1、 Unit Introduction
Water cooled magnetic levitation chiller, also known as water-cooled magnetic levitation variable frequency centrifugal chiller, is a new generation of large-scale central air conditioning/process cooling host. Its core difference from traditional screw machines and ordinary oil centrifuges is that it adopts the magnetic levitation oil-free centrifugal compressor is powered by cooling water (cooling tower) side heat dissipation as condensation method to produce low-temperature chilled water at around 7 ℃, which is transported to the end to achieve air conditioning refrigeration or industrial equipment cooling. This is currently the current trend large scale refrigeration equipment with high energy efficiency and long lifespan.
2、 Core working principle
2.1、Core technology of magnetic levitation compressor (most critical)
1. The suspension principle is controlled in real-time by displacement sensors, controllers, and electromagnetic actuators in a closed-loop manner. The compressor rotor is completely lifted by electromagnetic suction, and there is zero physical contact and mechanical friction when the rotor rotates at high speed abandon the traditional mechanical bearing+lubricating oil lubrication mode.
2. High speed permanent magnet synchronous motor direct drive impeller (speed 20000-40000r/min) for compression work, no gearbox transmission, low-pressure refrigerant gas is pressurized and heated by centrifugal force to complete the compression process.
2.2、 Complete water-cooled refrigeration cycle (four major components)
1. Compression: The magnetic levitation compressor compresses low-temperature and low-pressure refrigerant gas into high-temperature and high-pressure gas;
2. Condensation (water-cooled core): High temperature refrigerant enters the shell and tube condenser, exchanges heat with external cooling water, and liquefies. The heat is discharged into the outdoor atmosphere through the cooling tower;
3. Throttle: The liquid refrigerant is depressurized and cooled through an electronic expansion valve;
4. Evaporation: Low temperature and low-pressure refrigerant evaporates and absorbs heat in the full liquid/falling film evaporator, freezes water in the cooling pipe, and produces 7 ℃ cold water for end use. The refrigerant is then sucked back into the compressor for cyclic operation.
3、 Core structure composition
1. Host core: Magnetic levitation variable frequency centrifugal compressor (single head/multi head parallel modular), permanent magnet synchronous variable frequency drive;
2. Heat exchange system: high-efficiency shell and tube evaporator, shell and tube condenser (exclusively for water cooling);
3. Refrigerant system: electronic expansion valve, gas-liquid separator, refrigerant pipeline; Common environmentally friendly refrigerants: R134a, R513A, R1234ze (low GWP environmentally friendly type);
4. Control system: PLC intelligent control cabinet, remote communication module (BACnet/Modbus), multiple safety protections;
5. Auxiliary waterways: chilled water interface, cooling water interface, sewage exhaust valve, shock absorber base.
4、 Highlight advantages (compared to traditional oil centrifuges and screw machines)
1. Ultimate energy saving, significantly reducing operating electricity costs
The COP at full load can reach 6.3~7.0, and the comprehensive partial load energy efficiency IPLV can reach up to 12+; Building air conditioning operates at partial load for most of the year, saving 30% to 50% of electricity compared to conventional units; Wumo
Friction loss+oil-free film heat transfer resistance, the heat transfer efficiency of the evaporator/condenser will never decrease permanently; Permanent magnet motor efficiency of over 98%
2. Oil free system, minimal maintenance, and long lifespan
Completely eliminate the entire set of oil components including oil pump, oil separator, oil filter, oil heater, and return oil pipeline, significantly reducing the number of failure points;
No need to regularly replace refrigeration oil and oil filters, reducing annual maintenance workload by over 70%; Compressor design life ≥ 100000 hours (approximately 25 years)
3. Grid friendly, with minimal start-up impact
Variable frequency soft start, with a starting current of only 2-6A, far lower than the traditional unit's starting current of hundreds of amperes. The renovation of old distribution rooms does not require the expansion of transformers, reducing the investment in distribution renovation
4. Low noise and low vibration, strong environmental adaptability
No mechanical friction vibration, the overall operating noise is ≤ 73dB (A), and some loads are lower; Can be placed near office areas, wards, laboratory rooms, without the need for complex noise reduction projects
5. Wide load regulation range and high operational stability
10%~100% load continuously variable frequency regulation, infrequent start stop at low loads; Multi head modular units are mutually backup, and the failure of a single compressor does not affect the cooling supply of the entire machine, resulting in higher reliability.
6. Other additional highlights
Modular assembly, cooling capacity can be freely combined, single unit 160kW~5600kW full coverage; The computer room occupies a compact area and is suitable for the renovation of old projects;
There is no risk of lubricating oil leakage, the refrigerant system is clean, and it meets the high standards of clean rooms and data centers.
5、 Objective shortcomings
1. The initial procurement cost of equipment is high, which is more expensive than ordinary screw units and conventional centrifugal units, relying on 3-5 years of electricity cost savings to recoup costs;
2. Magnetic levitation bearings are precision electronic control components that rely on professional manufacturers for after-sales maintenance, which requires higher technical requirements for maintenance personnel;
3. In scenarios with extremely low cooling capacity (tens of kilowatts), the cost-effectiveness is not as good as that of vortex chillers, and it is more suitable for large and medium-sized refrigeration needs of ≥ 150kW.
6、 Typical application scenarios
1. Central air conditioning in large public buildings
Commercial complexes, super high-rise office buildings, five-star hotels, tertiary hospitals, university campuses, exhibition centers, and rail transit hubs.
2. Data center/computing power room (currently the largest incremental market)
IDC and AIDC intelligent computing centers require high PUE, efficient cooling throughout the year, and 24-hour uninterrupted reliable operation. Water cooled maglev is the mainstream choice.
3. Industrial process cooling
Electronic semiconductor clean room, biopharmaceutical factory, new energy battery factory, precision laboratory, large-scale food processing, chemical constant temperature process cold water supply.
4. Regional energy stations and energy-saving renovation projects
Urban centralized cooling stations, energy-saving replacement of old central air conditioning systems, and enjoying energy-saving subsidies and dual carbon policy dividends.
7、 Key Selection Core Parameter Reference
1. Single unit cooling capacity: 45RT~1600RT (160kW~5625kW);
2. Standard for chilled water: supply water at 7 ℃, return water at 12 ℃; Cooling water inlet at 30 ℃/outlet at 35 ℃;
3. Control protocol: Supports remote monitoring and group control linkage of building BA system;
4. Protection functions: overcurrent, high voltage, low voltage, antifreeze, power-off drop protection, rotor instability protection.
The water-cooled magnetic levitation chiller relies on three core technologies: magnetic levitation oil-free and zero friction, permanent magnet variable frequency direct drive, and efficient heat exchange through water cooling. With higher initial investment, it can achieve long-term ultra-low electricity costs, minimal maintenance, and long service life ，is a high-end, efficient, and energy-saving host for central air conditioning and process cooling in large-scale projects.
Precautions for Unit Use
Installation precautions
1. When lifting, positioning, and installing the unit, safety must be taken into account to prevent collisions and ensure the integrity of the equipment.
2.If the unit is installed outdoors, efforts should be made to avoid exposure to wind and rain (except for rainproof types), direct sunlight, or other heat sources that directly radiate; The computer room environment must be kept dry, clean, and ensure good ventilation, leaving space for unit maintenance and upkeep.
3. For air-cooled units, please ensure that there are no obstructions around the unit and reserve 1 meter of space; There is no obstruction within 2 meters of the top of the unit to ensure good ventilation.
4. It is recommended to install the unit on a strong and level ground, and install shock-absorbing rubber pads under the unit chassis to correct the level of the unit. If there are anchor bolts, they must be installed and fixed.
5. The circulating water pump used in conjunction with the unit should be selected and installed according to the data requirements such as water flow rate and water resistance required by the unit.
6. The water pump must be installed in front of the inlet of the unit, and it is recommended to install a filter at the inlet of the water pump to prevent foreign objects from entering the heat exchanger of the unit; If the unit is installed in areas with poor water quality, water treatment must be carried out first to avoid damage to the heat exchanger.
7. It is recommended to install valves, water pressure gauges, thermometers, water flow switches, and other equipment for the water pipeline system connecting the unit, in order to facilitate the inspection and maintenance of the unit's daily operation.
8.To prevent air from being trapped in the water system, the air must be completely discharged before starting the compressor.
9. The chilled water pipeline must be insulated properly to avoid loss of cooling capacity, condensation, and freezing.
10. The weight of the system connection pipeline shall not be borne by the machine body. Rubber shock-absorbing flexible joints and gate valves shall be installed at the inlet and outlet of the unit to avoid vibration and facilitate maintenance.
11.When configuring wires for the unit, wires with slightly larger cross-sections (with margin) should be selected according to the power consumption, and reliable electronic control components and grounding power sources should be installed to prevent accidents such as overload and leakage.
12. As the unit is equipped with reverse phase and phase loss protection, attention must be paid to whether the line phase is correct during wiring installation. The unit cannot operate normally when the phase is misconnected or missing.
13. The operator of the unit must observe the operation status of the unit at all times. Once any abnormal situation is found, please promptly troubleshoot. Forced operation will inevitably cause damage to the unit.
Precautions for operation:
1. Before starting up, check whether all water outlets and pipelines of the unit have been correctly installed and connected.
2. Before starting up, check if the power supply of the unit is connected and if the phase sequence is correct.
3. Before starting up, ensure the safety of the power and water sources. Please carefully refer to the equipment operation manual and strictly follow the instructions for use and operation.
Maintenance precautions:
1. Regularly replace the water in the water tank (it is recommended to replace it every 2 months).
2. Regularly clean the radiator of the unit. For air-cooled units, it is recommended to clean the radiator every 3 months; It is recommended to clean the shell and tube condenser and cooling tower of water-cooled units every 6 months (if the usage environment or water quality is poor, it is recommended to shorten the cleaning cycle).
3.If the unit is not used for a long time, please turn off the main power supply; When the ambient temperature is below 0 ℃ and the unit is shut down for more than 6 hours, the unit and pipelines may freeze, and the damage caused by this is not covered by the warranty. The best way to avoid pipeline freezing is to completely drain all the water in the unit system!
4. Regularly check the water quality on site to ensure that the water source is qualified (pH ≈ 7). If it contains corrosive substances and causes damage to the unit, it is not covered by the warranty.
5.When the unit encounters unavoidable faults during use, please inform our company of the unit model, component name, and other information so that we can provide you with services more quickly.
6.During the warranty period, our company promises to provide free maintenance services for the unit (excluding human damage, improper use, natural disasters, and uncontrollable factors).
Warning: This unit is a high-voltage, highly specialized mechanical equipment, and should be operated correctly by professional technicians strictly in accordance with the "User and Installation Manual".
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