AIR-CONDITIONING SYSTEM

I.

AIR-COOLED SPLIT-TYPE AIR-CONDITIONER

The Air-Cooled Split-Type Air Conditioner shall compose of an indoor unit and an
air-cooled outdoor unit. The indoor unit shall include an evaporator, an evaporator
fan, a fan motor, and an auxiliary control component enclosed in a cabinet
for indoor installation. The air-cooled outdoor unit shall include a condenser, a
condenser fan, a compressor, and other components enclosed in a weatherproof
cabinet. Both units shall be properly assembled, internally wired, thoroughly tested,
and charged with R-22 refrigerant at the factory and shall comply with relevant
standard.
The indoor cabinet shall be constructed of finished steel, baked resin paint for a
bottom panel and a top panel, and reinforced plastic for side panels and front grilles.
The cabinet interior shall be insulated by incombustible and self-extinguishable
diabetic material. The service panels shall be easily removal for service access to the
unit components. Facility of auto louver shall be incorporated.
The evaporator coil shall be the multi-pass cross-finned tube type, equipped with
aluminum plate fins, mechanically bonded to seamless oxygen-free copper tubes.
The fins shall be spaced at more than 12 fins per 25 mm. The coil shall be cleaned,
dehydrated and tested for leakage at the factory.
The evaporator fan shall be the forward-curved centrifugal type, statically and
dynamically balanced, and directly driven by a motor. The fan motor shall be
permanently lubricated.
A filter shall be of washable type and equipped at the air intake of the unit.
The outdoor cabinet shall be constructed of finished steel, baked with synthetic resin
paint. The fan guard wire net shall be mounted on top of the unit.
The condenser coil shall be the multi-pass cross-finned type, equipped with aluminum
plate fins mechanically boned to seamless oxygen-free copper tubes. The coil shall
be cleaned, dehydrated and tested for leakage at the factory.
The condenser fan shall be an aluminum propeller type, statically and dynamically
balanced, and the fan shall be directly driven by a motor for up-flow air discharge.
The motor shall be permanently lubricated, and shall be protected from water
invasion.

ACS-1

The
unit shall contain a hermetic
multi-cylinder
reciprocating compressor.
The compressor shall be a star-delta type, and equipped with vibration-proof rubber.
The hermetic compressor shall be a welded shell type, and shall be spring suspended
internally. The compressor shall be protected against a breakdown by the overcurrent
relay, pressure switch and a built-in internal thermostat.
The magnetic switch box incorporated in the unit shall contain magnetic contactors
for all motors, including condenser fan motor overcurrent relays; three minutes restart delay circuit and auxiliary relays.
All drain & refrigerant pipes and electrical wiring shall run in electrical trunking.
The refrigerant pipe work material shall be of copper and the drain pipe shall be of
PVC. All insulated pipe work shall be with 19 mm or thicker thickness of high
quality closed cell insulation tubing to prevent water condensation on the insulation.
The thermal conductivity shall not exceed 0.26 Btu/hr ft/deg. F/in or 0.0374 w/mk.

II.

MANUFACTURERS WARRANTY

During the first year after hand-over, should the compressor for any Air-conditioning
System develop any fault, it shall be replaced with a brand new one inclusive of gas.
After the first year, the compressor shall continue to carry a warranty in accordance
with the manufacturers terms and conditions.
The manufacturers warranty card shall be submitted and handed over to the Engineer
together with the air-conditioner.

III.

TESTING AND COMMISSIONING

The Contractor shall at his own expense, provide the necessary skilled labour,
facilities and materials for the testing, balancing, control setting and commissioning
of the air-conditioning system under this Contract.
The Contractor shall in general, carry out his own test and satisfy himself that the test
has been satisfactory prior appointment for the Engineer or his representative to
witness the test.
All successful tests shall be witnessed by the Engineer or his representative.
Tests to be carried out after complete installation shall be as specified hereunder.

ACS-2

1.0

SMMS AIR CONDITIONING SYSTEM. (Air-Cooled System)

1.1

GENERAL
Unit shall be Air-Cooled, SMMS Type Air Conditioner consisting of one outdoor unit and
multiple indoor units, each having capability to cool independently of requirements of the
rooms.
COP of 4.25 (8HP CDU system, heating operation) achieved by Toshibas unrivalled
Super Modular Multi System (SMMS) technologies and newly developed components.
Part load operation. A VRF system can achieve energy efficient operation especially in a
separated room layout as shown. Not all of the indoor units operate at the same time so
the system is almost always operating with a partial indoor unit load.
New high-performance bell mouth with smooth flow. Enlarged suction radius provides
smoother flow.
DC fan motor- Pressure fluctuations due to interference have been suppressed. Efficiency
is high, and noise has been reduced. High output / high-efficiency DC motor.
Vector-controlled inverter. The inverter boosts efficiency by controlling R410A and a
twin-rotary DC compressor. Efficient circuit built-in; new PIM and Smooth sine curve
realizes higher efficiency and less noise.
SMMS high performance COP. Partial load performance is the most important value for a
VRF with fluctuating performance due to changes in the number of units operating and/or
fluctuations in the air conditioning load.(10050% partial load operation)
New large-diameter propeller fan (flash wing fan). Enlarged fan diameter 630 710.
The concave leading edge of the fan blades reduces flow interference between adjacent
blades.
Outdoor heat-transfer.
- Compact heat-transfer tube with intakes on four sides.
- Heat-transfer tube with improved heat-transfer coefficient of the inner surface.
- Configuration of the finned heat-transfer tube.
R410A refrigerant is using for SMMS system. An ozone layer depletion coefficient of
zero has become absolutely essential for an advanced air conditioning system.
Twin-rotary DC compressor Two DC twin-rotary compressors (dual configuration) are
equipped per module (basic outdoor unit).
DC driven motor with rare earth magnet
- Compact- Higher efficiency
- Higher power motor torque
Precise manufacturing technology in the compression parts
- Higher efficiency (in wide range)
- Higher reliability

AS -1

High-efficiency DC twin-rotary compressorsEvery outdoor unit incorporates two new DC

twin-rotary compressors and dual-inverter drives this is unique to Toshiba and the air
conditioning industry.
ReliabilityWith dual-rotation, the load is distributed more evenly this means that the
operating sequence of the outdoor units and the individual compressors is rotated to
spread the operating hours more evenly.As the compressors are all inverter driven, power
surges are eliminated. Over- or under-utilisation of power, typical for non-inverter
compressors is eliminated, and there is no on/off power surge as the system adjusts to the
demand required by the occupant or system.
The use of inverter compressors reduces the risk of compressor failure, more common in
standard non-inverter systems.
Energy savingsDuring operation the system determines which heat exchanger can be used
most efficiently and selects the compressor to deliver the power required. Inverter systems
save energy as continuous operation offers the same capacity with lower power
consumption. This benefits all occupants by maintaining even room temperatures, as well
as the environment by reducing energy consumption.
1.2

DC TWIN-ROTARY COMPRESSOR ADVANTAGE

This is a comparison of compressor energy efficiency by compressor rotation.SMMS use
twin-rotary inverter compressor, energy efficiency through all range of compressor
rotation is more stable than scroll type compressor in characteristic.Scroll compressor can
achieve high-efficiency operation in narrow scope.As the VRF air conditioner required a
wide range of capacity, a twin-rotary compressor is well-suited for the VRF.

1.3

GREATER INSTALLATION FLEXIBILITY

The pipe runs for the SMMS have been extended to offer greater application flexibility.

1.4

EXTENDED PIPING CAPABILITIES

-Maximum actual length150 m
-Farthest equivalent length175 m
-Extension300 mMaximum height difference, outdoor unit is higher than indoor unit50 m
-Maximum height difference, outdoor unit is lower than indoor unit40 m
-Maximum height difference between indoor units30 m
-Maximum length from first branch65 m

1.5

FLEXIBLE BRANCHING
The versatility of the SMMS means that virtually any imaginable configuration of the
refrigerant Y-type branches and/or header piping can be used in an application to give the
shortest, most cost-effective piping installation. The piping can be run in any direction to
facilitate refurbishment work. The diameter of the liquid and gas pipes is reduced due to
the utilization of R410A refrigerant (in some units). More effective use of pipe shafts is
also possible, resulting in greater savings in installation costs.

AS -2

1.6

UP TO 48 INDOOR UNIT CONNECTIONS

Up to 48 units can be connected at up to 135% outdoor unit capacity in a single cooling
system.- Allows smooth response to floors with small rooms and tenants who change
layouts often.

1.7

OPTIMAL REFRIGERANT CONTROL

When a multiple number of indoor units are connected, an insufficient or excess amount
of refrigerant may be supplied to indoor units depending on the difference in length of the
connection pipe from the outdoor unit.This is caused by pressure loss and heat leaks as
the refrigerant travels through the pipes, resulting in incorrect amounts of refrigerant
being supplied to the indoor units.Optimal refrigerant control uses a multiple number of
refrigerant sensors to detect the air conditioning status of each indoor unit and control the
capacity (refrigerant amounts) very precisely to eliminate the variations.
Back-up function. In the unlikely event of one compressor within an outdoor unit failing,
it is possible in most circumstances to operate the second compressor on its own simply
by setting a switch on the interface PCB. In the case of a complete outdoor unit failure,
select another outdoor unit to be the header unit. In multiple outdoor unit systems any unit
can be selected to be the header unit.
Night operation (sound reduction) control(with optional PC Board (TCB-PCMO2E) and
locally supplied timer/switch)The unit also comes with a night-time low-noise mode,
which reduces operating noise at the programmed activation time.

1.8

OIL LEVEL DETECTION SYSTEM

These controls realize stable oil supplies.
1) Oil balance control, this control equalizes amount of oil between two compressors.
2) Oil supply control, this control accumulates oil in the oil separator. When oil is
insufficient, the system supplies oil to the compressors.
3) Oil supply control between outdoor units, this control supplies oil accumulated in the
oil tank of each outdoor unit to the outdoor unit with insufficient oil.

AS -3

2.0

REFRIGERANT CIRCUIT
The refrigerant circuit shall include an accumulator, liquid and gas shut off valves
solenoid valves and an electronic expansion valve. All necessary safety devices should be
provided to ensure the safety operation of the system.
Contractor shall supply and install all steel sleeves for piping penetrations through walls
partitions, floor slab and structural beams as required. Sleeves shall be as shown and as
specified with particular attention to caulking of the gap between pipes and sleeves to
satisfy fire separation and vibration isolation requirements.
2.1 Accumulator
The cylindrical accumulator shall be constructed from mild steel plates pressed
into shape. The accumulator shall have sufficient capacity to prevent any liquid
refrigerant from flowing back into the compressor suction.
2.2 Safety Devices
The following safety devices shall be part of the condensing unit. High pressure
switch, fuse, crankcase heater, fusible plug, over current relay for compressor,
thermal protectors for compressor and fan motors, recycling guard timer,
Compressor discharge gas temperature protection, Negative phase protection,
defective phase protection, Undervoltage protection Compressor contactor
chattering protection, Power transformer overheating protection & Abnormal high
pressure protection.
2.3 Pressurize Testing
The complete refrigerant circuit should be subjected to a pressure test of 28.0 kg
sq. cm. for at least 24 hours without any drop in pressure.
2.4 Pipe Materials
The refrigerant pipe shall be of de-oxidized phosphorous seamless copper pipe
conform to JIS H300 - C1220T.
The refrigerant (suction) piping shall be copper-gard pre-insulated pipe factory
fabricated using Single Machine-Injected System for Polyurethene Foam. The
Copper Tube Standard shall be AS1571/NZS 1571. The insulation shall be
machine injected polyurethane foam with a minimum overall density of 45Kg/m.
An environmental friendly gas shall be used as the blowing agent. The properties
of the polyurethane foam:
1)
Thermal conductivity, K-value : 0.017Kcal/m.h c
2)
Density
: 45kg/m
3)
Blowing agent used
: R141b gas ( cfc free )
The Standard Jacket Material used shall be Galvanised Steel Spiral lock-seam duct
with a minimum thickness of 1.5mm .
1 inch insulation with equivalent density of at least 0.0374 W/mK as per ASTM
C177 standard shall be used for discharge piping. All refrigerant piping exposed to
weather shall be boxed up by using stainless steel plate.
AS -4

3.0

OIL RECOVERY SYSTEM

Units shall be equipped with an oil recovery system to ensure stable operation with long
refrigerant piping (system installing with oil traps is not acceptable).

4.0

CONTROL
The control system should be connected by using 2-wire multiplex transmission system
links a single outdoor unit to multiple indoor unit with a 2-core cable. In addition, the
control system must come equipped with automatic address setting function (No manual
setting of addressing by means of rotary switches etc is allowed). An automatic checking
function for connections error of wiring and piping must come standard with the system.
Computerised PID control shall be used to maintain a correct room temperature with
minimum power consumption. Unit shall be equipped with its own 2 speed fan controller,
timer on/off switch, thermostat and LED indicators.
It shall also be equipped with a self diagnosis circuit for easy and quick maintenance and
service. It shall be able to indicate malfunction code displays. The LCD Remote Controller
shall memorize the latest malfunction code for easy maintenance.
VARIABLE SPEED DRIVE (VSD)
A variable speed drive (VSD) unit shall be used to drive the compressor motor and in-built
into the outdoor unit / condenser assembly. The VSD shall be capable of changing the
speed of the compressor using Pulse Width Modulation (PWM) technique proportionately
according to the cooling load requirement. The output of the inverter shall be of smooth
sine wave type.
4.1

Soft Starter (Starters)

All Condensing Units shall be of soft-start to ensure low staring current. The VSD
driven compressor shall be able to start at the minimum load and gradually
increased to the required voltage and/or supply frequency according to the actual
load requirement.
A recycling guard timer shall be provided to prevent the compressor to restart
again immediately after it was stopped.

4.2

Centralized Control System

A centralized control system shall consist of a Central Remote Controller, Unified
On/Off Controller and Schedule Timer. They shall be provided to control all the
functions of the Fan Coil units either together as a Central Control system or
individually as the specifications call for.
The function of each unit should be as follows:
4.2.1

Central Remote Controller

It should be able to control 64 groups (each group consists of maximum up to 16 Fan

Coil Units) or 128 nos. of Fan Coil Units with the same function of the LCD Remote
Controller which should be able to function as follows :
AS -5

Temperature setting for each Fan Coil Uof group.

Air flow setting for each Fan Coil Unit or group.
Fault indication of each Fan Coil Unit.
Zone control
It should be able to On/Off each individual or group.
It should also have the function to On or Off the entire system.
Maximum wiring length of 1 km
4.2.2

Unified ON/OFF Controller

The Unified On/Off Controller should be able to connect up to 16 groups (each group
consists of maximum up to 16 Fan Coil Units ) or 128 nos. of Fan Coil Units and it
should have the following functions :

Simultaneously or individually operate the Fan Coil Units

Normal operating status such as normal operation, alarm indication
Able to have centralized control indication
It must be able to combine with the Centralized Remote Controller
Maximum wiring length of 1 km

4.2.3 Schedule Timer

The Schedule Timer should be able to connect up to 64 groups (each group consists of
maximum up to 16 Fan Coil Units ) or 128 nos. of Fan Coil Units and it should have
the following functions :
It should be able to set 8 types of weekly schedule
Maximum 48 hours backup power supply
Able to have centralized control indication
It must able to be connected to either Centralized Remote Controller or Unified
On/Off controller
Maximum wiring length of 1000m

4.2.4 Highly Advanced Central Control Air Conditioning Management

System-Intelligent Controller
The device shall be of Color LCD Screen Panel. It must be of Touch Screen Operation
(No Buttons necessary). Hence, it shall be equipped with a Touch Pen. It shall have
Graphic Icon Display to indicate the units under control of this device. The weight of
this device shall not be more than 1.2 kg.
This device shall be able to connect up to 64 groups of Indoor Units, and each group
shall be able to connect maximum up to 16 nos of Indoor Units. This Controller shall
be able to start/stop the operation by group or zone. Collective starting / stopping must
also be available.
There must be a function whereby Temperature setting, Switching between
Temperature Control modes, switching of Speed and Direction of wind and Remote
Control Mode setting by the Group, Zone, or Collectively must be available.
The device must also allow for detailed Scheduled Operation by the Group, Zone or
Collectively. Up to 8 options for annual Schedule can be set. Each Schedule Control
shall be able to include 4 types of plans namely: for weekdays, Holidays, and 2
Options of Special Days. Each of the plans allows setting of up to 16 Operations.
AS -6

Up to 64 groups must be able to be controlled by this device. More than 1 group can
be consolidated into a zone, which can be registered, to allow the following settings by
the zone.

Temperature Setting
Switching between Operation Modes
Setting of Direction and Fan Speed
Disabling/Enabling the Individual Remote Control

This eliminates the need for repeating the same setting operation for each Group.
Function to allow Collective Setting for all Groups must also be available.

5.0

INTERFACING WITH BUILDING MANAGEMENT SYSTEM (BMS)

5.1

BACNET Gateway
A gateway to ASHRAE 135 (IEEE802.3) Local Area Network System can be performed
via the BACNET Gateway. The VRV communication system can be linked to any BMS
which is operating within the specification approved by BACNET.
The BACNET Gateway shall enable the following functions to be performed by BMS:

5.2

Schedule control based on yearly and weekly calendar

Interlock with the security system
Energy and power savings control
Monitoring and control of VRV system
Emergency stop control when fire alarm is detected

Intelligent Manager (I-Manager)

A manufacturers proprietary air-conditioning management system. This system can be
linked directly to the manufacturers VRV communication line and be interfaced to a
computer. Software shall be provided as a standard accessory.
The I-Manager shall be able to provide the following functions:

Schedule control based on yearly and weekly calendar

Interlock with the security system
Energy and power savings control
Monitoring and control of the system
Emergency stop control when fire alarm is detected
Proportionally divide power consumption (optional)

AS -7

6.0

MANUFACTURERS ENGINEERING SOFTWARE

6.1

Software For Equipment Selection

All selection shall be performed on a computerised software selection approved by the
manufacturer. All factors for the selection such as indoor and ambient temperature
conditions, de-rating compensating factors for refrigerant pipe length shall be included.

6.2

Software For Pipe Sizing And Refnet Joint Sizing

Selection for refrigerant pipe diameter and refnet joint models shall be performed in a
computerised software format in order to minimize human error.

6.3

Software For Computational Fluid Dynamics Simulation

Computational Fluid Dynamics (CFD) simulation shall be required on a case by case basis
and certified by the Manufacturer. This simulation shall be performed whenever the
Owner or Engineer suspect hot air recycling for outdoor units are likely to occur.

7.0

SERVICING
The Contractor shall be responsible for the recommended Servicing of the installation and
preparation of instructions for its operation and maintenance during the defect liability
period.

8.0

DRAWINGS AND MANUALS

The Contractor shall submit to the Engineer 4 sets of shop drawings, as-built drawings (1
set in Autocad Release 2007 file format), test results, maintenance manuals, operating
instructions and manual of all equipment and services installed.

9.0

INSPECTION, TESTING AND TRAINING

9.1

General Requirements
It is the responsibility of the manufacturer to ensure that the product is inspected and
tested at all stages of the manufacturing process in accordance to the
requirementsasstipulated in the specification. The cost of all inspection and tests shall be
borne by the manufacturer and shall be deemed to be included in the tender price.
The approval or passing of any such inspection and tests shall not prejudice the right of the
Company to reject the product if it does not comply with this specification when installed
or it does not give complete satisfaction in service. This condition shall apply only if the
causes of the above mentioned situations are due to any deficiency or wrong doing on the
part of the manufacturer toward the fulfilment of the requirements of this specification.

9.2

Acceptance Test
All test results carried out by the manufacturer shall be made available for inspection
during acceptance testing. The acceptance tests to be carried out by the manufacturer and
AS -8

witnessed by representatives of the Company and its appointed Consultant. Proposed

testing procedure shall be submitted to the Engineer before one months notice given prior
to the acceptance test.
Ten percent (10%) of the quantity ordered to the nearest whole number, with minimum
of 1 unit, shall be randomly selected for the test.

If any sample fails in any of the tests, two further samples shall be taken from the same
batch and submitted to the same tests in which the original sample failed. If both
additional samples pass the tests, all units in the batch from which they were taken shall
be regarded as complying with the requirements of this specification. If either of the
additional samples fails, the batch from which they were taken shall be regarded as failing
to comply with the specification.

10.0

TRAINING
Successful tenderer shall be required to provide adequate training for the Company
personnel on the installation, operation and maintenance of the equipment supplied. The
costs involved shall be borne by the successful tenderer.

AS -9

ELECTRICAL
1.

General
The Contractor shall supply and install the complete electrical installation for the electrical
supply and control of all items of equipment in this Contract. The air conditioning control
panel and earthing to air-conditioning units will be included.
All motors shall be wired complete with isolating switches, thermal overload, starters, etc.
and shall be identical make except where approval is given for special purpose motors.
Wiring throughout shall be in accordance with the I.E.E. wiring rules and the latest
amendments thereto and with any requirements of Local Supply Authority. Only licensed
and approved Electrical Contractors shall be employed.
Conduits shall be screwed galvanised throughout unless otherwise approved, and shall not
be less than in. in dia. All conduit used on the works, shall be new, free from burrs and
rough edges and shall be kept dry at all times. Inspection type fittings may be used where
necessary to facilitate the drawing in of conductors. All conduit work is to be completed
and inspected by the Engineer before wiring is commenced. Where flexible conduit is
necessary for any connection type of conduit may be used. Exposed wiring will not be
permitted.

2.

Cable Trunking
For ease of wiring of various systems, cables may be grouped and run on metal trunking.
They shall manufactured from galvanized mild steel of not less than 18 s.w.g for size up to
4by 4and not less than 16 s.w.g. for large sizes. The metal trunking shall be treated
with an etch type rust inhibitor and painted to approved in two coats of finishing enamel in
selected colour.
Trunking shall be supported adequately by suitable brackets fabricated from galvanised
mild steel flat.
Trunking runs shall be erected completely before any cable is drawn in and the number of
cables installed shall be such that a space factor of 45% is not exceeded.
All trunking shall have a copper earthing strip of appropriate size.
All wiring shall be looped and shall not contain joints, except where connections are made
at numbered terminal strips on the equipment. Standard colouring of conductors shall be
used throughout the installation and where necessary the colouring shall be indicated on
the air-conditioning wiring diagrams.
A earth wire shall be run to each motor and control and shall earth the equipment as
required by the Wiring Rules. In no case shall the earth wire be less than 2.5mm and it
shall terminate in an approved manner.
The Contractor shall submit lay outs and details of the proposed electrical installation to
the Engineer for approval in all case before work begins.

AS -10

3.

Supply
Electricity supply for the air-conditioning installation shall be 415 volts 50 cycles, 3 phase,
4 wire and shall be terminal and connected at the main air-conditioning switchboard, by
others. Termination boxes for the cables shall be supplied.

4.

Earthing
Earthing shall be carried out to the requirements of the specifications, all requirements of
the D.E.P and SESCO. Provided suitable earth leakage protection where required by the
supply Authority.
All power outlet, motors and accessories shall have an earthing conductor. A separate
earthing conductor shall be provided from the switchboard or distribution board for each
and every circuit. Sub-circuit earthing conductors shall be not less than 2.5mm sq. (green
PVC sheathed) and sub-main earthing conductors shall be not less than 6-mm sq. (green
PVC sheathed).

AS -11

VENTILATION FAN

1.

GENERAL
Fans shall be capable of giving the specified performance when tested in accordance
with B.S. 848. Although estimated values of the resistance to air-flow of items of
equipment may be indicated this does not relieve the Sub-Contractor of the
responsibility for providing fans capable of delivering the required air volume
through the system.
Each fan shall be capable of continuous operation, having the capacity as indicated in
the Schedule of Equipment & Works and/or in the drawings when running at the
specified speed against the friction in the system as installed.
Fans shall be properly selected to handle the air quantity specified with noise level
less than 60 db. Silencers shall be installed where the fan cannot achieve this sound
level.

2.

AXIAL FLOW FANS

The Sub-Contractor shall supply and install propeller fans capable of delivering the
required air volumes as shown in the drawings and given in the Schedule of
Equipment & Works.
Fans shall be designed for maximum reliability and performance with minimum
power consumption and noise level. Fans shall be capable of providing volume
regulation and speed control down to 10% of the full speed. Motors shall be totally
enclosed squirrel cage induction type with life-lubricated bearings.
The basic fan shall be tested in accordance with B.S. 848 and shall comprise motor,
impeller, mounting arms which incorporate neoprene anti-vibration mounts at the
arm extremities.

VE-1

DUCTWORK

1.

GENERAL
The contractor shall supply and install all ductwork required to the dimensions and
details shown on the drawings and in accordance with the following: Duct dimensions indicated on the drawings are clear internal dimensions, the first
dimension given being that of the side shown in any view.
Internally insulated ducts shall be increased in size to maintain the clear internal
dimension.
It is the responsibility of this contractor to check actual spaces available on site,
prior to fabrication of the ducts. If any departures from the drawings are deemed
necessary, the contractor shall submit details of such departures and reasons to the
Consulting Engineer for approval.
All ductwork installations shall also meet Local Fire Authority's requirements.

2.

SHEET METAL DUCTS-LOW PRESSURE

All ductwork shall be fabricated from best quality steel sheet. Sheets on which
cracking or flaking of the protective coating occurs during fabrication will be
rejected.
All ducts shall be machine formed, to true dimensions, cross-broken on all surfaces
exceeding 12 inches in width and be free from waves, bulges and buckles. Raw
and sharp edges shall be removed from all duct components and gaskets and other
parts of joints shall not intrude into the air stream. Ductwork shall be constructed
so that branding and other identification marks are displayed on the outside
surfaces.
Ductwork which is to be acoustically insulated shall not be cross broken.

AD-1

Gauges, transverse joints and bracing shall be as follows:

Max. Side (ins.)

Birmingham
Gauges

Transverse
Joint

Bracing

Max. Spacing
of Joint or
Bracing

Up to 12

24

Drive Slip

Nil

13to 24

22

Drive Slip

Nil

25to 30

22

1barred
Drive Slip

1x 1x 16g
angle

4 ft

31to 60

20

1barred
Drive Slip

1x 1x 16g
angle

4 ft

61to 90

20

1 barred
Drive Slip

1 x 1x
16g angle

4 ft

Over 91

20

2x 2x
3/16barred
Drive Slip

2x 2
angle

4 ft

Longitudinal joints used in the above duct construction shall be Pittsburgh lock on the
corners and grooved seams elsewhere.
Alternatively, ducts of maximum side exceeding 40" may be constructed of 22g
material using angle flanged joints at 4'0" maximum centres as specified above for
transverse joints and 1 1/2" inside standing seams at 30" max. centres for longitudinal
joints.
Gaskets to flanged joints shall be of soft rubber of jointing material similar to Prestik.
Bolt and rivet centres all flanges shall not exceed 4".
Spot welding shall not be used. Slips shall be made from material two gauges heavier
than the duct.
Bends without turning vanes shall have an internal radius equal to at least 3/4" of the
duct width. Square bends shall have double section turning vanes constructed of 24gauge material and in accordance with the standard drawings.
The sides of transformation pieces shall have a slope of not greater than 1 in 7 for
expansions and 1 in 4 for contractions.

AD-2

3.

FLEXIBLE CONNECTIONS
Connections between ductwork and any item of equipment that may move or
vibrate shall be made using flexible connections of fibreglass reinforced PVC of
minimum length of 3 inches. Flexible connections shall be securely fastened at
each end and be air tight.
Where shown on the drawings final connections to outlets shall be made with
flexible ductwork to permit relocation of the outlet within 1'0" of its original
position in any direction.
The flexible ductwork shall be formed from spirally wound aluminium corrugated
and lock formed with factory applied insulation and polythene vapour barrier. The
ducting shall be of approved manufacture and shall be installed as per
manufacturer's recommendations. To make final connections to outlets, the outlet
shall be fitted with a plenum box with spigot connection suitable for the size of
connection to be made.

4.

SEALING OF DUCT
Ducts shall be air-tight at the operating pressure.
Machine folded joints in ductwork shall be smooth and air tight. Slips shall be
caulked at each corner. Any hand formed joint in ductwork shall be fully caulked.
Non hardening caulking compound shall be used for caulking. Air leak at any
portion of duct work during testing shall be dismantled and made good.

5.

SPLITTERS
Splitters for adjustment of air distribution to the respective branches shall be
installed whether indicated on the drawings or not.
Splitter shall be made from not less than 22g galvanised steel in double streamless
section securely fastened to a 1/2 inch steel rod which pivotted in bronze or nylon
bushes fixed to the duct and provided with a lockable type quadrant for splitters of
length under 20 inches. Splitters of length 20 inches and over shall have steel rods
hinged to the air entering edge and passing through a suitable clamp on the side of
the large duct to permit positional adjustment and provide rigid anchorage in any
position.
Splitters may be of the fixed type if the branch duct serves only one outlet but most
be of the adjustable type if more than one outlet are served on the same branch duct.

6.

SUPPORTS AND HANGER FOR DUCTWORK

All ductwork shall be firmly supported and securely fastened in place.

AD-3

Horizontal ducts shall be supported at centre by steel rods or straps as follows: Sides of
Rectangular Duct

Support Material

Spacing

Up to 36" in width

1"x10" galvanised
steel strap

8 ft

Up to 60" in width

1 1/2"x10g galvanised
steel strap

6 ft

Up to 84" in width

1 1/2"x1 1/2"x1/8"
angle 3/8 dia rod

4 ft

Over 84" in width

2"x2"x3/16" angle

4 ft

Where ducts pass through floors, walls or partitions, the free space shall be
adequately caulked with suitable diameter asbestos rope or felt gasket and a neat
sheet metal angle flange arranged to cover the free space.
Vertical duct shall be supported at not more than 6 ft. at each floor level.
Up to 26" in width

1 1/2"x1 1/2"x1/8" angle

3/8" dia. rod

Up to 60" in width

1 1/2"x1 1/2"x3/16" angle

3/8" dia. rod

Up to 84" in width

2"x2"x3/16" angle 3/8" dia. rod

Maximum stress in hanger's rod, strap and bolts shall not exceed 5,500 psi.
Diameter of bolts shall not be less than 3/8". All steel angles and rolled steel flat
used of hangers shall be treated for protection of corrosion.
7.

ERECTION AND DUCTWORK DETAILS

1.

All ductwork detail drawings shall be submitted to the Engineer for approval
before fabrication.

2.

All ducting systems shall be erected in a workmanlike manner and when

completed shall be rigid the free from sway or movement; and shall be
true-to-size, accurately lined up and truly air-tight.

3.

Turning vanes or air turns shall be used on all duct bends where the radiums
of the bend is less than 1-1/2 times the width of the duct and on all right
angle bends. Turning vanes and air turns shall be streamlined.

4.

All ducts shall be adequately stiffened and bracketed to prevent drumming

or vibration and shall be free from internal sharp edges or projections.

AD-4

8.

SHEET METAL DUCTWORK INSULATION

All supply and return ductwork of G.I. sheet metal construction shall be insulated
externally with 25mm thick fibreglass of not less than 2 lb/ft3 density with a thermal
conductivity not greater than 0.24 Btu/hr/ft2/Fo per inch thickness and an approved
fire-resistant, double-sided reinforced aluminium 450 or insulco 525 foil insulation
adhered to one side. All ductwork below a non-air conditioned floor (e.g. roof slab)
shall be thermally insulated with 50mm thick blanket type fire proof fibreglass of
minimum 2 lb. per cu. ft. density and a thermal conductivity of not more than 0.24
Btu/ft2 Fo/hr. The fibreglass shall be securely cemented to the ductwork with an
approved adhesive. The first 6m of the supply air duct shall be c/w internal acoustic
insulation.
Insulation shall be carried out over all flexible connections and points subject to
condensation. A channel section of 32mm wide with 12mm deep leg of 1mm
galvanised iron sheet shall run along the bottom of ductwork over 600mm in width
so as to prevent sagging of insulation. The channel shall be secured to flanged
connection with self-tapping screws; the head of the screws shall be covered with
vapour seal adhesive tape.

9.

TOILET EXHAUST DUCTWORK

All toilet exhaust ductwork within return air plenum ceilings or shafts shall be
carefully treated with a suitable sealing compound such as manufactured by 3M or
approved equal, at all joints and seams to ensure that the duct is airtight and leakproof.

AD-5

DIFFUSSERS, REGISTERS, GRILLES AND VAV SYSTEMS

GENERAL
1.

DIFFUSERS, GRILLES & REGISTERS

Diffusers, grilles and registers shall be of extruded aluminium construction and
shall be installed in the sizes and locations as shown on the drawing.
Opposed multiblade volume control dampers shall be fitted at the back of all
diffusers, grilles & registers, unless otherwise indicated. The damper blades shall
be ganged for operation from an accessible screw adjustment. The damper shall be
finished matt black.
Square ceiling diffuser shall incorporate not less than 4 diffusing cones and shall be
designed to give uniform airflow over the entire area.
Registers shall be designed with horizontal and vertical deflection vanes of aerofoil
section. The vanes shall be provided with a sponge rubber gasket around the mating
surfaces with the frames. Spacing between vanes shall not exceed 18mm.
Grilles shall be of free flow type with louvres which are 12mm deep and forming a
grid of 12mm square.
Square ceiling diffusers, registers and grilles shall be designed with a removable
core to permit maintenance. The means of fixing of frames shall be such that screw
heads are not visible on the face.

2.

RETURN AND EXHAUST AIR GRILLES (CEILING MOUNTED)

Ceiling mounted grilles shall be of all aluminium construction and shall be supplied
in baked enamel finish in a colour selected by the Architect. The louvres shall form
a 12m x 12mm grid and shall be 12m deep. The grille frame and core shall be such
that no screw heads are visible on the face of the grille after fixing.

3.

TOILET EXHAUST GRILLES

Grilles shall be of the perforated face type constructed from zinc coated steel and
with a epoxy coated finish to a selected colour.
Grilles shall have a removable perforated core with a minimum 50% free area.
Grilles shall be fitted with a rear mounted, opposed blade volume control damper
and shall have secure concealed fixing.

DI-1

4.

VAV SYSTEM

a)

Variable Air Volume Diffuser (VCD)

Variable air volume square diffusers where indicated in the drawings shall be
VARI-DISC model VCD (variable-volume ceiling diffuser) VARIABLE
GEOMETRY type. Each unit shall be finished in a chip resistance baked epoxy
powder coating to the architects colour requirements.
Volume regulation shall be by means of electric actuator, factory set to vary air
volume from 100% to 30% of maximum. The electric actuator shall drive a control
disc vertically up and down in the diffuser so as to vary the aperture through which
air passes.
All parts likely to need service must be easily accessible either through the diffuser
spigot or the adjacent ceiling tile.

b)

Pressure Control Damper

Pressure control dampers where indicated on the drawings shall be of the
VARIABLE GEOMETRY tight shut-off PCD type, provided with ceiling strip on
all vanes such that they shall close to a minimum of 2% of total free area to reduce
leakage to a minimum when fully closed.
All PCD danpers shall be supplied complete with galvanised sheet steel casings,
earofoil profile aluminium vanes rotating in substantial nylon bearings and shall be
provided with proportional/integral electronic pressure controllers contained within
an enclosure fitted to the outside of each of the damper casings. A remote pressure
sensor having an operating range of 0-100 Pa shall be interconnected to the
controller by means of control cable provided by the controller supplier.
All PCD dampers shall be provided with an electric actuator fitted on the downstream side of the pressure controlling vanes. An access panel shall be provided by
the contractor and shall be situated in the ducting on the down-stream side of each
of the dampers.

c)

Temperature Controller
Temperature controllers shall be compatible with the electrically actuated
VARIABLE GEOMETRY VAV terminal such as the VARI_DISC and WBD and
shall be capable of controlling up to 6 units simultaneously (1 master and 5 slaves).
They shall be of the standard Proportional/Integral type able to accurately control
flow such that room temperature is within 0.5C of set point.
All temperature controllers must be catered for by 24V or 240V power supply
brought either to a pair of terminals fitted within a control panel or a 5 amp socket
outlet adjacent to the master unit. A temperature sensor must be supplied with each
controller.

DI-2

d)

Ribbon Cable
Ribbon slaving cable provided with sockets at both ends shall be used to
interconnect master/slave and slave/slave VAV terminals. Slaving cable shall be
purchased from the controls supplier to ensure compatible master/slave unit
operation.

5.

INSECT SCREENS AND LOUVRES

All external supply and discharge air louvres shall be of the sizes indicated on the
drawings and shall be supplied and fixed by the Contractor unless otherwise shown
on the drawings. They shall be suitable for removal and be complete with suitable
non-corrodable insect screens and shall be constructed of aluminium. Insect screens
shall be a 6mm mesh made from 2mm diameter wire.

DI-3