Distribution Board shall be by others.
8.6 SWITCHBOARDS
This section outlines the manufacture of electrical Switchboard Control Assembly (SCA)
for the housing of mechanical services electrical and control equipment, including
starters, thermal overloads, circuit breakers, switches, control gear and associated wiring
for the reliable operation of equipment associated with the air conditioning, ventilation,
and mechanical services systems.
It is the intention of this section of the specification that all new SCA is based on a
generic design as detailed within this document – this is to ensure a consistent
installation and a common standard throughout the Woolworths network.
For new installations, the SCA shall be supplied and shall conform to this section of the
Mechanical Services Specification. For store refurbishments the supply shall conform to
Woolworths tender request.
The switchboard/control assembly shall comprise four sections:-
• Main Switch Section: is for termination to the segregated main isolator is Form 2
construction in accordance with AS3439:2002.
• Distribution Section: houses distribution circuit breakers with its chassis behind an
escutcheon.
• Contactors and Overload Section: The control panel section housing all contactors,
protective devices, relays etc for the individual operation of each mechanical-system
and alarm panel.
• Electronic Controller Section: Is for housing proprietary system controllers, I/O cards,
associated transformers and associated components.
The S.C.A. shall comply in all respects with this specification, AS3439:2002 (and
subsequent amendments) (previously AS1136) and the accompanying drawings and to
the following characteristics:-
• Test voltage for switchgear and control gear assemblies - 1000 V.A.C. Indoor
stationary cubicle type;
• Form 2;
• Rated short-time with stand current 25KA for 1 sec;
• Degree of protection IP54;
• Designed for a supply voltage 415 volts A/C;
• Rated input current to be full load of connected equipment;
Proof of performance of the board shall be substantiated by switchboard manufacturers’
submission of a type test certificate from a qualified testing laboratory.
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The design shall provide for full discrimination and cascading of the circuit protective
devices.
The section for switching of sub-system, circuitry shall be labelled 'Authorised Personnel
Only", this section shall not allow any person operating switches and circuit breakers to
come into contact with live parts.
All other sections of the SCA shall be labelled as indicated on switchboard drawings and
labelling details shown in section 18.1.14 & 18.1.15 .
The electrical supply for all air conditioning and mechanical services equipment shall
emanate from the MSSB.
8.6.1 MAIN SWITCH SECTION
Main isolator circuit breaker. This breaker shall be provided with bus-bar flags on the
line-side for the connection of the sub-mains. The bus-bars shall be supported by
substantial insulated brackets and spaced to allow ease of termination of the submain
and to meet the requirements as previously specified.
A main neutral link to which the sub-main neutral shall be connected and each
system neutral.
An approved power monitoring device to be fitted to each incoming submain to the
SCA, capable of remote monitoring through the alarm monitoring system (see also
9.4.4.4).
8.6.2 DISTRIBUTION SECTION
A distribution section with a bus-bar, rated to suit the full load current of the S.C.A and
to meet the requirements as previously specified, to connect to the circuit breakers
protecting the refrigeration systems control equipment.
Cabling from the circuit breakers shall be run between the switchboard section and
the control cubicle to conform to the requirements of this specification and AS3439
(and subsequent amendments).
Circuit breakers and RCD’s for each system for short circuit and overload protection
of all motors, defrost heaters, sump heaters, drain heaters, fans, head fans, lighting
and control circuits.
8.6.3 CONTACTOR & MOTOR CONTROL SECTION
Equipment to provide phase failure protection, sequential starting and delayed
starting after overload, oil failure or safety pressure, cut-out, re-set.
Motor Start Fuses (on existing projects), D.O.L. contactor, overload unit and having
under voltage and a phase failure relay for the control of each compressor motor.
Phase asymmetrure monitoring shall be provided on incoming mechanical services
submain (one off for overall mechanical system) and shall stop operation of all threephase
motors including compressors and condenser fans on detection of phase
failure event. Corresponding indication of Phase Failure shall be indicated by
electronic control and alarm system.
In the section labelled 'Authorised Personnel Only' the circuit breakers protecting
items of equipment shall be labelled with permanently affixed labels to indicate
connected equipment. .
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Where reduced voltage (part wind) start is incorporated into system design, the
Contractor shall ensure that two overload devices are installed per compressor.
All other relays and equipment for the proper functioning of the plant as specified.
8.6.4 DESCRIPTION OF EQUIPMENT
• Major equipment shall be selected in accordance with items shown in section
14.0.
• Contactors shall be manual reset operation.
• All relays and control switchgear should be rated and operated at 240Volts
except where required for safety reasons as in case of Trax Oil level switches
etc. Preferred control voltage for extra low voltage circuits is 24V AC. Probes
and sensors are to be operated and rated as per respective electronic control
supplier requirements. Relay bases shall be of the totally enclosed, moulded
type.
• All electrical equipment to be installed shall be of sufficient amperage capacity
with a margin to suite the plant offered.
• All equipment to be installed shall operate within the manufacturer's ratings.
Motor starters shall be selected for AC3 rating.
• Approval to use alternative equipment to that indicated must be obtained in
writing.
• Approved cable terminations, lugs or pin types shall be used throughout.
"Lugged" type terminals shall be used on all cables 6mm square and above. Pin
type crimped terminations shall be used on cables less than 6mm square.
8.6.4.1 CONNECTIONS
All cables unless enclosed shall be neatly arranged and loosely tied
and supported neatly, where necessary.
All control cables to and from the switchboards shall terminate at an
approved terminal block. No more than two cables shall terminate at
any one terminal point. Power cables for Compressor and
Condenser motors may be directly terminated on respective
Contactors/over-loads.
The switchboard shall comprise a factory made and assembled, free
standing floor mounted front connected enclosure with switchgear
and control gear arranged as to Woolworths current standard.
On Site assembly of switchboard shall not be permitted.
The switchboards shall be totally wired to terminations as detailed
above such that connections terminate at location and terminals
designated and marked for the appropriate cables.
All wires and cables (unless otherwise specified or subject to
statutory fire rating) shall be V75 thermoplastic insulated copper
stranded of Australian manufacture.
Access for conduits and ducts shall be provided by removable
aluminium gland plates.
Access to the front of the switchboard shall be by means of sheet
metal doors fully dust sealed.
Page 77 of 157 77

8.6.4.2 CONSTRUCTION
The overall cubicle structure shall be fabricated from first quality,
minimum 2mm gauge cold reduced, sheet steel to AS1595 (and
subsequent amendments). Sheet steel shall be Zinc coated to
minimum 10 micron thickness. The cubicle shall be of welded metal
type construction.
The base shall be minimum 75mm x 40mm x 10mm M.S channel.
The base channel shall form a continuous box section around the
base of the switchboard there shall be no openings made in this
base such as those used for slinging.
Doors over 1 meter long shall be stiffened to provide sufficient
rigidity. All doors are to be provided with chrome plated Pintle hinges
with stainless steel pins.
All door handles / locks shall have a 3-point locking mechanism.
Door handles shall be a flush latch lift and turn locking unit. Locks
using an external tool to operate shall be replaced.
Panels and doors supporting equipment which require cut outs in the
sheet metal shall be suitably braced to offset any reduction in rigidity
caused by the cut outs to prevent undue movement or vibration
resulting from operation of equipment within the switchboard or that
mounted on the panels or doors.
The electrical compartments shall have interior lighting and
mechanical ventilation operated by a door switch as indicated in the
attached electrical diagrams. Switchboard lighting & fans shall be
installed to the ‘Contactor and Overload’ and ‘Electronic Controller’
Sections only. Mechanical ventilation shall be activated when doors
closed, as indicated on attached electrical diagrams.
The front of the switchboard must incorporate a fascia board
consisting of a back engraved Perspex panel which shall carry Run
(green) and Fault (red) lights for all equipment items. The
equipment items referred to here are;
• Fans (Supply, Exhaust and the like, excluding Condenser
Fans)
• Packaged air conditioning equipment
• Heaters (Including boilers, heat pumps etc)
• Compressors and individual safeties e.g. Motor O/L,
HP/LP, Oil Safety.
• A lamp test button shall be provided on this fascia board.
A 'fire signal activated' (red) lamp shall also be provided
on this fascia board.
External MSSB fascia shall contain the following switches for the
general control of the system:
• Master Control Switch: This on-off switch shall shutdown
the entire air conditioning system as well as all
mechanical ventilation systems, when switch is in the off
position.
• Compressor Sequence Changeover Switch: This switch
changes the sequence of the compressors. The switch
shall be labelled Compressor 1 - Compressor 2.
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• In installations with four or more separate compressors,
provision must be made to sequence change each
individual compressor for equal running time.
• Air conditioning Selector Switch: This switch labelled 'Air
conditioning/Vent' enables the main air conditioning plant
to be run in an A/C auto or ventilation modes. All exhaust
systems remain unaffected by this switch.
• Compressor Hours Run Meters: One for each
compressor
• Duct electric heater shunt trip circuit breaker must be
installed so that ‘Re-set’ can be carried out with all MSB
doors closed
• The Internal MSSB fascia test switches shall be mounted
on a hinged panel. Test switches shall be provided for
every item of equipment within the switchboard and they
shall be traffolyte, labelled 'Test/Off/Auto. Fire Alarm
Relay shall also be labelled.
8.6.4.3 PAINTING / POWDER COATING
All of the sheet metal work shall be degreased using an approved
solvent. The metal conditioner shall remove oil and greases. Finish
paint work shall comprise at least two coats of a two-pack Urethane
paint applied to a thickness of at least 75 microns.
Powder coating shall be of even thickness of at least 70 microns.
Paint/powder coat colours shall be electric orange on all external
surfaces and white interior, gear trays, escutcheons and equipment
panels.
8.6.4.4 LABELLING
All circuits and equipment (including circuit breakers, relays,
controller equipment and the like) shall be clearly identified by
means of engraved labels as per the attached detail list (see
sections 18.1.14 and 18.1.15).
8.6.5 MANUFACTURERS
Labels shall be affixed adjacent to the equipment they identify and
under no circumstances shall they be fixed to ducts or duct covers or
other removable components.
All labels shall be of the stand-off type and be readable without the
need to disturb wiring or equipment and shall be mechanically
fastened. The label shall refer to the area being served by the
particular control switch or indicator light, e.g. “Donut Exhaust”.
Abbreviations must not be used.
All incoming and outgoing terminals shall be permanently identified,
all cable terminating at these terminals shall have ferrules with
identical markings.
Switchboards may be manufactured by any of the manufacturers nominated in
Section 17.2:
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8.7 FIELD WIRING & CABLING INSTALLATION
Field wiring and installation shall comply with the following:
Isolating switches for essential services shall be provided with lock on switches, i.e.:smoke
exhaust fans. All wires and cables for essential services are to be fire rated MIMS
or Radox to statutory requirements.
All wiring to field equipment or control devices shall be run in conduit unless there are
more than 6 cables used in which case cable trays shall be used.
AHU lights (4 off) shall be 36W weatherproof fluorescent and shall be installed in each of
the AHU conditioner housing sections and switched from a position adjacent the AHU
main access door. The switch shall be labelled AHU Housing Lighting.
All wires and cables except where otherwise specified shall be type V75 thermoplastic
insulated or thermoplastic sheathed. All wiring shall be copper stranded cables of
Australian manufacture.
All wiring shall be installed using the loop-in system. Joining of cables shall only be made
at fittings or accessories. The use of connectors shall not be permitted except where
required by the SAA Wiring Rules for the connection of heat resisting cables and as may
be directed by Woolworths Engineer.
All circuits shall include a separate earth and neutral, which originates from the same
switchboard as the circuit active conductors.
All conductors in a conduit shall be drawn in at the one time and be capable of being
easily withdrawn from the conduit if required. Particular care shall be taken with the
installation of cables to avoid twisting. Wiring passing through walls, floors and areas
where abrasion may occur shall be sleeved.
All wiring in which abrasions of the insulation occur will not be accepted and shall be
replaced by the contractor at their own expense.
T.P.S cables shall not be installed where open to view, except when run in dedicated
cable trays and only in stock rooms and plant rooms.
Where T.P.S cables are installed in accessible locations concealed from view or above
removable ceiling tiles they shall be secured to the roof framing, slab or softwood battens
with clips, straps, clamps or saddles or catenary wire. Cables shall be supported at a
maximum 1200 mm spacing with cables secured to prevent any strain on the
connections.
T.P.S cables shall not be run in locations where the cables cannot be easily withdrawn
for rewiring purposes. Where T.P.S cables are installed in inaccessible locations such as
cavities, stud partitions, non removable false ceilings etc; the cables shall not be clipped
or secured.
Where T.P.S cables are concealed within cement rendered wall or concrete slabs, the
cables shall be enclosed in conduit.
T.P.S cables installed in locations which are subject to mechanical damage shall be
adequately protected
T.P.S cables shall be separated from other services cabling. Cables shall not be laid
directly onto ceiling tiles, nor be secured to ceiling air ducts, hangers or sprinkler pipes.
Supply and install separate dedicated services cable trays, ducts and catenary.
Separate earth wires shall be installed originating at the switchboard for each sub-circuit.
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Earth wires shall be so arranged so that the continuity of the earthing conductor is not
broken if an accessory is removed. In particular, where an earth wire is looped into an
accessory it shall be held together by crimping or other approved means prior to insertion
in the accessory.
8.8 VSD INSTALLATION – FIELD WIRING
All cables connected between VSD and driven motors where VSD’s are not fitted with LC
filters shall be fully shielded throughout the entire cable length as follows:
• Approved screening methods are either individual metal conduits for each VSD, or
individual 4 core & ECC braid screened cables for each motor;
• No discontinuity in the metal conduitor screen is permitted throughout the entire cable run;
• The metal conduit/screen shall be used exclusively as E.M.C shielding and shall be
connected to an earth terminal at the VSD end;
• A separate earth wire shall be run to equipment for protective earthing purposes.
Cable entries to VSD control cabinets shall be made through the gland plates built into
the cubicle, fitted with cable glands and sealed to maintain the (IP54) protection rating of
the VSD control cubicle. No site penetrations, drilling, hole cutting or any other
alterations to cabinets, other than gland plate penetrations, shall be undertaken without
the written approval of the manufacturer.
Cable length from the VSD to motors shall be kept to as short as practical, in accordance
with the drive manufacturers’ instructions.
All other cables such as mains and control cables shall be segregated and/or routed
separately from VSD output cables.
8.9 CONDUITS, CABLE TRAY & LADDERS
8.9.1 CONDUITS
The minimum size of conduit shall be 32mm dia for power cables and 25mm for data
cables.
All conduits shall be run concealed wherever possible in walls, floors and ceilings.
Where exposed to view they shall be run parallel to doors, structural members and
corridors and as directed on Site by the Purchaser.
The draw in system of wiring shall be used throughout. Draw in boxes shall be
placed at all outlets and no intermediate boxes shall be permitted unless approved by
the Purchaser.
The wires will be drawn from point to point through draw in boxes. Boxes shall be
suitably sealed.
Deep type outlet boxes with the outer face flush with the finished surface of the
concrete shall be used for embedded conduits.
Conduits emerging from underground in stock areas Plant Room or the like shall be
protected to a height of 2 metres by a 2mm thick sheet steel hat section. The hat
section shall be of sufficient width to adequately protect cabling from side impact.
The sheet steel protection shall be securely fixed to the wall and have a finished paint
coat of electric orange. Treatment of the sheet metal shall be as specified for the
switchboard.
Flexible conduits shall be used from ducts or rigid conduit as final connection to
equipment and motors. Approved conduit connections and fittings only shall be used.
Page 81 of 157 81

Alarm cables shall be segregated from power and control cables.
Conduits shall be connected to duct by screwed conduit and bushed fittings, the
holes for conduit connections being made by means of machine type hole saw or
cutter, to provide a near and correct size diameter hole.
Where ducts change direction sufficient bending radius shall be allowed for easy
installation of cables.
Where ducts penetrate fire walls or where required by Authorities fire barriers and fire
proofing shall be provided by the Contractor. Ducts shall be used for wiring in the
Plant Room with flexible conduit droppers to motors.
8.9.2 CABLE TRAY
Where cables rise vertically, the contractor shall support these on cable cleats or
clamps, the cable tray or ladder being securely fixed to holding brackets as specified
herein.
Cable tray and cable ladder routes shall be checked to ensure that they do not clash
with other services.
Cable trays shall be manufactured from steel, folded edge not less than 20mm high
and be of 0.8mm thickness with punched slots. Minimum cable tray size shall be
150mm.
Fixing cable tray to building structure shall utilise Gripple suspension system using no
smaller than 2mm wire. Supports shall be fixed at intervals not exceeding 1200mm.
Edges shall be folded with a radius. Slots shall be free of burrs and sharp edges on
the side to which cables are installed.
Where the cable tray changes direction, sufficient bending radius shall be provided to
allow easy installation of cables. The midway point of the arc of the change in
direction shall be supported by a threaded rod.
Where cables leave the cable tray, plastic sleeves shall be provided on the
metalwork.
Cables shall be supported with nylon ties at 1000mm centres for vertical runs and
2000mm centres for horizontal runs.
Where trays penetrate fire walls or where required by Authorities, fire barriers and fire
proofing if the tray shall be provided by the Contractor.
Holes in the tray and edges where cables pass over shall be sleeved.
Cabling on cable trays in outdoor areas shall have covers fitted to protect against UV
and predator attack.
8.9.3 CABLE LADDER
Cable ladder shall be sized to support the cables, which it is to carry plus 20% space.
It shall be of no less than medium duty. Bend, tees and similar accessories shall be
factory fabricated.
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Cable ladder shall be supported from heavy duty cantilever brackets or suspension
rod systems as appropriate, spaced in accordance with the manufacturer’s
recommendations and secured with hold down clamp.
The suspension rod system shall consist of 10mm minimum Zinc passivated rods,
nuts and Unistrut support channel brackets or suspension supports and shall be
provided in accordance with the manufacturer’s recommendation or every 3 metres
whichever is the least.
8.9.4 LABELLING OF DUCTS AND CABLE TRAYS
All ducts, cable trays and cable ladders shall be clearly labelled “MECHANICAL
WIRING ONLY” at 6 metre intervals. Where cable tray used, the label shall be
fastened to a flat metal section secured to the underside of the tray.
8.10 CONDENSERS & OIL COOLERS
Where remote multi-circuited condensers are installed, all condenser fans shall be
separately wired to ensure that in the event of an overload situation, the affected motor only
shall stop.
8.11 COMMISSIONING
The correct function and operation of the installation shall be demonstrated as part of the
acceptance tests including in detail the connections and operation of the high temperature
alarm system.
8.12 DEFECTS LIABILITY & MAINTENANCE
The warranty requirements of section 1.9 shall also apply to the electrical section of the
specification.
The electrical Sub-contractor or the nominated service agent shall inspect the installation on
a six (6) monthly basis for the duration of the free service period in conjunction with and
coinciding with the refrigeration technician. The Sub-contractor shall ensure that all
ventilation fans and filters are cleaned and electrical connections are tight.
At the completion of the Defects Liability period, the electrical sub-contractor shall conduct
thermal scan of all refrigeration switchboards and provide report to the Refrigeration
Engineer and Mechanical Services Asset Specialist. Any irregularities identified by the
thermal scan shall be rectified with no cost to Woolworths.
8.13 RESIDUAL CURRENT DEVICES (RCD’S)
All lighting circuits, GPOs and anti-sweat circuits shall be protected by Residual Current
Devices.
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9.0 CONTROLS
9.1 GENERAL
• The CPC controls application guide (refer section 19.0) shall be referred to when
installing and commissioning HCAC controls.
• Control system recycling at start-up shall be provided.
• A time delay on start up of main plant items shall be provided.
• Where current limiting starting is required by the local authority, then closed
transition auto transformer (high temperature protection) shall be provided.
• A fail safe control system shall be provided, including the fire trip system.
• All exhaust fans as well as the air conditioning system shall shut down upon
receipt of a fire signal by de-(energising the control circuit. The shut down trip
shall be in the form of a relay energised by 1 external 24 Volt supply installed and
connected by fire contractor. The relay will be provided in the board by the
mechanical contractor and all terminals shall be coloured red. Plant reset shall be
effected at the fire alarm panel by resetting the sprinkler pressure switch.
• Remote normal fault indication A/C status lamp located over door in cashiers
office, shall be provided as per detail drawing (ref section 18.1.7). When the
system is operating normally the green light shall be illuminated and when fire
trip or any item of the mechanical services is in fault the red lights shall be
illuminated.
• Mount one double general purpose outlet incorporating earth leakage protection
inside the control section of MSSB adjacent to test switch panel. Provide internal
switchboard lights to illuminate all internal components and controlled by an
isolation switch adjacent to the test switch panel
9.2 TEMPERATURE / HUMIDITY CONTROL
Temperature and humidity sensors for trading area air conditioning plant are to be
located within the store at 2.2 metres above floor, behind face of columns within 10 m of
the main return air grille.
Note:
� Minimum of two sets of sensors required for stores greater than 2000m 2 . Additional
sensor to be located centrally within the space.
� Humidity sensors not required if store does not have refrigerated cases.
Office amenities and liquor areas shall be controlled locally by either proprietary VRF/V or
CPC controller. Proprietary controllers shall be linked to the main CPC controller
providing full visibility of control functions to CPC in addition to having ability to control
temperature/humidity set points and on/off scheduling.
Control of chilled water temperature when installed shall be precise PID type controlling
the leaving chilled water temperature.
9.3 ENERGY MANAGEMENT
9.3.1 GENERAL
The controls, ductwork, and equipment shall be configured to enable the HVAC
system to always operate in the most economic mode. In addition the energy
management capability shall also determine the HVACs effect on the whole store
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energy consumption in particular refrigerated display cases. The system shall have
the capability to override is internal economiser mode to achieve the lowest energy
consumption for the store.
The contractor shall provide in addition to the Camel load calculation an estimated
annual energy consumption based on historic BOM data.
9.3.2 STRATEGY
a) Air Distribution - Minimum fresh air to be introduced into system.
• Use of CO2 sensor to determine minimum fresh air to trading area
• Kitchen Exhaust system to only operate when respective kitchen
equipment operating (30 min run on timer also required)
• Make up air provided to specific kitchen exhaust hoods.
• Fresh air make up to main AHU to automatically balance changes in
quantities of air being exhausted through kitchen exhaust hoods
b) Load Management
• Economy Cycle (refer section 3.6)
• Night set back and air purge (Occupied / Unoccupied operation mode).
• Dehumidification control (Supermarket& Liquor brands only)
• Load predicative capability.
c) Mechanical Plant Management
• Suction temp (SST) control enabling SST to float from 6.0 o C to 7.5 o C
when dehumidification is not required.
• Heat reclaim from Refrigeration Plant
9.3.3 CONTROL ENABLERS
The following enablers are mandatory and are in addition any other controls
specified or required to achieve the energy management outcomes:
• Enthalpy algorithms.
• Variable Air Volume Control – AHU VSD, Modulating dampers
• Input from refrigeration systems signalling availability of heat reclaim.
• Inputs from refrigeration plant and store energy metres. (Supermarket&
Liquor brands only)
• Store and ambient temperature and humidity sensors.
• Input from kitchen exhaust systems
• Input from trading area CO2 sensor
• Suction pressure transducers
• Electronic expansion valve
• AHU air pressure sensors
9.3.4 ENERGY MONITORING
The following energy consumption data shall be monitored using the CPC
controller:
• Main A/C Compressors
• Main A/C Condenser Fans
• Main A/C Evaporator Fan
• Total Mechanical
Data shall be expressed in kWhr per hour which shall be stored for 12 months on
the system.
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Note: Also refer to section (9.4.4.4)
9.4 REFRIGERATION PLANT CONTROLS
9.4.1 SAFETY CONTROLS
All compressors regardless of the type of system in which they are commissioned
shall be fitted with mechanical safety controls. These controls shall comprise of the
following as a minimum and shall be incorporated into system design in addition to
any electronic control system installed:
9.4.2 HP/LP SAFETY CONTROLS
• Mechanically adjustable HP/LP pressure control switch. Controls shall be
Penn P77 series (or other approved). Controls may be individual controls or
a dual pressure control.
• The HP/LP cut out shall be connected to the compressor side of the service
valves so that it cannot be isolated from the compressor.
• The HP/LP cut out shall be connected to the compressor using flexible hose
only. No rigid connections shall be permitted.
• Auto reset HP with 15 min time delay restart.
− This time delay may be the same as that for delayed restart after
overload.
− Shall register a notice to the alarm and monitoring system only with
no alarm to be registered.
− Shall be commissioned and set in alignment with requirements of
AS1677.2: and with respect to compressor design pressures
− (Compressor DP x 0.9).
• Auto reset LP.
− Shall be set to prevent the refrigeration system pulling vacuum;
− Shall be commissioned and set with respect to the system suction
pressure. Suggested setting is system suction pressure minus
35kPa.
9.4.3 OIL SAFETY CONTROLS
9.4.3.1 COMPRESSORS INCORPORATING OIL PUMP
− Compressors incorporating an integral oil pump, an oil pressure
differential failure switches shall be connected.
− Oil safety switch shall be Danfoss MP54 type or otherwise approved.
− Oil safety switches shall be of the manual reset type.
− All oil failure switches shall be connected to the high temperature
monitoring system which in turn records and signals an oil pressure
alarm.
− This device does not remove the requirement for an oil level
regulator.
9.4.3.2 COMPRESSORS NOT INCORPORATING OIL PUMP
− Compressors not incorporating an oil pump, additional oil
management systems need be incorporated into system design.
− An optical oil indicating device shall be incorporated.
− All oil level controls shall be connected to the high temperature
monitoring system which in turn records and signals system oil
alarm.
− This device does not remove the requirement for an oil level
regulator.
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9.4.4 ELECTRONIC ALARM AND CONTROL SYSTEMS
9.4.4.1 GENERAL
A high temperature alarm and monitoring system shall be supplied
and installed to all mechanical systems and form part of the
mechanical contractors’ scope of works.
Each rack system shall be supplied with dedicated components for
control and alarm functions.
Interconnection of individual control/alarm systems shall only be
permitted for communication, monitoring and alarm annunciation.
The mechanical contractor shall supply communication and heat
reclaim signal wiring to the Refrigeration control panel. Termination
of this wiring shall be by HVAC electrician.
Note: CPC systems shall communicate via shielded Cat-5 cable
terminated at a 5-port hub, located in the Low-Temperature
Switchboard.
Note: Where CPC is the Mechanical Controller, the Heat Reclaim
signal shall be sent via the controller global network;
The system shall be supplied and installed with all necessary
probes, transducers, interfaces, connecting wires and connection to
a telephone point for a complete installation.
All control systems shall be of a make and type approved by
Woolworths. At the time of issue, approved control manufacturer is
the:
• CPC Einstein E2.
9.4.4.2 CPC ECHELON CABLE
Where a CPC control system is being installed, the contractor shall
ensure the correct echelon wiring is used. The specified Echelon
Cable is ET3801-107. No alternatives shall be accepted under any
circumstance.
9.4.4.3 SYSTEM CONTROL
• Compressor start/stop control including unloader and
compressor staging control;
− Suction pressure control, monitoring and cut-out
with delay restart;
− Compressor logic control to minimum 4 suction
groups;
− Suction float control;
• Condenser fan control;
− Floating head pressure control, monitoring and
cut-out with delay restart;
• System Defrost control;
− Capable of achieving defrost controls for up to 12
defrosts/24 hours either electric or off cycle;
• Phase loss monitoring;
Page 87 of 157 87

9.4.4.4 SYSTEM MONITORING
Regardless of the installation and system configuration, the following
shall be incorporated into the mechanical monitoring system:
• kWh monitoring of incoming mechanical submain;
• Main A/C Condenser
• Main A/C Supply fan
• Miscellaneous Monitoring
− Monitor compressor discharge temperature.
Probe to be located no more than 150mm from
each compressor service valve. Probe to be
wrapped with insulating tape;
− Monitor suction return vapour temperature. Probe
to be located on each suction return stub and be
located no more than 150mm from compressor
service valve or suction header;
− Monitor condenser air on temperature. Probe to
be located no more than 150mm from air-on side
of coil face.
− Monitor liquid return temperature immediately
before liquid receiver.
− Monitor store temperatures
− Monitor ambient temperature and humidity (one
probe not to be located near the condenser deck
and positioned in a manner so the probe is not
affected by direct sunlight or reflective heat).
− Monitor store humidity (Supermarket& Liquor
brands only)
− Measure air temperatures across heat reclaim coil
where installed (Supermarket& Liquor brands
only)
• Suitable detectors shall be incorporated to measure and
immediately record an alarm condition at each of the
following points
− Loss of oil pressure at each compressor
− Loss of electrical power supply to compressor
rack;
− Bursting disc over pressure
− Low liquid level
− HP/LP Safety
− Condenser fan fault
9.4.4.5 LOGGING HISTORY
Logs of connected probes and equipment shall be kept in controller
memory and be available through dial-up connection as follows:
• 12 Months (hourly readings):
− All kWhr meters information
• 4 Weeks (5min log intervals):
− Pressure Transducers
− Ambient and Store Temperature Probe
− Store Humidity
− VSD running percentages
− Refrigerant leak detector readings
− Heat Reclaim and condenser split operation
− Stepper and water valve opening percentages
Page 88 of 157 88

9.4.5 ALARMS
Fault or over temperature situation in the following instances shall generate an alarm
through the Refrigeration/Mechanical control network. Details of the alarm shall be
communicated through to the Staff Interface PC (supplied by the Refrigeration
Contractor).
9.5 COMPRESSORS
• HP/LP Safety (per compressor);
• Motor Overload / Fault (per compressor, supply / exhaust fan). Note –
Condenser fans monitor fault per condenser only;
• Loss of oil pressure (per compressor);
• Bursting disc over pressure;
• Low liquid level (system only);
• Fan Failure;
9.5.1 OPERATION AFTER POWER OUTAGE
All compressors shall be wired in a normally off mode in case of control system
failure.
Compressors having an external phase protection module with an integral delay start
timer fitted shall have timers set to stager compressor re-starts.
Compressors utilising internal phase protection module or having an external phase
protection module without an integral delay start timer shall have additional delay
timers wired into the main control circuit to stager compressor re-starts. Timers shall
be set at two second intervals
9.5.2 CAPACITY CONTROL
9.5.2.1 RECIPROCATING COMPRESSORS
Where practically possible, capacity control shall be fitted to
compressors operating in a multiplex configuration. Such capacity
control shall preferably be by the fitting of a solenoid to the
compressor cylinder head unloading one bank of cylinders on fall in
suction pressure. Provision shall be made to ensure that the
compressor loads on a regular basis on up to 10 minute adjustable
cycles.
9.5.2.2 SCROLL COMPRESSORS
For parallel compressor systems, capacity control shall be achieved
by use of variable speed drive fitted to largest compressor.
Additional stages of capacity control shall be achieved by cycling
other compressors within pack.
9.5.2.3 SCREW COMPRESSORS
Capacity control shall be achieved by utilising either infinite step or
VSD controllers.
9.6 CONDENSER FAN CONTROL
The electronic alarm and control system (ref 9.4.4) shall be utilised to ensure reasonable
system discharge pressures are maintained. The condenser fans on all systems shall cycle
using the aforementioned electronic condenser fan control.
All systems offered shall incorporate “Floating Head” design, i.e. the saturated condensing
temperature (S.C.T.) shall be allowed to “float” according to ambient conditions. The
minimum S.C.T. allowable shall be restricted by the compressor manufacturers printed data
Page 89 of 157 89

and recommendations. Particular attention shall be paid to component selection and design,
to ensure correct system operation at both design condition and minimum S.C.T.
No third party condenser fan control systems shall be used with the exception of stand-alone
condensing units.
The control and monitoring system shall be interlocked with the condenser fan overload
device and monitor fan ‘faults’ with respect to detail in section 8.10.
9.6.1 INDIVIDUAL FAN SWITCHING
This control method shall be limited to existing systems only.
Systems using this method of control shall have individual output relays assigned for
each condenser fan.
In the event of control system failure, all condenser fans shall revert to off condition
until the system can take control.
The electronic condenser fan control shall include for the rotation of the lead
condenser fan.
9.6.2 EC / VARIABLE SPEED CONTROL
This control method shall be used wherever possible on new installations and
refurbishments. The Mechanical Alarm and Control system shall control fan speed at
all times and have ability to display fan speed and status at all times.
In the event of control system failure, condenser fans shall operate at the selected
speed until the control system can regain control.
When EC fans are in use, the control signal shall be wired to each fan with each fan
acting as a ‘master’.
Fans shall be set up to operate in Day / Night mode with a lockout fan speed of
680rpm applying when ambient temperatures are less than or equal to +35°C. An
option to run at a higher than normal day mode speed up to but not exceeding
1080rpm shall apply when ambient temperatures exceed +35°C.
9.7 OFFICE, AND AMENITIES AREA AIR CONDITIONING UNITS
Wall mounted thermostat and manual override control (set for 2 hrs).
Systems shall be linked to the main HVAC control system (CPC where temperature settings
and run times can be programmed).
9.8 MECHANICAL VENTILATION
9.8.1 BAKERY & HOT CHICKEN EXHAUST AND MAKE UP AIR SYSTEM
Operation of supply & exhaust fans to be interlocked to operation of ovens by
current switch on the submain for the respective oven. See attached generic
electrical wiring schematics for additional information on interlock.
Run & Fault indicator lamp to be installed adjacent the oven by Mechanical
Contractor. Lamps to be 24V maximum. Lamps to be installed on Clipsal
Chemical Grey mounts to match switchgear in the preparation areas supplied by
the Light & Power Electrical contractor.
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The Contractor shall commission operation of the fans so they operate for twenty
minutes following the end of the cooking cycle. The current switch will need to be
commissioned to register between ‘standby’ and ‘operational’ current in order to
register the end of cooking / cleaning cycle.
9.8.2 DONUT EXHAUST SYSTEM
On - Off switch for fan to be installed adjacent to the Bakery hood by the Electrical
Contractor in accordance with the standard electrical Drawings. This switch is on
common stainless steel plate with the oven and interlocked bakery exhaust
system.
The Contractor shall install wiring to this location connections (termination) by the
Electrical Contractor.
9.8.3 HOT CHICKEN EXHAUST SYSTEM
If more than one exhaust hood is installed for hot chicken exhaust application, one
(1) fan shall be supplied per exhaust hood in order to minimise unnecessary
exhausting of conditioned air.
9.8.4 HOT CHICKEN MAKE UP AIR SYSTEM
A singular supply air system shall be installed, regardless of the arrangement of
the exhaust systems. A VSD complying with section 6.18 and automatic dampers
shall be incorporated and commissioned to supply the required volume of make-up
are to the operational hood only.
9.8.5 DISHWASHER EXHAUST SYSTEM
The dish washer hood exhaust fan shall be controlled by means of a true off delay
timer installed within the dishwasher by the manufacturer. When the machine is in
use the timer will energize, the fan will then operate during the wash cycle and for
an additional time period once the machine has completed its cycle. Once the set
time has elapsed, the timer will reset and consequently be ready for the next cycle.
Mechanical contractor shall provide wiring to the dishwasher fan isolation switch
located adjacent to the work station phone shelf (ref drawing M16). Switch
supplied by the electrical contractor.
Mechanical contractor shall provide wiring from voltage free terminals (provided in
enclosure at dishwasher) to fan contactor.
Waterproof conduit shall be used from dishwasher to enclosure located on wall
(enclosure supplied by electrical contractor complete with pull wires).
9.8.6 FISH EXHAUST
The fish exhaust fan shall run whenever the fish area lighting is switched on. Light
switch shall be appropriately labelled by the Electrical Contractor.
The coil of the exhaust fan contactor shall be wired through a set of contacts in a
relay supplied and installed by the Electrical Contractor.
The relay will be housed in a separate enclosure close to the air conditioning
switchboard and shall be energised on the closing of the light fitting switch.
The enclosure shall be labelled to indicate that two supplies are within the
enclosure.
The fan shall be wired within the air conditioning switchboard so that on operation
of the fire trip the fan will cease to operate.
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9.8.7 STOCK ROOM EXHAUST SYSTEM
Remote On/Off switch with green neon indicator light shall be located in the Stock
Room area near the Service Desk.
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10.0 PAINTING AND LABELLING
10.1 GENERAL
For the purpose of uniformity the following colours are preferred for the painting of the air
conditioning equipment.
10.2 PAINT COLOURS
Compressors As supplied by manufacturer
Supply Fans As supplied by manufacturer
Shell & Tube Condensers As supplied by manufacturer
Condenser
Piping
Water Pump & Emerald Green
(To Dry Coolers)
Air Cooled Condensers As supplied by manufacturer
Chilled Water Pumps & Piping Blue
Refrigerant Piping Yellow
Drain Piping Black
Exposed Electrical Conduits &
Ducts
Orange
Switchboard Casing Orange
Switchboard Doors Orange
Conditioner Access Doors White
The baked enamel finish on pre manufactured proprietary equipment, whether plant room
or roof mounted, will be accepted as the finished colour.
All reflective surfaces behind return air grilles, exhaust air grilles, supply air outlets and all
louvres shall be painted matt black.
10.3 LABELLING
All pressure gauges, controls and control equipment, instruments and all valves shall be
labelled and be clearly identified as to function.
Each refrigerant circuit shall be identified with a system number.
Condensers, liquid receivers, compressors, cooling coils, and associated pipe work shall
each be fitted with the identifying number signifying the system.
All labels shall be engraved laminated plastic with black letters on a white background.
Lettering shall be not less than 12 mm high.
Electrical equipment shall also be labelled as defined in Section 8.0 Electrical.
All roof equipment under this specification shall also be suitably labelled with lettering of
at least 25 mm high.
An engraved laminated plastic label detailing the plant stop/start and fault reset
procedures shall be fixed to the face of the air conditioning switchboard.
All labels shall be mechanically fixed using screws or rivets.
Label shall only be fixed to permanently mounted equipment. Labels fixed to any
removable or demountable protective guard, access panel, electrical duct covers or the
like will be rejected.
ONLY ENGRAVED LAMINATED PLASTIC LABELS MECHANICALLY FIXED TO
PERMANENT FIXTURES WILL BE ACCEPTED.
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11.0 COMMISIONING, TESTING, MAINTENANCE AND SERVICE
11.1 COMMISSIONING
On completion of the works the Contractor shall fully commission all components forming
part of the Contract Works.
After full commissioning and before any tests are witnessed by Woolworths. The test
results must to be forwarded to Woolworths. The commissioning data shall include but
not be limited to:
• Results of pressure and vacuum testing of each refrigerant circuit.
• That control wiring and systems have been checked and are fully operational.
• That all safety controls and high temperature safety cut-outs are fully operational.
• That not less than the design quantities are being attained.
• That a general air balance including a final air balance (i.e. a thermal balance) has
been completed. This shall include air volumes at each diffuser.
• That the outside air quantity has been adjusted to required design flow rate.
• That heat reclaim system is operational.
• That calibration of all automatic control equipment has been completed.
• That not less than the design condenser water quantity has been attained. (Dry cooler
system when installed).
• That not less than the design chilled water temperature and water flow has been
attained. (Chilled water system, when installed).
• That the design and as approved suction and discharge pressures have been
achieved.
• That the approved evaporator superheat has been attained.
• That the full load current of each electric (continued) motor has been checked and is
within the name plate rating.
• That any abnormalities, vibration and noises have been corrected.
• That all defects highlighted during the construction phase have been rectified.
The Contractor shall ensure that these tasks have been carried out and provide
certification that the recorded results satisfy the full design intent of this design Brief and
the Schedule of Technical Data.
If the air conditioning system is commissioned other than during summer then the
refrigerant charge must be checked and topped up and capacity checks carried out again
before peak cooling demand is experienced. Summer commissioning check is required.
11.2 CONTROL SCHEDULE
The contractor shall commission the air conditioning and mechanical ventilation system
as per the following schedule. Also refer to the Controls Application Manual section 19.0
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11.3 TEST WITNESSING
The air conditioning and mechanical ventilation systems shall pass any test deemed
necessary by Woolworths.
Woolworths shall be present to witness the tests. The Contractor shall record all test
results and shall forward a copy of the final results to Woolworths.
A copy of all test results shall also be included in the Operating & Maintenance
Instructions.
The Contractor shall make all arrangements for the tests and shall provide all instruments
and gauges necessary for the tests, at no extra cost.
Woolworths will not witness any tests until the installation has been fully commissioned
and commissioning data has been previously presented to Woolworths for comment.
Possible tests may include, but may not be limited to the schedule of tests shown in
Appendix C.
The Contractor shall give at least seven (7) days prior notification of a suitable date for
testing. Failure to provide the commissioning data and/or prior notice of a suitable date
for testing will result in the Certificate of Practical Completion being withheld.
11.4 PUTTING INTO OPERATION
When the work has been completed or taken over by Woolworths and placed into
commercial operation the Contractor shall make available a skilled supervisor to start up
and run the equipment for a minimum of one day.
The Contractor shall liaise with the Woolworths Refrigeration Engineer to arrange testing
of heat reclaim system with the Woolworths appointed refrigeration contractor. Suitable
notice to be given.
A Contractors’ representative shall instruct Woolworths staff on site in the operation,
control and maintenance of all of the installed plant.
A representative of either the Contractor or the appointed service agent for the project
shall be in attendance on the opening day of trading.
11.5 MAINTENANCE AND SERVICE
11.5.1 GENERAL
The mechanical contractor shall allow in the tender for maintenance and servicing
from date of practical completion to the end of the maintenance and defects
liability period, to comply with requirements of AS 3666, Local Authority and any
other statutory body having jurisdiction.
Maintenance, in addition to rectification of faults, emergency service and carrying
out of capacity tests as required, shall also include a minimum of 12 regular
monthly visits for routine maintenance.
Routine maintenance shall be deemed to be the regular maintenance of
equipment as recommended by suppliers including but not limited to the following
items:
• Check and adjustment of all belt drives and direct couplings.
• Oiling and greasing of all bearings as necessary including fans.
• Check of operating setting and calibration of all controls including heaters.
Page 96 of 157 96

• Check of operation of all electrical switchgear, including setting and
operation of motor overloads.
• Check of all motors for temperature rise, operating current leakage.
Record all parameters.
• Cleaning of evaporator coil basins and flushing of drains.
• General (continued)
• Check and replace dry filter media as required in air conditioning plant and
make-up air systems (if applicable)
• Clean grease filters.
• Check, test and report on fire alarm relays and smoke fan exhaust
systems (if applicable).
• Check SST/SCT
• Check Winter/Summer set points
At the conclusion of each maintenance visit, a check list of items serviced shall be
provided to the Store Manager and the service log book shall be completed and
signed, and within seven days a report, together with a copy of check list shall be
forwarded to the Store Manager, with cc copy to Woolworths.
11.5.2 DOCUMENTS
The contractor shall provide the following documents to the Woolworths EMS
Dept:
• Project Scope of works
• All commissioning details, documents, schedules and reports.
• As built drawings in PDF and DWG electronic formats.
11.5.3 END OF WARRANTY SERVICE
(Woolworths Standard Form to be used)
On the final visit at the end of the Defects Liability Period the maintenance works
shall include but not be limited to the following items:
• Re-tension of all switchboard connections, and check all motor starters,
relay controls, motor overloads and all system safety controls.
• Fully leak test refrigerant systems.
• Check and certify fire damper operation.
• Replace dry media filters in all air conditioning plant air handling units and
make-up air systems (if applicable).
• Clean outside air, return air, and exhaust air outlets.
• Clean grease filters.
• Clean coils, trays and flush drains.
• Check, test and report on fire alarm relays and smoke fan exhaust
systems (if applicable).
• Check SST/SCT
• Check Winter/Summer set points
11.5.4 RECTIFICATION OF DEFECTS
All defects shall be promptly rectified, with final inspection defects completed
within one (1) month of site visit. Retention moneys or Bank Guarantee will not be
released until 12 correctly dated and completed maintenance service reports have
been received. The defects liability period and equipment warranties will be
extended until the final inspection has been completed.
On completion of final defects, retention monies or bank guarantee will be
released.
Page 97 of 157 97

11.5.5 QUALITY CONTROL
All air balancing shall be to NEBB standards using NATA certified equipment and
the commissioning personnel shall have successfully completed and accredited
NEBB agents.
All flow rate quantities shall be balanced to within 5% of the design values.
Recorded data shall be submitted on standard NEBB report forms and they must
bear the signature of the person who recorded the data. The recorded data shall
also include the identification details of the calibrated equipment used and copies
of their current test certificates.
Page 98 of 157 98

12.0 OPERATING AND MAINTENANCE
12.1 GENERAL
On completion of satisfactory performance tests three (3) sets of Operating &
Maintenance Instructions shall be compiled.
The Operating & Maintenance Instructions shall include a full description of the
equipment and sufficient instruction for the efficient operation and maintenance of the
installed plant.
The Operating & Maintenance Instruction manuals shall be neatly prepared in vinyl
covered hard backed folders with stamped lettering on the front cover as follows:
OPERATING & MAINTENANCE INSTRUCTIONS
FOR
AIR CONDITIONING & MECHANICAL SERVICES
FOR
WOOLWORTHS LIMITED
(ADDRESS AS APPROPRIATE)
12.2 INCLUSIONS
The Operating & Maintenance Instruction Manual shall include:
• As built drawings as 2 hard copies and one disk copy for in-house record.
• Schematic Electrical Control Diagrams
• Commissioning Test Records
• A complete list of all components used in the installation Manufacturers information
and parts lists.
• Service schedule
• Description of the air conditioning plant and control systems
• Equipment operating procedures
• Equipment test results
• Stop start and fault reset procedures
Note: An engraved laminated plastic label showing the stop/start and fault reset
procedures shall also be fixed to the face of the switchboard. (See also Painting &
Labelling).
12.3 PLANT MAINTENANCE LOG BOOK
In addition to the Operating & Maintenance Instructions, the Contractor shall also supply
a vinyl covered hard back loose leaf folder complete with suitable forms to serve as a
Plant Maintenance Log Book.
The forms shall be of a type acceptable to the local authorities having jurisdiction and
shall be suitable for written entries covering both routine and preventive maintenance
activities.
Page 99 of 157 99

As – installed drawing
Provide a single plan at 1:100 scale indicating plan view all ductwork runs and equipment
locations. This drawing shall be plastic laminated and mechanically fixed to plantroom
wall in a nominated position
12.4 METAL BOX
A metal box manufactured from galvanized sheet metal complete with a hinged lid shall
be supplied and permanently fixed to a wall in the plant room.
The metal box shall be adequately sized to accommodate a complete copy of the
Operating & Maintenance Instructions and the Plant Maintenance Log Book.
12.5 DISTRIBUTION
Following acceptance of the Operating & Maintenance Instructions the Contractor shall
arrange for distribution to the locations hereunder:
• One (1) hard copy to be located in the plant room on the site, as detailed above.
• One (1) hard copy to be given to the Woolworths store manager on the site.
• One (1) disk copy to be forwarded to Woolworths Limited PO Box 8000 Baulkham
Hills NSW 2153 Att: Senior Engineer.
• Electronic copy to be emailed Woolworths Senior Engineer
(mirobertson@woolworths.com.au).
(The electronic drawings shall be in Auto Desk - Revit format. These files shall be on CD
and clearly marked with file names. A full schedule of electronic files shall be submitted
with the CD)
Page 100 of 157 100

13.0 REFURBISHMENT WORKS
All refurbishment projects shall include the following items in addition to the general scope of
works:
• Upgrade humidity and temperature sensors to current specification
• Compressors operating on R22 shall be upgraded to current specification
• Check airflow is to acceptable limit, clean coils.
• Change all air filters to current specification
• Re calculate heat load, confirm design meets revised heat load.
• Rebalance air handling system
• Clean condenser – comb coils
• Leak test and recharge system if necessary
• Recommission plant
• Oil change to compressor.
• Replace all copper gauge lines with flexible lines ( remove flare connections as
practicable)
• Provide new mechanical safety switches
• Install pressure relief vent lines and valves (many systems do not have these)
• Flush out drain lines to all systems including splits.
• Check and replace any faulty pipe clips.
• Replace driers.
• Replace air filters
• Check and inspect receiver
• Re-lamp MSSB
• Clean and replace missing labels & electrical duct covers
• Check all electrical connections
• Upgrade controls to current spec (CPC) including pressure transducers and electronic
expansion valves
• Clean all supply and return air ductwork internally including AHU’s.
Page 101 of 157 101

14.0 APPENDIX A – STANDARD ELECTRICAL COMPONENTS
DESCRIPTION MINIMUM
RATINGS
REQUIRED
DISTRIBUTION SECTION
SUPPLIER 1 SUPPLIER 1
PART NUMBER
SUPPLIER 2 SUPPLIER 2
PART NUMBER
MAIN ISOLATOR 400A 50KA SCHNEIDER LV432756 +
NHP S400NN3 +
NON AUTO
LV432598
T2HS40R6GM
DISTRIBUTION CHASSIS 630A
SCHN
CNS63006 NHP XB8006U
40KA
1SEC
EIDER
COMPRESSOR CHASSIS 250A 25KA SCHNEIDER LV431629 NHP S250NN3
ISOLATOR
NON AUTO
108 POLE CHASSIS
ISOLATOR
160A 25KA SCHNEIDER LV430310 NHP S160NJ3160
COMPRESSOR CHASSIS 630A 40KA
1SEC
SCHNEIDER CNS63015SS NHP XASSL630-15U
CPC & MISC CONTROL SECTION
CIRCUIT BREAKERS 6,10A 6KA SCHNEIDER 25801, 25802,
NHP DTCB61-
25803
6C,10C,16C
RCB0 10,16A 10KA SCHNEIDER 26858, 26859 NHP DSRCBH
240VAC
1030A,1630A
LINE FILTER 6A 240VAC SCHAFFNER /
WESTEK
FN352 Z 6/06
CONTROL RELAYS 6A 240VAC, SCHNEIDER RXM2AB2 B7, P7 NHP 55.32, 55.34
24VAC
RXM4AB2 B7, P7
240VAC, 56.32,
56.34 24VAC
LED LAMPS 22mm IP66
LED
SCHNEIDER XB4BVM SERIES NHP DT7 SERIES
VENTILATION FAN 240VAC ZEIHL W2S130-AA
LIGHTING CONTACTOR 240VAC 20A SCHNEIDER 15962, 15959 NHP DTC24-40-240,
DTC20-20-240
COMPRESSOR POWER & CONTROL
VSD COMPRESSOR CIRCUIT
BREAKER
160A 25KA SCHNEIDER LV430830 NHP S125GJ3125
DOL / PART WIND
COMPRESSOR CIRCUIT
BREAKER
160A 25KA SCHNEIDER GV7 RE 40,50,80 NHP S125GJ SERIES
VSD COMPRESSOR
CONTACTOR
80A AC3 SCHNEIDER LC1-D80 U7 NHP CA7-85-00 240V
DOL / PART WIND
25A, 38A, SCHNEIDER LC1-D SERIES NHP CA7 SERIES
COMPRESSOR CONTACTOR 50A, 80A AC3
DOL / PART WIND VARIOUS TO SCHNEIDER LRD SERIES NHP CT7 SERIES
COMPRESSOR OVERLOAD 53A
DOL COMPRESSOR PHASE
PHASEFALE MP15 NHP / DPB-02-C-M48 /
FAILURE ASYMMETRY
RELAY
SCHNEIDER RM17TA00
LED LAMPS 22mm IP66
LED
SCHNEIDER XB4BVM SERIES NHP DT7 SERIES
CONTROL RELAYS 6A 240VAC, SCHNEIDER RXM2AB2 B7, P7 NHP 55.32, 55.34
24VAC
RXM4AB2 B7, P7
240VAC, 56.32,
56.34 24VAC
KEY SWITCH 6A 240VAC SCHNEIDER ZB4BG2 +
ZB4BZ101
NHP D7PSM22PX10
CIRCUIT BREAKERS 6,10A 6KA SCHNEIDER 25801, 25802,
NHP DTCB61-
25803
6C,10C,16C
TIMERS ON/OFF SCHNEIDER RE11RAMU,
NHP DAA-01-C-M24
DELAY 1C/O
RE11RCMU
DBA-02-C-M24
CONDENSER POWER & CONTROL
CIRCUIT BREAKERS SINGLE
PHASE
CIRCUIT BREAKERS THREE
PHASE
6A 6KA SCHNEIDER 25801 NHP DTCB61-6C
32A, 50A,
63A 6KA
SCHNEIDER 25834, 25836,
25837
NHP DTCB6-332C, 350C,
363C
Page 102 of 157 102

DOL CONDENSER PHASE
PHASEFALE MP15 NHP / DPB-02-C-M48 /
FAILURE ASYMMETRY
RELAY
SCHNEIDER RM17TA00
CONDENSER VSD LINE AND 25A, 38A, SCHNEIDER LC1-D SERIES NHP CA7 SERIES
BYPASS CONTACTORS 50A, 80A AC3
CONDENSER MOTOR 12A AC3 SCHNEIDER LUB12 + LUCB NHP KTA7 SERIES +
CIRCUIT BREAKER AND
CONTACTORS
SERIES
CA7 SERIES
CONTROL RELAYS 6A 240VAC, SCHNEIDER RXM2AB2 B7, P7 NHP 55.32, 55.34
24VAC
RXM4AB2 B7, P7
240VAC, 56.32,
56.34 24VAC
EC CONDENSER MOTOR
CIRCUIT BREAKERS
12A AC3 SCHNEIDER GV2M SERIES NHP KTA7 SERIES
SUB SYSTEM POWER & CONTROL
KEY SWITCH 6A 240VAC SCHNEIDER ZB4BG2 +
ZB4BZ101
CONTROL RELAYS 6A 240VAC, SCHNEIDER RXM2AB2 B7, P7
24VAC
RXM4AB2 B7, P7
CIRCUIT BREAKERS SINGLE
PHASE
6,10,
16,20,25,32A
6KA
10, 16, 20, 25,
32A, 6KA
CIRCUIT BREAKERS THREE
PHASE
RCB0 10,16,32A
10KA
240VAC
LIGHTING CONTACTOR 240VAC 20A,
40A
NHP D7PSM22PX10
NHP 55.32, 55.34
240VAC, 56.32,
56.34 24VAC
SCHNEIDER 2580 SERIES NHP DTCB61 SERIES
SCHNEIDER 2583 SERIES NHP DTCB6-3 SERIES
SCHNEIDER 26858, 26859,
26861
SCHNEIDER 15962, 15959,
15966, 15967,
15968
NHP DSRCBH
1030A,1630A,
3230A
NHP DTC24-40-240,
DTC20-20-240,
DTC40-40-240,
*THE STATED NAME OF SUPPLIER IN 'SUPPLIER 1' COLUMN IN NO WAY DICTATES
PREFERENCE OVER SUPPLIER NAMED IN 'SUPPLIER 2' COLUMN
Page 103 of 157 103

15.0 APPENDIX B: SCHEDULE OF TECHNICAL DATA
15.1 GENERAL
The Designer shall complete the appropriate sections of the following Schedule of
Technical Data, as applicable to each installation, and submit the completed Schedule to
Woolworths for approval at completion of design work and prior to accepting any Tender.
15.2 AIR HANDLING UNIT CASING
The Designer shall complete the appropriate sections of the following Schedule of
Technical Data, as applicable to each installation, and submit the completed Schedule to
Woolworths for approval at completion of design work and prior to accepting any Tender.
Type of Construction
Factory or Site Fabrication
Manufacturer
15.3 REFRIGERANT
Refrigerant No.
15.4 COOLING COIL
15.4.1 DIRECT EXPANSION (WHEN APPLICABLE)
Make & Number
Number of Rows Deep
Fin Density fins/m
Air Face Velocity
Air on Temperature C DB C WD
Air Off Temperature C DB C WB
Refrigerant Pressure Drop kPa
Refrigerant Velocity m/s
Coil Superheat °K
SST °C
Number of Thermostatic Expansion Valves
Air Side Pressure Drop Pa
15.4.2 CHILLED WATER COIL (WHEN APPLICABLE)
15.5 SUPPLY AIR FAN
Make & Number
Number of Rows Deep
Fin Density fins/m
Air Face Velocity
Air On Temperature C DB °C WB
Air Off Temperature °C DB °C WB
Water Temperature In °C Out°C
Water Flow l/s
Water Pressure Drop kPa
Air Side Pressure Drop Pa
Make
Type
Total Air Quantity l/s
Page 104 of 157 104

System Resistance Pa
Speed RPS
Motor Size KWE
"V" Belt Size & no. off
15.6 AIR FILTERS
Make
Type
Face Velocity M/s
Number Off
15.7 COMPRESSORS
Make & Number off
Capacity Each kWR Total kWR
Type - Semi hermetic
Motor Size Each KWE
Speed RPS
Suction Temperature °C
Saturated Suction Pressure kPa / SST (oC)
Condensing Temperature (SCT)
Economiser (type, min capacity)
Unloaders (qty and capacity)
°C
15.8 CONDENSERS
1. Air Cooled
Make
Number off
Circuits No. off
No. of Fans – Each
Temperature Difference °K
Head Pressure Control Method
2. Shell and Tube
Make
Number off
Water Flow 1/s
Water Temperature In °C Out °C
15.9 AIR COOLERS - DRY
• Water to Air
Make
Number Off
Circuits No. Off
Fans No. Off - Each
Water Flow l/s
Water Temperature In °C Out °C
Overall Operating Temperature
Difference – Refrigerant to Air Off °K
Head Pressure Control Method
Page 105 of 157 105

15.10 CHILLER SET
Make
Model Number
Refrigerant Circuits No. Off
Chilled Water Temp ____In°C Out °C
Chilled Water Flow l/s
Evaporator Temperature °C
Condensing to Air Temperature °KTD
Chilled Water Temperature Control Method
Discharge Pressure Control Method
15.11 AUXILIARY FANS
a Stock Room Exhaust
Make
No. off
Total Capacity l/s
b. Toilet Exhaust
Make
Total Capacity l/s
c. Bakery Oven Exhaust
Make
Total Capacity l/s
d. Bakery Oven Make Up
Make
Total Capacity l/s
e. Donut Cooking
Make
Total Capacity l/s
f. Chicken Cooking Exhaust
Make
Total Capacity l/s
g. Chicken Cooking Make Up
Make
Total Capacity l/s
h. Fish Preparation Area Exhaust
Make
Total Capacity l/s
i Cold Aisle Return Fan
Make
Total Capacity l/s
Page 106 of 157 106

16.0 APPENDIX C: TEST DATA SCHEDULE
The following Test Data Schedule may be used as a guide for plant test purposes. Other
tests, however, may be conducted at Woolworths discretion.
PROJECT: DATE:
16.1 AIR QUANTITIES
Supply Air
Return Air
Outside Air
Design Actual Velocity
l/s l/s m/s
Submit a drawing showing the measured air quantity at each register, diffuser, return
air grille, toilet exhaust grille and cooking exhaust hoods.
16.2 REFRIGERATION SUPERHEAT
At each Evaporator
At each
Compressor
16.3 PLANT CAPACITY
Return air
Temperature
°C WB
°C DB
Outside air Temperature
°C WB
°C DB
Air on Coil
Temperature
°C WB
°C DB
Air off Coil
Temperature
°C WB
°C DB
Total Capacity kW
System
No.1
System
No.1
System
No.1
System
No.2
System
No.2
System
No.2
Page 107 of 157 107

16.4 CONTROLS
Air conditioning control thermostat set point - Summer °C / Winter °C
Heater safety thermostat set points and time delay to
cut out.
Time delay
Set Point
Min/Sec
Temp.
Hot Water Coil °C
Compressor High Pressure Safety Cut-out set point kPa
Compressor Low Pressure Safety Cut-out set point kPa
Condensing Pressure Control Set point kPa
16.5 PLANT OPERATING CONDITIONS
Ambient temperature °C DB
°C WB
Operating Discharge Pressure
Compressor no. 1 kPa / SCT
Compressor no. 2 kPa / SCT
Operating Suction Pressure
Compressor no. 1 kPa / SST
Compressor no. 2 kPa / SST
16.6 ELECTRICAL
Note: Information to be provide for each A/C unit/system
Supply Fan Motor Full Load amps
Running amps
Compressor Motor
Compressor no. 1 Full Load amps
Running amps
Compressor no. 2 Full Load amps
Running amps
-
Page 108 of 157 108

16.7 NOISE LEVELS
Air Conditioned Spaces dB(a)
Ventilated Occupied Spaces dB(a)
Page 109 of 157 109

17.0 APPENDIX D: APPROVED SUPPLIERS & EQUIPMENT
17.1 MECHANICAL CONTRACTORS
State Supplier
NSW
SA
QLD
Vic
WA
NT
Equilibrium Air Conditioning
Faircloth & Reynolds
Crest Air Conditioning Pty Ltd
J.E.C. Air Conditioning Services
Benmax Engineering
James & Scott Air
Airmaster Australia.
Air Comfort Services
Hayden Engineering
National Air Conditioning
Season Air
Airmaster Australia.
AE Smith
Faircloth & Reynolds
Isothermal Pty Ltd
John Goss Mechanical
Hastie Services
National Air Pty Ltd
JL Williams
Airmaster Australia.
Haden Engineering
Apex Air
A.E. Smith & Son
James & Scott Air
Airmaster Australia.
Hexagon Services
Mechanical Project Management
Jako Industries
Mechanical Constructions
Envar
Centigrade
CMS Engineering
Airmaster Australia.
York Air Conditioning
Carrier Air Conditioning
Mecair Engineering
Faircloth & Reynolds
Page 110 of 157 110

17.2 SWITCHBOARD MANUFACTURES
Supplier
S J Electric Pty Ltd
G B Electric
PM Switchboards
JP Richardson Industries
Elite Electrical group
Faircloth & Reynolds
R G Ladd Pty Ltd
K E Brown Electrical Switchboards
17.3 COMPRESSORS
17.3.1 SCREW COMPRESSORS
• Bitzer
• Frascold
17.3.2 RECIPROCATING COMPRESSORS
• Bitzer
• Bock
• Copeland
• Dorin
17.3.3 SCROLL COMPRESSORS
• Bitzer
• Copeland
17.4 CONDENSERS
• Buffalo Trident: RC, DV, LDV, VB, FMC
• Heatcraft KRC, WRC-B (with cyclone kit in all regions);
• Geenhalgh
17.4.1 CONDENSER FANS
• Zeihl-Abegg
• EBM Papst
17.5 HEAT EXCHANGERS
17.5.1 SHELL & TUBE
• Bitzer
• Inline Brolga
17.5.2 PLATE
• Alfa Laval
17.6 PUMPS
• Kelly & Lewis
• Grundfoss
Page 111 of 157 111

17.7 VRF UNITS
• Fujitsu
• Daikin
• Mitsubishi Electric
• Panasonic
17.8 ROOF TOP PACKAGE UNITS
• Temperzone
• Actron Air
17.9 FANS
17.9.1 CENTRIFUGAL FANS (LESS THAN 2000 L/S)
• Fans Direct
• Fantech
• CFM
17.9.2 CENTRIFUGAL FANS (GREATER THAN 2000 L/S)
• Fantech
• Fan & Blower
17.9.3 AXIAL FANS
• Ziehl Abegg
• EBM Papst
• Fantech
• Fans Direct
17.9.4 MIXED FLOW FANS
• Fantech – Mixivent Series
• CFM – EC Blue
17.9.5 PLUG FANS
• Ziehl Abegg
• EBM Papst
17.9.6 KITCHEN EXHAUST FANS
• Fantech - Heritage Series
• CFM - MCV
17.9.7 ROOF MOUNTED EXHAUST FANS
• Fans Direct
• Fantech
• CFM
17.10 AIR CURTAINS
• Mitsubishi GK 35 series
17.11 CHILLERS
• York
• Climaveneta
• Carrier
Page 112 of 157 112

17.12 CONTROLS
• HVAC controller - CPC Emerson
• Thermostat - CPC Emerson
• Humidistat - CPC Emerson
17.13 VARIABLE SPEED DRIVES
• Vacon
• Toshiba
• Emerson
17.14 BOILERS
• Raypak
• Baxi
Page 113 of 157 113

18.0 APPENDIX E - SCHEDULE OF DRAWINGS
18.1 GENERAL
The following are the standard drawings to be used for tendering purposes and for
guidance only, in preparing the air conditioning and mechanical ventilation design.
The dimensions shown on the following details are approximate only and may vary.
The Designer and/or Contractor shall be responsible for checking the dimensions, in
each case, and include the correct sizes in the preparation of the design.
All drawings shall be read in conjunction with the architectural, store layout and structural
details applicable to each project.
Title #
Woolworths Standard Duct Layout M 19
Chicken Cooker Exhaust Hood - Single SD20
Chicken Cooker Exhaust Hood - Double SD20 A
Bakery Oven Exhaust Hood Single SD21
Bakery Oven Exhaust Hood Double D21A
Doughnut Cooking Exhaust Hood SD22
Chicken Cooker Exhaust Hood - Cylindrical SD23
Air Conditioning Status Lamp Plate SD24
Air Conditioning Refrig Schematic (1,2,3) SD25
MSSB External Fascia layout SD26A
MSSB Internal Fascia layout SD26B
Air Conditioning Refrigeration Piping Schematic SD27
Dishwasher Hood SD28
Switchboard Layout BW380048S
Std Power Diagram Mech SD1
BCA Climate Zone Map
Page 114 of 157 114

18.1.1 CHICKEN COOKER HOOD – SINGLE - SD 20
Page 115 of 157 115

18.1.2 CHICKEN COOKER HOOD – DOUBLE - SD 20A
Page 116 of 157 116

18.1.3 BAKERY HOOD – SINGLE - SD 21
Page 117 of 157 117

18.1.4 BAKERY HOOD – DOUBLE - SD 21A
Page 118 of 157 118

18.1.5 DONUT HOOD- SD 22
Page 119 of 157 119

18.1.6 CHICKEN COOKER HOOD - CYLINDRICAL - SD 23
Page 120 of 157 120

18.1.7 AIR CONDITIONING STATUS LAMP PLATE - SD 24
Page 121 of 157 121

18.1.8 AIR CONDITIONING REFRIG SCHEMATIC (1,2,3) – SD25
Page 122 of 157 122

18.1.9 MSSB EXTERNAL FASCIA LAYOUT – SD 26A
Page 123 of 157 123

18.1.10 MSSB INTERNAL FASCIA LAYOUT – SD 26B
Page 124 of 157 124

18.1.11 AIR CONDITIONING REFRIGERATION PIPING SCHEMATIC – SD27
Page 125 of 157 125

18.1.12 DISHWASHER HOOD SD 28
Page 126 of 157 126

18.1.13 BCA CLIMATE ZONE MAP
Page 127 of 157 127

18.1.14 SWITCHBOARD LAYOUT
Page 128 of 157 128

18.1.15 MECHANICAL SWITCHBOARD STANDARD LABELS
Page 129 of 157 129

18.1.16 STD POWER DIAGRAM
Page 130 of 157 130

19.0 APPENDIX F - CONTROLS APLICATION MANUAL (CPC)
19.1 EXECUTIVE SUMMARY
The installation of the Emerson Climate Technologies’ control system will provide
Woolworths with an effective and reliable energy management system capable of providing
significant savings by unifying the store’s HVAC, lighting and energy monitoring under a
single controls platform.
Page 131 of 157 131

19.2 CONTROL STRATEGY OVERVIEW
19.2.1 INTRODUCTION
19.2.1.1 General
The Emerson Climate Technologies Building Management System (ECT BMS)
will provide Woolworths with a cost effective energy management solution for
each site. It will deliver a high level of control, incorporating DDC controls, Store
Manager Interface and a total store control system.
The E2 controller is a microprocessor-based control system designed to provide
complete control of compressor groups, condensers, HVAC Zones and other
components related to refrigeration and building control. The E2 is the controlling
component of a three-network configuration (RS485 I/O, Echelon ® Lonworks
Networks, and Ethernet) that includes input and output communication boards,
remote communication software, and a variety of sensors, probes, and
transducers.
The E2 CX, which controls HVAC systems for low-rise retail, industrial, and
commercial buildings. The CX’s primary function is to provide energy-efficient
control of air handling units (AHUs), rooftop units (RTUs), and other systems
related to environment control. In addition, the CX provides extensive sensor
control, logging, and graphing features that allow the user to view accurate realtime
information about system conditions. The CX is equipped with many power
monitoring and demand control features that give you the information you need to
keep your site’s energy consumption low.
Page 132 of 157 132

19.2.1.2 Networks
RS485 Networks
The RS485 Input/Output (I/O) Network connects all input and
output communication boards together in a single open
communications loop. This loop, or “daisy chain,” connects the
E2 to multiple input and output communication boards, and
terminates at the last input or output board on the network. Daisy
chains are the only allowable network structure for CPC RS485
I/O and Modbus networks. Branching and “star configurations”
can seriously affect network performance and therefore are not
allowed. Proper termination is an important part of reducing I/O
network noise. For daisy chain networks, the devices at each end
of the daisy chain must be terminated with a 150-ohm resistor. All
CPC-manufactured devices with RS485 and MODBUS ports are
equipped with on-board termination jumpers that, when set to the
“termination” position, provide the 150 ohms of resistance
necessary to terminate the network endpoint. Third-party devices
may or may not have on-board termination — consult the
manufacturer’s instructions for termination information. If an end
device does not have termination jumpers, you can terminate the
network by placing a 150- ohm resistor across the RS485+ and
RS485- terminals of the device’s connector.
Echelon Networks
Echelon devices are networks together into configurations called segments. A
segment is a group of up to 64 Echelon devices that are connected together on
an unbroken series of wires. The recommended way of constructing an Echelon
Network is called daisy-chaining. In the daisy chain network configuration,
devices are arranged by subnets, which consist of one E2 and all Echelon
devices associated with the E2. First, all devices in a subnet are connected in
an unbroken chain without branches or “star configurations”.
Then, if more than one E2 is present on-site, all chains are connected so that
the entire network forms a large unbroken chain, called a daisy chain this allows
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for all devices in the Echelon Network to be hard wired together for trouble free
communication.
Echelon networks require the devices on each end of the daisy chain to be
terminated with a 108- ohm resistor across the signal-carrying leads. Most
CPC-manufactured Echelon devices have on-board termination jumpers that,
when set to the “terminated” position, provide the required termination
resistance (refer to the device’s own installation documentation). If the device
does not have termination jumpers, CPC offers an Echelon termination block
(P/N 535-2715) that may be wired in series right before the end device or at the
end of an Echelon network run. The termination block provides the necessary
108-ohm resistance for network termination. (Note: For The only Specified
Echelon Cable - Euro Tech cables, 8 Epic Place Villawood NSW, 2163 contact:
Fred Varda Tel: 02 9645-5444 fax: 02 9645-5433, Part Number ET3801-107
Grounding Networks
Proper grounding is an essential part of reducing network noise. Failure to
properly ground power and network wiring is one of the most common causes
of Critical noise problems. Follow these guidelines when installing
RS485/MODBUS and Echelon networks, and refer to them when
troubleshooting problematic installations to ensure the grounding is correct.
The length of all ground wires should be kept to 6 inches (15.3 cm) or less. Use
a 14AWG wire or larger.
The best earth ground sources to use are listed below, in priority order:
• A large metal panel or plate that is connected to a good electrical ground. A
panel or plate that is at least 3 feet by 3 feet (0.9 m by 0.9 m) is desirable.
• Earth grounded steel rack.
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19.2.2 PID CONTROL
PID Control is a specialized method of closed-loop control that strives to maintain
equality between an input value and a user-defined set point by operating a device
or a number of devices at somewhere between 0% and 100% v of full capacity.
PID Control works by making adjustments to the output at a constant rate called
the update rate (usually 2-6 seconds). For every update that occurs, PID Control
takes a reading from the input sensor or transducer, measures the distance
between the input and the set point (also called the error), makes a series of
calculations, and adjusts the output percentage in such a way as to move the input
towards the set point in the most efficient manner.
The “calculations” that determine the new value of the output after each update are
made by three different modes of control: Proportional (“P”) Mode, Integral (“I”)
Mode, and Derivative (“D”) Mode. Each mode of control makes its own adjustment
to the output percentage, and the three adjustments are added to the previous
output percentage to determine the new output percentage. In mathematical terms,
every update will affect the output percentage as follows:
NEW OUT% = OLD OUT% + (“P” mode adjustment) + (“I” mode adjustment) + (“D”
mode adjustment) each of the three modes (P, I, and D) serves a different and
important purpose, as described below:
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19.3 WIRING / POWERING
19.3.1 TRANSFORMER
All transformers for Devices are supplied as part of the Woolworths HVAC Controls
Package. The supplied transformers are to be used only for the Emerson devices
stated below and not to be shared with other devices -
19.3.1.1 E2
The E2 Series requires one (1) #804421 Transformer per unit
19.3.1.2 Multiflex
Up to ten (10) Multiflex I/O Cards can be installed on the one (1) #640-0048
Transformer, additional transformers are required for more than ten (10).
19.3.1.3 EC3-x31
The EC3-x31 Series requires one (1) #804424 Transformer per unit
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19.3.2 SENSOR WIRING
19.3.2.1 Pressure Transducer
CPC transducers are used for monitoring and control of compressor suction and
discharge pressures, they convert pressure readings to proportional electrical
signals between 0.5 and 4.5 volts. The transducer is designed with a 1/8-inch
male FPT fitting for connection to a standard access fitting. Each pressure
transducer is supplied with 20 feet of cable for connection to a 16AI input board.
The pressure transducers should be mounted in a vertical position (pressure port
down) above crank case oil level to prevent drainage of oil into transducer port.
19.3.2.2 General Purpose Sensor
These sensors are used to monitor mixed, supply and return air temperature.
When used in this application, the sensors are supplied without enclosure covers.
The sensors should be mounted directly in the air stream of the supply or return
air duct. The sensors are not supplied with any mounting hardware for this
application.
19.3.2.3 Outdoor Humidity Sensor
The outdoor RH sensor used for control and monitoring of outdoor conditions
should always be mounted on the south side if in the Southern Hemisphere. The
sensor should be mounted under an overhang or otherwise out of direct sunlight.
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19.3.2.4 Indoor CO2 Sensor
The Indoor CO2 sensor used for control and monitoring of indoor air quality
conditions should always be located in a central location with in the zone to be
measured, away from doors, windows, vents, heaters, and outside walls that
could affect temperature readings.
19.3.2.5 Indoor Humidity Sensor
The indoor relative humidity sensor used for control and monitoring of indoor
humidity should be mounted in a central location within the zone to be measured,
away from doors, windows, vents, heaters, and outside walls that could affect
temperature readings. Note that this sensor generates a small amount of heat;
therefore, do not mount temperature sensors directly above RH sensors.
19.3.2.6 Indoor Temperature Sensor
Inside temperature sensors are supplied within a wall mounted enclosure for
attachment to a standard switch plate. The temperature sensor should be located
in a central location—within the zone to be measured—away from doors,
windows, vents, heaters, and outside walls that could affect temperature
readings. In addition, the sensor should not be mounted above other sensors that
generate heat during operation (such as Relative humidity sensors).
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19.3.3 GENERIC POINTS SCHEDULES
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19.4 CONTROL STRATEGY
19.4.1 MAIN AIR HANDLING UNIT (AHU)
19.4.1.1 General
An AHU control application consists of 3 separate control algorithms. The main
algorithm monitors the indoor temperature (s) and activates heating and cooling
stages when necessary to maintain a user defined set point. Another algorithm
monitors the indoor humidity and brings on additional heating and cooling stages
to reduce the indoor humidity level. The third controls either a two position
(digital) or variable position damper (analog) according too the outside air
conditions.
19.4.1.2 AHU Selector Switch
The Main AHU Selector Switch located on the HVAC Electrical switchboard has 3
positions that determine the control stage in the E2 –
19.4.1.3 Occupied / Unoccupied
The Building Occupied and Unoccupied times are controlled by a time schedule
with in the E2 CX. The times entered are dependant on the stores locations and
trading hours. Occupied times are set to be enabled one (1) hour before and after
store trading hours.
19.4.1.4 Night Purge
The AHU Night Purge function utilizes cool early morning are to cool down the
store to reduce the morning energy usage, allowing less early morning cooling
requirements.
The AHU Night purge will operate if the following conditions are met
The average store temperature is above the cooling set point
The outside temp is more than 4dc below store space temperature
The outside Humidity is less than 75%
When The AHU’s are in Night Purge the following will occur
The AHU temperature control will not be utilized
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The economy dampers will be driven open 100%
The AHU’s supply air VSD’s will run at 80%
Night purge will run for a minimum 10mins and will continue to run until the store
AHU set point is achieved. Night Purge is Enabled and Disabled by the Night
Purge Time schedule by default.
19.4.1.5 Optimum Start / Stop
The optimum start/stop (OSS) is a feature that works alongside the AHU’s
Unoccupied / Occupied application’s temperature control modes. OSS takes
control of heating and cooling before the AHU is scheduled to change to
Occupied and also on the change the Unoccupied. As a result the Temperature
will make comfortable set point changes allowing gradual running of heating and
cooling furthermore reducing energy consumption.
When the ECT EMS receives a occupied signal from the store trading time
schedule the AHU application switches from Disabled (Unoccupied) to Enabled
(Occupied) allowing the OSS to bring store up to occupied set point in a smooth
energy efficient manner.
19.4.1.6 Fan Control
The E2 CX control for the fan is Continuous; the fan is always on, even when the
AHU is not in heating, cooling, or dehumidification mode. The Continuous Fan
mode is enabled buy the Fans “Run Proof” status, this inputs informs the E2’s
AHU application that the fan is operational. When the “Run Proof” status input is
“Bad” or Open the AHU application will disable all heating and cooling with in the
Air Handling Unit.
19.4.1.6.1 Single-Speed Fans
Single-speed fans require no advanced control parameters. Whether in
Continuous or Auto mode, the fan will be ON when Fan Control calls for it
to be ON, and OFF when it calls for it to be OFF.
19.4.1.6.2 Variable-Speed Fans
Variable-speed fans may operate at any percentage of its maximum
speed. The method AHU Control uses to determine the speed
percentage is dependent on whether the heat and cool outputs are
staged or modulating.
19.4.1.6.3 Variable-Speed Fan Operation
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For staged AHU outputs, each stage must be programmed with its own
speed percentage set point. The AHU Control application looks at all of
the active stages, takes the highest speed percentage set point, and
operates the fan at this speed. For example, if cool stage 1 is active with
a 30% speed percentage set point, the fan will likewise operate at 30%
speed. If a second stage with a set point of 50% were to become active,
the fan speed would increase to 50%. For each heating and cooling
stage, you may specify both occupied and unoccupied speed percentage
set points.
19.4.1.6.4 Dehumidification with VS Fans
When in dehumidification mode, a user-defined slowdown percentage is
subtracted from the variable-speed fan percentage. This percentage will
continue to be subtracted until the AHU exits dehumidification mode.
SAF Variable Speed Drive Modbus Communication – Layout
19.4.1.7 Heat / Cool Control
In its most basic form, Temperature Control simply reads a control input value,
compares it to the active temperature set point, and activates or deactivates
heating or cooling stages in an effort to satisfy the set point. The majority of user
setup that must be done in Temperature Control involves specifying which input
is to be used as the control source, defining different set points for use in
occupied, unoccupied, summer, and winter modes, and setting up the operating
characteristics of the heating and cooling stages.
An AHU controls all aspects of an air handling unit, including up to eight stages of
auxiliary or reclaim heat, six cooling stages, dehumidification, analog or digital
economization, and support for single-, two-, or variable speed.
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19.4.1.7.1 Cooling Stages
a) Electronic Expansion Valve Control (EXV)
This strategy incorporates the use of EXV for superheat control
across each cooling coil. Each EXV is driven by an EC3-x31
which operates the valve according to the superheat that is
calculated by actual pressure vs. outlet temperature. LLSV’s are
not required when using the Emerson EXV.
EC3-X31 is the superheat controller with LON connection for
stepper motor driven Alco Electrical Control Valves EX4...EX8.
The EC3-X31 has a Lon Works FTT10 interface. The connection
to the LON network is via the RJ45 connector labelled “COM”.
The EC3-x31 is connected using the optional ECC-Nxx cable
assembly or a standard CAT5 network cable with RJ45 plugs
assembly. LON A is on pin1 and LON B is on pin2 of the RJ45
connector. Full monitoring and control adjustment is achievable
through the E2 CX controller.
EC3-x31 Electronic Expansion Valve Controller – Enable
(Note: For The only Specified Echelon Cable - Euro Tech cables, 8 Epic Place Villawood NSW, 2163 contact: Fred Varda Tel:
02 9645-5444 fax: 02 9645-5433, Part Number ET3801-107
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EC3-x31 Electronic Expansion Valve Controller – Layout
19.4.1.7.2 Heating
a) Refrigeration Heat Reclaim (Free Heat)
This strategy incorporates the refrigeration medium and high temperature
parallel racks series heat reclaims systems. This method of free heat
when available is always the first 2 stages of the Air Handling Units
heating and dehumidification strategies.
b) Boiler Heating
Hot Water control will be enabled in heating mode, the hot water pump
will be enabled then a time delay of 2min before Boiler is enabled if water
flow switch is sensing water flow. The Pump will have a 5min run on time
once heating call is terminated. Hot water flow and return sensors are
monitoring sensors only.
Hot water modulating valve is driven via 0-10 volt output to maintain the
user defined set point for heating and dehumidification modes.
Boiler Enable
c) Heat Pump Units
These units are used to eliminate the use of electric and/or gas heating
systems. They are set as heat stages in the E2 CX’s AHU Application.
Each Heat pump unit has a CPC Multiflex 168 I/O Card and a EC3-x31
EXV Unit. See manufactures guide lines for setups and commissioning if
the unit.
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.
Heat Pump Diagram with Multiflex and EC3-x31
19.4.1.8 Dehumidification
Air Handling Units use a special dehumidification algorithm based on the
Proportional loop in PID control. When dehumidification is enabled by the Zone
application, the AHU application will activate a percentage of its total cool stage
capacity, the amount of which depends on how close the current relative humidity
is to the set point.
When dehumidification is called for a separate logic with in the E2 is enabled in
order to heating to shift above the cool set point. This logic will shift the heating
and cooling set points in order to achieve “heating before cooling” logic. This
logic is incorporated into the system to maintain a consistent sales floor
temperature dew point.
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Air Handling Units Set Points
19.4.1.9 Economy Cycle
Economizer dampers on AHUs are used to bring outside air into the building for
use in cooling. When temperature and humidity conditions are favourable, the
Economization dampers are opened, and outside air is allowed to flow into the
AHU. Economization is generally used by the AHU just as a cool stage would be
in Temperature Control; if cooling is needed, and conditions are favourable for
economization, the dampers will open and economization will begin. If more
cooling is needed, the cooling stages would then cycle on as normal. The E2
supports control of both two-position (digital) and variable-position (analog)
economizer dampers.
Economization Enable
Before the AHU Control application may open economization dampers, it
must first determine if the outdoor air conditions are favourable for
economization. The Control Strategy Used is In vs. out Enthalpy. This
strategy requires indoor and outdoor humidity sensors and also indoor and
outdoor temperature sensors. The enthalpy of the outdoor air is calculated
and compared to the enthalpy of the indoor air. If the outdoor air enthalpy is
less than the indoor air enthalpy, economization is enabled. Otherwise,
economization is disabled. You may choose a different economization
checking method for use in summer and winter months.
Economization Lockout Features
In addition to the method listed above, there are two economization lockout
features that apply to all AHUs using economization.
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Max Outside Air Humidity
The Max outside Air Humidity is the highest allowable humidity level for the
outside air. If the outside relative humidity is higher than this set point,
economization will not be allowed to occur.
Minimum Supply Temp
The Minimum Supply Temp is a user-defined set point that locks out
economization if the supply air temperature falls below a minimum supply
temperature set point. This feature ensures that the air coming from outside
is not too cold.
Digital Economizer Control
Control of digital or two-position economizers is relatively simple. When
conditions are favourable for economization, the dampers will be opened
when cooling is needed. If not favourable, the dampers will be closed.
Analog Economizer Control
For variable-position dampers, economization is generally used by the AHU
just as a cool stage would be in Temperature Control. If cooling is needed,
and conditions are favourable for economization, the dampers will open and
economization will begin. If more cooling is needed, the cooling stages
would then cycle on as normal. The position of the analog economizer
damper is Important only for the purposes of keeping the mixed air
temperature (a combination of the outdoor air coming through the dampers
and the return air temperature) near the user-specified set point. The
damper is controlled using
19.4.1.10 CO2 / Fresh Air Damper
When the CO2 level in the space reaches the threshold, the outdoor dampers will
modulate open to ventilate for the higher occupancy conditions. A calculation of
supply air fans running at the time is also taken into consideration and subtracted
from the amount of unconditioned outside air that is bought into the space. The
CO2 Sensor that monitors and controls the damper is located on the Sales Floor.
19.4.2 COMPRESSORS
19.4.2.1 General
The E2 CX refrigeration controller uses suction group applications to cycle
compressors in an effort to maintain a constant suction pressure in refrigeration
system. A suction group may contain up to 16 compressor stages (standard,
variable-speed, or unloader).
19.4.2.2 Compressor Enable
19.4.2.3 Infinite Controlled Compressor
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Infinite Controlled Compressor Schematic
Along side the E2, a Multiflex 168DO (810-3067) is required to control a 3 –
32VDC Solid State Relay for the increase and decrease capacity coils. The DO
board generates either a high (12VDC) or a low (0VDC) Signal. The decrease
capacity coil is directly energized on compressor start up and shut down and is
controlled by an On/Off Relay output that is initiated by the Compressors “Run
Proof” input status.
Once a cooling call from the AHU has been initiated and the Compressors
minimum off delay has passed and no faults are present the “decrease capacity”
Coil is energized and the compressor will start. Once time delay for the decrease
capacity coil has elapsed the increase or decrease capacity coils will operate
depending on the Actual pressure vs. pressure set point. Set point is set in the
Suction Group setup and used to control the capacity. A pre set amount is
entered to initiate increase or decrease in capacity.
During operation loading and unloading is achieved when actual pressure is
below or has exceeded the pressure set point. The Loading / unloading capacity
coil will be energized by the DO Pulsed output, times and delays are set by the
user to ensure correct operation. No unloading or loading occurs while the
pressure is within the dead band.
If at any time the unit goes into fault condition the decrease capacity coil is
energized and the unit will be forced off. If the fault condition is no longer present
and the start delays have elapsed the unit will begin its start procedure.
When cooling is no longer required the unit will have a preset pump down period
and then be disabled, at this point the decrease capacity coil will be energized
and the unit will start its minimum off time.
19.4.2.4 Standard Compressor Control
Once a cooling call from the AHU has been initiated and the Compressors
minimum off delay has passed and no faults are present the relay will energized
and the compressor will start, it will operate a series of either on/off style
unloaders in order to maintain the user defined set point. Set point is set in the
Suction Group setup and used to control the capacity.
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When cooling is no longer required the unit will have a preset pump down period
and then be disabled, at this point all unloaders will be disabled and the
compressor will not run until its preset off time has elapsed.
19.4.3 CONDENSERS
19.4.3.1 General
The air cooled strategy uses a simple PID control loop that compares a single
Control In input to a PID set point. The resulting percentage is used to activate
the condenser fan(s) necessary to bring the input value down below the set point.
Control inputs for air cooled strategies most commonly come from a pressure
transducer mounted on the discharge line, the condenser inlet, or the condenser
outlet.
19.4.3.2 Analog Output Condenser Fan Control
Variable-speed fans simply use the percentage to determine the fan speed.
Thus, a 51% PID percentage will result in the fan running at 51% maximum
speed. This is achieved by a 0-10v output from the Multiflex 168AO (#810-3065).
The 0-10 output is a direct relation to the PID percentage. E.g. PID is at 51% the
0-10v output will be 5.1 Volts DC.
19.4.3.3 Single Speed Condenser Control
Single-speed fans translate the PID percentage into a percentage of total fan
capacity. For example, if the PID percentage is 75%, then 75% of all condenser
fan stages will be ON. All Fans using this strategy will have equal runtimes.
19.4.4 PACKAGE UNITS
19.4.4.1 Control
Office and amenities areas are controlled by VRV Systems. The E2 CX monitors
Zone Temperatures and enables the VRV system by Output on Multiflex relay
card. The enable is based on the store trading time schedule. An override button
is also incorporated allowing an override time of 1 hour before the system reverts
back to disable. The heating and cooling stages are controlled by the local
controllers inbuilt in the VRV systems.
19.4.4.2 Echelon Interface
The E2 CX has the ability to control, monitor and communicate with the following
units via Echelon communications –
Dakin VRV – Using a DMS504B51 Interface Module
Mitsubishi LMAP02-E, PAC-YV02LMAP
19.4.5 SUPPLY AND EXHAUST FANS
19.4.5.1 Temperature Controlled Fans
These modules read values from one or more analog sensor, compare them to a
set of cut in / cut out set points and operates a digital output (such as a relay)
based on the analog input in relation to a set point. Fans Run Proof and fault
status are also monitored for remote and local integration purposes.
EF-0x Switch room Exhaust
Controlled by locally mounted temperature sensor
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19.4.5.2 Digital Controlled Fans
These modules read the values from one or more digital input, combine them
using a series of logical commands and operates a digital output (such as a
relay) based on the result of the logical combination.
EF-0x Loading Dock Exhausts
Remote on/off switch with green neon indicator light shall be
located in the loading dock area
EF-0x Stock Room Exhausts
Remote on/off switch with green neon indicator light shall be
located in the Stock Room area.
EF-0x Bakery Exhausts –
Controlled by an On-Off switch for fan interlocked with ovens to be
installed adjacent the hood. There is also a 20 minute run off timer
programmed.
SF-0x Bakery Supply –
Fan will be enabled in conjunction with Bakery Exhaust.
EF-0x Dishwasher Exhaust –
Controlled by a relay that energizes when ever the dishwasher is in
“wash” cycle.
EF-0x Donut Exhaust –
Controlled by an on/off switch for fan to be installed adjacent to the
Bakery hood.
EF-0x Chicken Exhaust –
Controlled by an on/off switch locally fitted.
SF-0x Chicken Supply –
Fan is enabled in conjunction with Chicken Exhaust
EF-0x Fish Prep Exhaust –
Controlled by a relay that energizes when the fish area lighting is
switched on
RAF-0x Return Air Fan –
Controlled by the main Air Handling Units supply fan run proof
status.
19.4.5.3 Time Schedule Controlled Fans
These modules read the values from a time schedule application with in the E2
CX, which commands and operates a digital output (such as a relay) based on
the result of the applications operating hours.
TEF-0x Cleaners Room
EF-0x Toilet Exhausts
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19.4.6 LOGGING
19.4.6.1 Logging Configuration
Logs of connected probes and equipment will be kept in the controller memory
for fourteen (14) days and will be available via remote connections:
15 minute log group
KWH Meters
5 minute log group – (Base Log)
Indoor Temperature Probes
Indoor Humidity’s
Indoor CO2
Outside Probes
Outside Humidity’s
AHU Probes
VSD Percentages
Damper Percentages
1 minute log group
Compressor Transducers
Mechanical Faults
Mechanical Proofs
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19.5 GENERIC NAMING CONVENTION
It is customary practice to name the Equipment in the controller given below is a brief description of
the terminology and corresponding names as might be seen in the Emerson controller at
Woolworth’s facilities:
Item / Circuit Description Naming Convention
Compressors CP-0x
Condensers CP-0x-Cond01
Air Handling Units AHU-0x
Roof Top Units / Air Coil Units ACU-0x
Hot Water Units / Boilers HWU-0x
Exhaust Air Fans EF-0x
Supply Air Fans SF-0x
Return Air Fans RAF-0x
Outside Air Fans OAF-0x
Hot Water Units / Boilers HWU-0x
Electric Duct Heaters EDH-0x
Outside Air Conditioners OAC-0x
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19.6 GENERIC PARTS
19.6.1 ITEMS AND PART NUMBERS FOR THE GENERIC SYSTEM
Part # Description Amount
834-0410 E2 CX-400 1
804421 ECT 623 60VA Transformer 24v 2
640-0048 Ten Board Transformer 1
810-3066 Multiflex 168, 16 Inputs & 8 Outputs 3
810-3065 Multiflex 168AO, 16 Inputs, 8 Outputs, 4 Analog Outputs 2
810-3067 Multiflex 168DO, 16 Inputs, 8 Outputs, 4 Digital Outputs 1
800-2200 0-200 PSI Transducer with 20-foot Lead, Requires 5VDC Input 2
800-2500 0-500 PSI Transducer with 20-foot Lead, Requires 5VDC Input 2
804283 Standard Discharge Air Sensor 20-foot Lead 4
201-1191 High Temperature Sensor for E2 Units 4
111-3163 Temperature Sensor in Wall Mount Enclosure 6
203-5751 Wall Mount Relative Humidity Transmitter 1
203-5754 Outdoor Relative Humidity Transmitter 1
210-2000 CO2 Sensor - Wall Mount Diffusion 1
E50-C2 KWH Meter 1
807795 EC3-x31 Echelon Based Superheat Driver 4
807657 ECD-002 Hand Controller/Display 4
807644 EC3-x31 Terminal Kit 4
804803 PT4-M15 Plug And Lead 4
804281 ECN-P60 Pipe Mount Probe 4
802350 PT5-07M Transducer 7 Bar 4
804424 ECT 323 25 VA Transformer 4
800624 EX-7 U21 – Electronic Expansion Valve 4
804650 Plug And Lead Assembly for EX Range 4
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19.7 PRE COMMISSIONING SIGN OFF SHEET
19.7.1 GENERAL
Before Emerson Climate Technologies commences the onsite controls
commissioning the contractor will check all items on the Pre Commissioning Sign
off Sheet. Once complete and signed the check list will then be emailed to the
corresponding Emerson Climate Technologies Technician and a the day can be
set for controls commissioning.
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19.8 SENSOR LOCATIONS
19.8.1 AIR HANDLING UNIT
19.8.2 SALES FLOOR
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19.9 POWER MONITORING
19.9.1 EMERSON E50 KWH METER
The E50 DIN Rail Power Meter provides a solution for measuring energy data with
a single device. Inputs include Control Power, CT, and 3-phase voltage. The E50
Supports multiple output options, including solid state relay contacts, Modbus (with
or without data logging), and pulse. Data Outputs include -
Power (kW)
Energy (kWh)
Diagnostic alerts
Current: 3-phase average
Volts: 3-phase average
Current: by phase
Volts: by phase Line-Line and Line-Neutral
Power: Real, Reactive, and Apparent 3-phase total and per phase
Power Factor: 3-phase average and per phase
Frequency
Power Demand: Most Recent and Peak
19.9.2 KWH OPERATION
The KWH Meter will be set to monitor and log all power information. The meter will
also be capable for demand control or load shedding.
Demand Control applications are used by E2 to keep the total power usage of the
building environmental system below a specific demand set point dictated by the
power company. Demand Control applications achieve this by reducing power
consumption in one or more applications in the other E2 applications as necessary
until the total KW is below the set point. This process is called load shedding. The
Demand Control application is designed to calculate power usage in much the
same way power companies do, which ensures that it will be able to meet the
power company’s demand limit accurately. The Demand Control application is also
designed with a large amount of flexibility in the way load shedding is prioritized,
which allows users to maximize power economization with a minimal amount of
interference into the normal operations of the building’s HVAC systems.
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