I. Unit Introduction
Magnetic Levitation Air-Cooled Natural Cooling Chiller Unit: A high-end, large-scale chiller integrating three core energy-saving technologies: magnetic levitation oil-free variable frequency centrifugal compressor technology, air-cooled condensation heat dissipation, and natural free cooling. It directly produces 7℃ chilled water, eliminating the need for a cooling tower and achieving zero cooling water loss. Relying on low-temperature outdoor air, it operates year-round in various modes, making it a large-scale energy-saving cold source backup for data centers and projects requiring continuous year-round cooling.
II. Core Structure and Two Underlying Technologies
(I) Core Components
1. Magnetic Levitation Oil-Free Variable Frequency Centrifugal Compressor (Heart)
2. Air-Cooled V-Type/W-Type Microchannel High-Efficiency Condenser (with Natural Cooling Heat Exchange Coil)
3. Falling Film/Flooded Evaporator, Electronic Expansion Valve, Economist
4. Plate Heat Exchanger (Ethylene Glycol Indirect Heat Exchange)/Direct Cooling Natural Cooling Coil
5. Antifreeze Ethylene Glycol Circuit, Electric Three-Way Switching Valve, Intelligent PLC Linkage Control System
6. EC Variable Frequency Low-Noise Axial Flow Fan, IoT Remote Monitoring Module
(II) Detailed Explanation of Two Core Technologies
1. Magnetic Levitation Oil-Free Compressor Technology
1.1 Electromagnetically levitated rotor rotates at high speed, zero mechanical friction, completely eliminating the lubrication system, and eliminating easily damaged parts such as oil pumps, oil separators, and oil filters;
1.2 Permanent magnet direct drive variable frequency, stepless adjustment from 10% to 100% load, partial load energy efficiency IPLV can reach 10~18, far exceeding screw chillers and ordinary centrifugal chillers;
1.3 No oil film adheres to the heat exchanger tube wall, heat exchange efficiency does not decline over a long period, design life 25~30 years; soft start impact is small, friendly to the power distribution system.
2. Air-cooled + Natural cooling dual coupling technology
2.1 Air-cooled foundation: Relying on outdoor fans to force air heat dissipation, the entire system does not require cooling towers, cooling water pumps, or water treatment agents, completely saving water;
2.2 Natural cooling logic: Through plate heat exchanger + ethylene glycol antifreeze, it utilizes outdoor low-temperature air to pre-cool/directly cool chilled water. The control system automatically switches between three operating modes according to the outdoor temperature difference.
III. 3 Fully Automatic Operating Modes (Intelligent switching throughout the year)
Mode 1: Pure mechanical compression refrigeration (high summer temperature, outdoor >18℃)
When the outdoor temperature is high, natural cooling cannot be utilized. The magnetic levitation compressor operates at a variable frequency, while the conventional air-cooled compressor provides refrigeration, ensuring a stable outlet water temperature, consistent with the operating logic of high-end air-cooled magnetic levitation units.
Mode 2: Partial Natural Hybrid Cooling (Spring/Autumn Transition Season)
When the outdoor temperature is moderate, the chilled water return first passes through a natural cooling coil pre-cooled by outdoor cold air, then enters the evaporator where the compressor provides a small amount of supplemental cooling. The compressor operates at a reduced load and low frequency, resulting in a significant reduction in load and energy savings of over 30%.
Mode 3: Fully Natural Free Cooling (Winter/Late Spring/Autumn Low Temperatures)
When the outdoor air temperature is 3-5°C lower than the chilled water supply temperature, the compressor completely shuts down. Heat exchange is performed solely by the outdoor fan and ethylene glycol circulation pump, consuming very little auxiliary power, achieving "near-zero electricity cost cooling." In northern regions, this can operate stably for 3-6 months annually, reducing the data center PUE to below 1.15.
2 natural cooling options are available:
1. Ethylene glycol indirect plate heat exchanger (mainstream, freeze-resistant and stable);
2. Freon direct cooling natural cooling (eliminates ethylene glycol, simplifying the system).
IV. Core Advantages
1. Ultimate Dual Energy Savings, Optimal Electricity Costs Throughout the Year
1.1 Magnetic levitation itself boasts ultra-high energy efficiency under low load, saving 35%~50% more electricity than traditional air-cooled screw chillers year-round;
1.2 Combined with natural cooling, the compressor can be shut down during winter. In cold northern regions, the compressor can be completely shut down for 4-8 months in winter, with only water pumps and fans consuming electricity, resulting in extremely high COP; during the transitional season, partial natural cooling reduces the compressor load by half or even more. The overall energy saving rate in cold regions can reach up to 60%, offering a strong long-term return on investment advantage.
2. Extremely Simple System, Zero Water Consumption
The air-cooled architecture completely eliminates cooling towers and cooling water systems, resulting in no evaporation loss and no water drift or sewage discharge. It is the first choice for arid and water-scarce regions and projects with strict water resource management; there are no issues with cooling water scaling, algae, or pipe corrosion.
3. Extremely low operation and maintenance costs and low failure rate
3.1 Magnetic levitation oil-free design eliminates the need for lifetime replacement of refrigerant oil and oil filters. Annual maintenance only requires fin cleaning and electrical testing, reducing maintenance workload by 70%.
3.2 All oil circuit-related faults are eliminated. The magnetic bearing has power-off protection, reducing the risk of bearing seizure and extending overhaul cycles.
4. Flexible installation and low civil engineering costs
The entire unit can be installed outdoors on rooftops or ground level, eliminating the need for a dedicated chiller room or excavation for cooling water piping. Compared to traditional air-cooled screw chillers, it occupies 30% less space and is 60% lighter for the same cooling capacity, resulting in lower rooftop load pressure and strong adaptability to renovation projects.
5. Stable Operation and High Added Value
5.1 No risk of cooling tower freezing and cracking in winter; high reliability due to natural cooling in low-temperature environments.
5.2 Minimal vibration, noise ≤70dB, outlet water temperature control accuracy ±0.1℃, suitable for precise temperature control processes.
5.3 Outstanding carbon reduction effect, meeting green building, carbon neutrality, and energy consumption quota requirements.
V. Disadvantages and Limitations
1. High Initial Equipment Investment
The complete configuration of magnetic levitation compressor + natural cooling piping plate is 50%~100% more expensive than ordinary air-cooled screw chiller units. The initial investment is large, and the cost is recovered through years of electricity cost savings.
2. Limited Benefits of Natural Cooling in Hot South China
The Pearl River Delta and South China have long periods of high temperatures throughout the year and very short low-temperature windows in winter. The entire period of natural cooling operation is less than one month, relying mostly on compressor cooling. This lengthens the investment payback period and makes it less cost-effective than in northern regions.
3. Requirements for Power Supply Stability and Maintenance Personnel
Magnetic levitation drive controllers and magnetic bearings are precision electronic components; significant voltage fluctuations necessitate the installation of voltage stabilization devices. Core faults require original equipment manufacturer (OEM) engineers for troubleshooting; general HVAC personnel cannot perform in-depth repairs, and specialized spare parts are relatively expensive.
4. Outdoor Unit Noise and Placement Constraints
Outdoor fans generate considerable noise during continuous operation. Soundproofing is required if the unit is located near residential areas. Sufficient load-bearing capacity and placement area are required on rooftops, and buildings with aesthetically pleasing facades require shielding.
5. Glycol Solution Requires Some Maintenance
Indirect heat exchange systems require regular monitoring of antifreeze concentration and replenishment of corrosion inhibitors to prevent pipe corrosion and winter freezing, adding some routine management work.
VI. Precise Applicable Scenarios (Preferred)
1. Large and medium-sized data centers, intelligent computing centers, and IDC server rooms (most suitable), requiring uninterrupted cooling throughout the year, low PUE, and no water-cooled cooling tower installation conditions;
2. Large commercial complexes, hospitals, and office buildings in cold northern/high-altitude regions with year-round central air conditioning;
3. Industrial parks in water-scarce western cities with high water costs and policy restrictions on cooling tower use;
4. Lithium battery workshops, pharmaceutical plants, precision laboratories, and other processes requiring constant temperature and continuous heat dissipation year-round;
5. New/renovation projects with high electricity prices, long-term operation (8 years or more), and energy conservation and carbon reduction assessments.
VII. Scenarios Not Recommended
1. Small projects in tropical South China, requiring comfort air conditioning only for short-term summer use;
2. Temporary cooling sources with tight budgets, short-term leases, and relocation within 5 years;
3. Buildings next to street-facing residential buildings with insufficient roof load-bearing capacity, no outdoor placement space, and zero tolerance for outdoor unit noise.
Magnetic levitation air-cooled natural cooling chiller unit = inherently high efficiency of magnetic levitation compressor + air-cooled waterless system + free natural cooling in winter, triple superposition, suitable for top energy-saving solutions for data centers in the north.
High initial investment, but long-term energy saving and peace of mind. In the south, it is only suitable for large-scale projects with high load and continuous cooling throughout the year.
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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