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Project Profile

Hamilton Telephone Exchange

Industry: Commercial Office and Buildings

Project Name: Hamilton Telephone Exchange
Location: Newcastle, NSW
Main Goal of Project:
  • A complete DDC (Direct Digital Controls) upgrade of a strategic telephone exchange with Maxim and Genesis Controls, as the existing controls were pneumatic and no longer functioning reliably.
  • Increased capacity of the Chilled water plant by adding two new air cooled water chillers and pumps bringing the total to 4 chillers.
  • Lead Lag control and fault rotation of the chillers.
  • Energy saving functionally which included Economy cycles and Demand Based Ventilation control.
  • New BMS (Building Management System) dynamic monitoring software.
  • New alarm notification system.
  • High level Interface to two new Computer Room Air Conditioner (CRAC) units for level 1 equipment rooms.

Main Requirements of Project

  • Complete replacement of all pneumatic controls and field devices with a new Building Management System, modulating dampers and control valves / modulating actuators.
  • Addition of Economy control for the main central plant air handling system.
  • Upgrade of level 1 AHU units using Stulz CRAC units with Modbus High Level Interface for monitoring purposes.
  • Full redundancy control of the entire main plant including the chillers, pumps and AHU.
  • Demand based ventilation control for the Car park.
  • New user interface using Magellan Explorer.


Controls Used:
Software Used: A variety of applications are catered to using the following software:
Heating: The majority of the site is a cooling only application primarily for equipment room areas, however there are office areas located on levels 1-3 in the centre of the building that require heating. Heating is achieved using hot water from a central boiler for the AHU’s (Air Handling Unit) that controls these areas.
Cooling: All cooling is achieved via chilled water supplied from the central chilled water plant. The only DX (Direct-Expansion) cooling within the exchange are the 2 new Stulz CRAC units located on level 1.
Data Logging: Each controller is data logging temperatures, equipment status, faults etc. In addition to this the same information is logged to a database enabling the information to be displayed in the Magellan package.
Air Flow Control: The main air handler in the level 4 plant room has a VSD (Variable Speed Drive) that is set up for soft start operation. The AHU itself has a hot deck/cold deck arrangement as it is heating/ cooling the centre zone offices from levels 1-3. All other units are constant volume systems.
Water Flow Control: Based on the building load, the BMS sequences the 4 chillers and pumps, and controls the Main Chilled Water bypass valve based on system pressure. The hot water plant consists of a single boiler and hot water pump.
Ventilation: All ventilation fans are controlled on either time schedules or temperature. The BMS controls demand based ventilation for the carpark which is based on the CO (carbon monoxide) measured in the basement.