FUSION Free-Cooling Chiller

FUSION continuously monitors ambient temperature, process-water inlet and outlet values and instantaneous cooling load. The controller automatically selects the most efficient mechanical, hybrid or full free-cooling mode. As ambient temperature falls, the free-cooling coil supplies more capacity and compressor run time decreases. Under suitable conditions, the compressors stop completely and cooling is provided only by outdoor air.

Savings depend on climate, required water temperatures and annual operating hours. In regions with long periods of low ambient temperature, annual energy use may fall by 30–60%. In full free-cooling mode, compressors are off and only fans and pumps consume electricity, allowing instantaneous consumption to fall by more than 80% versus mechanical cooling in suitable conditions.

The highest savings occur at sites needing cooling throughout the year, especially in winter. Data centres, plastics plants, industrial processes and 24-hour production lines are suitable. As process-water temperature rises, free cooling can start at a higher ambient temperature, so facilities able to use warmer chilled water gain more annual free-cooling hours and energy savings.

In hybrid mode, outdoor air partially pre-cools process water and compressors produce only the remaining capacity needed to reach the target outlet temperature. Savings therefore begin before outdoor air is cold enough for full free cooling. Hybrid operation usually lasts longer than full free cooling and can provide a significant share of annual energy savings.

Periodic maintenance checks the free-cooling coil and microchannel condenser surfaces, EC fans, compressors, pumps, control valves, water flow and sensors. Glycol concentration, freeze protection, mechanical-hybrid-free-cooling transitions and energy-monitoring data are also assessed. Clean heat-transfer surfaces and correct glycol concentration are important for preserving performance.

FUSION serves year-round industrial applications requiring stable process-water temperature, including mould, hydraulic-oil and process-water cooling in injection and extrusion; mixers, calenders and presses in rubber; and production equipment, filling lines and process water in food and beverage. It can cool reactors and tanks in pharmaceuticals and chemicals, and CNC machines, laser cutters and welding equipment in automotive and metalworking. It also suits electronics, power plants, data centres and telecommunications requiring uninterrupted technical cooling. The greatest advantage occurs in long-hour processes with winter cooling loads, where compressor use falls or stops as ambient temperature drops.