List of leading industrial air conditioner manufacturers and an explanation of how to select an industrial air conditioner
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Industrial air conditioners are large-scale systems specifically engineered to cool expansive industrial spaces, such as warehouses and factories. While they operate using a cooling method similar to that of residential air conditioners, industrial units boast a significantly higher cooling capacity, enabling them to maintain consistent temperatures across wide areas effectively. Unlike their residential counterparts, industrial air conditioners incorporate multiple compressors, numerous evaporators, extensive ductwork systems, powerful fans, sophisticated controllers, and intricate filtration units.
Traditional air conditioners are primarily designed to offer comfort by maintaining a pleasant temperature environment, whereas industrial air conditioners are crucial for managing precise temperatures vital for handling delicate materials, executing specialized industrial processes, and ensuring equipment operates efficiently. Industrial settings demand accurate temperature and humidity management facilitated by highly advanced filtration systems. Depending on the system’s configuration, all components of an industrial air conditioning setup might be housed in a unified packaged unit or distributed among separate units. While residential units target a specific area by cooling a predetermined square footage, industrial air conditioners are designed to manage temperature across multiple zones for prolonged durations.
Components found in industrial air conditioning systems are akin to those in any air conditioning unit; however, the industrial versions are distinguished by their size, robustness, and durability. These components are crafted to ensure endurance and reliability. The primary goal of an industrial air conditioning system is to regulate temperature, manage humidity levels, and control air quality over extensive areas, often encompassing several thousand square feet.
Industrial air conditioners, fundamental to climate control in large-scale commercial and manufacturing facilities, are precisely engineered to match specific environmental conditions, process requirements, and scale. As with all specialized HVAC equipment, industrial air conditioning systems come in diverse sizes—from compact floor models to massive rooftop units designed to serve complex, multi-story factories or warehouses. The ability to accommodate a wide spectrum of application requirements is essential, as each industrial operation demands air conditioning units optimized for its particular load, operational hours, and environmental challenges.
When evaluating industrial air conditioner types, it’s important to distinguish between physical size and cooling capacity. The true measure of an industrial AC system’s effectiveness is its heat removal capability, calculated in British Thermal Units (BTUs). For instance, a single “ton” of air conditioning removes 12,000 BTUs of heat per hour. To select the best industrial HVAC solution, you must first assess the facility’s cooling load—factoring in building volume, occupancy, equipment-generated heat, process heat loads, and external heat gain. Qualifying and quantifying these factors ensures you choose the right commercial HVAC system for efficient, reliable temperature control.
Properly sizing an industrial air conditioning unit is critical for operational efficiency and energy savings. An undersized system, although it may be less costly upfront, will overwork, leading to increased utility costs, inadequate climate control, poor occupant or product comfort, and shortened equipment lifespan. Conversely, an oversized unit results in frequent cycling, temperature fluctuations, higher humidity, uneven cooling, and avoidable power consumption spikes. Both scenarios can ultimately impact product quality, production uptime, and maintenance costs—core concerns for facility managers and operations.
To maximize system performance and ROI, partnering with a certified industrial air conditioning contractor or HVAC engineer is highly recommended. These professionals use proven calculation methods—such as Manual N and Manual J load calculations—to determine the appropriate equipment size, system type, and control strategy. Key factors include building insulation, ceiling height, production machinery, internal heat sources, airflow demands, and the nature of materials processed. State-of-the-art air conditioning solutions are designed to deliver optimal temperature stability, safeguarding personnel well-being and product integrity while complying with OSHA and industry environmental standards.
Beyond structural and mechanical considerations, selection of the ideal industrial HVAC system must take into account process needs, air quality requirements, energy efficiency targets, and the specific compliance standards of your industry—whether that’s food processing, pharmaceuticals, electronics, or heavy manufacturing. Top industrial air conditioner manufacturers offer customized climate control solutions, integrating advanced controls, filtration, humidity management, and connectivity for real-time monitoring. These tailored installations help manufacturers maintain product quality, protect sensitive machinery, and ensure compliance with workplace safety guidelines.
In modern commercial and industrial environments, air conditioning is fundamental for ensuring worker comfort, equipment reliability, and regulatory compliance. Office complexes, retail spaces, distribution centers, clean rooms, and high-heat manufacturing lines all require different forms of commercial HVAC units and industrial cooling systems. The most prevalent types include central air conditioning systems, ductless split and mini-split AC units, multi-split solutions, variable refrigerant flow (VRF) and variable refrigerant volume (VRV) systems, and large capacity chillers. While “industrial air conditioner” is sometimes used to describe robust commercial systems, the catch-all term HVAC—standing for heating, ventilation, and air conditioning—encompasses an even broader range that may also include integrated heating elements like industrial furnaces or boilers for comprehensive environmental control.
Central air conditioning units are cornerstone HVAC systems for climate management in expansive facilities. These systems work by circulating and exchanging air, using advanced ductwork to maintain interior temperatures according to programmable controls and building automation systems. By consistently removing warm, stale air and supplying cool, filtered air, central AC units ensure consistent temperature and indoor air quality throughout large-scale operations—supporting productivity, equipment longevity, and regulatory compliance.
In industrial and commercial settings, central air conditioning systems differ significantly from their residential counterparts in both scale and performance. Standard residential central AC units typically deliver 5 to 8 tons of cooling—sufficient for homes—but industrial models are engineered for cooling loads that often exceed 50 tons, with units designed to handle the substantial thermal loads generated by equipment and occupants in factories, data centers, and commercial warehouses.
The widespread adoption of central industrial air conditioners is driven by their superior energy efficiency, discreet operation, low noise levels, and seamless integration with building management systems (BMS). Industrial central air conditioning encompasses several system designs, including split systems, packaged rooftop units, and VRF/VRV setups, each tailored to meet the demands of facility layout, production processes, and sustainability objectives. The ideal system is determined after a thorough HVAC site assessment and collaboration with experienced manufacturers or their authorized dealers, ensuring adherence to best practices and regulatory requirements for commercial HVAC installations.
A split central air conditioning system features an outdoor condensing/compressor unit that connects to an indoor air handling unit or evaporator, delivering efficient and scalable cooling. This separation allows for increased energy efficiency, flexible installation, and some degree of noise isolation—all essential for industrial, manufacturing, or process-critical environments. Split system AC units are commonly selected for spaces requiring focused zoned temperature control, such as server rooms, laboratories, or sensitive production cells.
Among available commercial HVAC system types, ducted split AC systems remain a reliable option. Outdoor units—housing the robust compressor and condenser heat exchanger—are linked to indoor blower units that force cooled air via ductwork to various building zones. In ductless split AC variants (mini-split or multi-split), indoor air handlers are installed directly in each conditioned zone, reducing the need for extensive ducting and minimizing maintenance related to dust, mold, or debris buildup, making this solution ideal for modular office spaces, intermittently used areas, and buildings with retrofit limitations.
Split AC systems provide increased flexibility in installation, energy management, and zoning compared to larger packaged rooftop air conditioners. They are often preferred during facility expansions or for supplementary cooling in high-load areas. Their modular design supports cost-effectiveness and simplified upgrades or repairs. Connecting indoor and outdoor components typically involves refrigeration piping, insulated copper lines, and low-voltage electrical wiring for system controls and safety interlocks.
Packaged rooftop units (RTUs) are a staple of industrial and large commercial air conditioning applications. These all-in-one systems incorporate the compressor, condenser, expansion mechanism, evaporator coil, and controls within a single, weatherproof housing—typically mounted on a facility’s roof or dedicated service pad. RTUs are engineered for heavy-duty performance, capable of delivering substantial volumes of conditioned air through extensive duct networks to multiple floors and large open spaces.
The primary advantage of packaged central air conditioning systems is their consolidated, space-saving configuration, which simplifies installation, maintenance, and retrofit projects. By locating the entire HVAC unit outdoors, facility managers reduce indoor noise disruption and free up valuable floor space for production equipment or storage. All key components—controls, electrical panels, and service access points—are conveniently housed for quick diagnostics and scheduled industrial HVAC maintenance.
Designed for scalability and robust performance, packaged commercial air conditioners are built with reinforced frames, heavy-duty fans, and advanced filtration. Installations may feature customizable configurations (with either air-cooled or water-cooled condensers) to suit the facility’s energy infrastructure and climate conditions. These HVAC solutions are ideal for industrial plants, logistics centers, schools, and office towers where centralized cooling must serve multiple zones, each with varying load profiles.
The longevity and resilience of packaged industrial air conditioning units surpass residential equivalents—delivering reliable operation even in demanding, high-uptime environments. By leveraging advanced features like variable speed drives, economizers, and remote monitoring, facility managers can optimize system performance for lower lifecycle costs and increased sustainability.
Variable Refrigerant Flow (VRF) and Variable Refrigerant Volume (VRV) systems represent the cutting edge of commercial and industrial HVAC technology. These are advanced multi-split systems engineered for precise, energy-efficient climate control in multi-zone environments—making them ideal for large office campuses, hospitals, hotels, and modern manufacturing plants. With VRF/VRV tech, multiple indoor units are independently controlled and connected to one or several outdoor inverter-driven compressors, using refined refrigerant management to match actual cooling and heating loads in real-time.
VRF industrial air conditioning systems differ from traditional central air by utilizing refrigerant as the sole heat transfer medium, rather than combining air and chilled water loops. They leverage inverter compressor technology—modulating output to meet fluctuating demand—resulting in substantial power and operational cost savings. This variable control reduces wear and tear, extends component lifespan, and ensures stable indoor temperatures for people, products, and equipment.
The architecture of VRF and VRV systems is inherently modular; outdoor units can be piped to numerous indoor zones with custom local controls and occupancy sensors, supporting dynamic zoning and on-demand usage. Communication cabling and control wiring facilitate advanced networked management, integrating seamlessly with building automation systems. Such granular control prevents overcooling or overheating, further improving energy efficiency.
Industrial VRF/VRV systems are available in three configurations: cooling only, heat pump (allowing either heating or cooling), and heat recovery (simultaneously providing both). As fully ductless HVAC solutions, VRF/VRV systems are optimal for intricate building layouts with architectural or retrofit constraints. The core of these systems—the inverter compressor—enables variable motor speeds to precisely match real-time load fluctuations, minimizing energy waste and carbon footprint. Additionally, their environmentally friendly refrigerants contribute to sustainability goals and support compliance with evolving refrigerant regulations (such as R410A and other low-GWP refrigerants).
The agile responsiveness of VRF and VRV technology makes it well-suited for modern commercial construction and industrial retrofits focused on minimizing energy bills and maximizing system adaptability. Initial system costs are typically higher due to the required customization for individual zones, but these are offset by long-term utility savings, enhanced occupant comfort, and fewer maintenance needs. These solutions offer smart control interfaces, remote monitoring, and predictive diagnostics—key considerations for smart factories and Industry 4.0 HVAC integration.
Industrial chillers serve as large-scale cooling systems that utilize chilled water or other cooling fluids to absorb heat—making them indispensable for process cooling, data centers, plastic molding, chemical processing, and heavy-duty air conditioning. As circulated water captures ambient or process heat, it is routed through a chiller system, where specialized heat exchangers and refrigeration cycles transfer this heat away, either venting it to the atmosphere or dissipating it via cooling towers.
Industrial chillers are classified by their cooling technology, energy source, and the method of heat rejection. Common designs include centrifugal chillers, modular chillers, water-cooled screw chillers, air-cooled screw and scroll chillers, and absorption chillers (which use thermal energy instead of mechanical compression). All chiller systems feature core HVAC components such as the evaporator, compressor, condenser, and expansion valve, and rely on advanced refrigerants to maximize heat transfer efficiency. Chillers are frequently integrated into centralized plant cooling systems, supporting both building-wide air conditioning and mission-critical process applications.
Air Cooled Chiller – Air cooled chillers are self-contained HVAC cooling units ideal for smaller buildings, light industrial applications, or facilities lacking access to water for heat rejection. These systems remove heat from circulating water or process fluids and expel it directly to the outside air using condenser fans—eliminating the need for external cooling towers. Air cooled chiller systems require precise airflow management and are typically used where moderate capacity, ease of installation, and lower maintenance are priorities. As a result, they are common in schools, small factories, and data closets.
Water Cooled Chiller – Water cooled chillers use water as the primary cooling medium and often incorporate cooling towers to dissipate heat, resulting in higher energy efficiency and greater cooling capacity for large-scale industrial and commercial HVAC systems. Water is circulated through a network of pipes to distributed air handling units or terminal coils, providing even and reliable temperature management throughout sprawling facilities. In addition to the standard HVAC refrigeration components, these systems utilize cooling towers for efficient heat rejection to the atmosphere.
Water cooled chillers are the preferred option for high-load environments—such as manufacturing plants, hospitals, and multi-building campuses—thanks to their compact mechanical footprint, long operational lifespan, and reduced maintenance needs. The ability to install water cooled chillers indoors protects them from the elements, further decreasing long-term service costs and enhancing system reliability. With superior thermal transfer properties and advanced system integration capabilities, water cooled chillers remain the backbone of many process cooling infrastructures.
Although industrial air conditioners and residential air conditioners share several core components—such as compressors, evaporators, condensers, and refrigerant lines—their operations, applications, and performance capabilities diverge significantly. Both HVAC system types supply cool air at a preselected temperature catering to the comfort needs of their environments. However, the primary distinction lies in the sheer cooling capacity and scalability required by industrial air conditioning systems, which far outpace anything a residential air conditioner can achieve. Understanding these differences is crucial for property owners, facility managers, and HVAC professionals needing to select the right air conditioning solution for their unique needs.
Residential air conditioning systems are designed with occupant comfort in mind, prioritizing a quiet, energy-efficient operation that maintains a consistent indoor climate in homes and apartments. If a residential air conditioner fails, it generally results in the loss of comfort and inconvenience, prompting quick adjustments or repairs. In stark contrast, when an industrial air conditioning system fails, the consequences can be serious—impacting worker safety, disrupting critical manufacturing or production lines, and jeopardizing sensitive equipment or raw materials. Such downtime can translate to missed production targets and significant financial losses, underscoring the mission-critical role of properly designed commercial and industrial HVAC systems.
The most obvious factor setting industrial HVAC units apart is size. Residential HVAC systems are typically sized based on room dimensions, insulation quality, number of occupants, and home design. Conversely, industrial air conditioning units are engineered around a comprehensive heat load calculation, which encompasses not just the total air volume but also additional sources such as heavy equipment, process machinery, commercial lighting, and electronic devices. Industrial environments often produce substantial internal heat gains, requiring precision engineering and significantly larger cooling capacities.
Industrial air conditioners are much larger and more complex, often consisting of packaged units with expansive housings and multiple access panels for advanced maintenance. Residential units are smaller, more accessible, and typically have split or packaged central configurations that make household service straightforward.
By way of comparison, a typical residential air conditioner delivers 8 to 10 tons of cooling capacity, perfect for detached homes or small apartments. Modern industrial cooling systems, on the other hand, frequently exceed 50 tons of capacity, with some large-scale applications—such as data centers, warehouses, and manufacturing plants—demanding hundreds of tons of cooling. This vast difference in total capacity directly impacts power consumption, system efficiency, and ongoing operational expenses. As industrial cooling needs increase, so too does the complexity of energy management and building automation requirements.
Industrial HVAC systems are engineered for continuous, high-demand operation. While the average residential air conditioner may run 6 hours per day or less, an industrial or commercial air conditioning system can run 10 hours a day or even around the clock (24/7), particularly in mission-critical facilities. Increased usage and heavy workload require that every component, from compressors to variable speed drives, be robust, durable, and energy-efficient. Features such as programmable controls, smart sensors, and predictive maintenance tools are commonplace in advanced commercial HVAC systems, providing superior reliability and performance for high-occupancy or process-sensitive spaces.
Industrial air conditioning systems utilize a variety of unit types and advanced configurations to address large, complex environments. These range from rooftop packaged air conditioners, split systems, and water-cooled chillers, to custom-built air handling units with integrated building management system (BMS) connectivity. Critical commercial applications might use cooling towers, hydronic systems, or modular variable refrigerant flow (VRF) and variable refrigerant volume (VRV) systems for tailored climate control and zoning flexibility. For indoor air quality (IAQ), many systems offer HEPA filtration or dedicated fresh air units.
In contrast, residential air conditioning is typically delivered via split-system central air conditioners, wall-mounted AC units, ductless mini-splits, or small packaged terminal units. These solutions are optimized for comfort, quiet operation, and easy installation in single-family homes, apartments, or condos. While central air offers the highest efficiency for whole-house cooling, single-room air conditioners suffice for supplemental or spot cooling.
| Unit Types | |
|---|---|
| Residential Air Conditioning Systems | Industrial Air Conditioning Systems |
| Wall Split Systems | Split Systems |
| Ducted Split Systems | Ducted Systems |
| Water Cooled Package Units | Ductless Systems |
| Cooling Towers | Air Cooled Systems |
| Chillers | Water Cooled Systems |
| Chilled Water Fan Coil Units | Evaporative Coolers |
| Variable Refrigerant Flow Systems | Central Air Conditioning |
| Cooling Towers | |
| Condenser Pumps | |
| Chilled Water Pumps | |
| Water Chillers | |
| Air Chillers | |
| Reciprocating Chillers | |
| Scroll Chillers | |
| Heater Banks | |
| Variable Speed Drives | |
| Variable Refrigerant Flow Systems | |
| Variable Refrigerant Volume Systems | |
| Fresh Air Systems | |
Modern residential air conditioners feature user-friendly thermostats with limited zones. By contrast, commercial and industrial HVAC systems are markedly more complex—featuring centralized control panels, programmable logic controllers (PLCs), and advanced building automation systems. These allow properties, factories, and offices to zone cooling by department, product, or equipment type, maintaining optimal temperature and humidity for people and processes alike. Centralized systems improve energy efficiency and operational oversight, allowing for data-driven adjustments and effective resource allocation.
Industrial air conditioning complexity is further enhanced by modular construction, offering flexibility for future expansion and system upgrades. Residential systems, typically pre-set once installed, have fixed capacities, limiting options for significant modifications or retrofits.
Residential HVAC units, particularly outdoor condensers, are installed near the home for easy access and to limit indoor noise. Interior units (such as wall or window ACs) are designed for convenience and aesthetics. Industrial air conditioning units, in contrast, are most often positioned on rooftops or in dedicated mechanical rooms to optimize space utilization, minimize noise disruptions, and facilitate safe, efficient scheduled maintenance. Proper placement also supports system security and reduces accidental interference—an important consideration for large properties and manufacturing facilities.
Carefully planned installation is essential for industrial complexes, considering maintenance accessibility, airflow optimization, and compliance with local safety codes. This reduces downtime, maintains equipment performance, and ensures the long-term dependability of the commercial HVAC system.
Standard residential air conditioner installations often involve identical design and model selection across multiple homes in a subdivision, based on uniform square footage and occupancy patterns. In contrast, every industrial cooling project is unique. Customized HVAC system design for industrial applications takes into account building layout, process needs, environmental loads, regulatory requirements, and future expansion plans. This bespoke approach maximizes efficiency, increases equipment lifespan, and ensures process-specific climate control.
Industrial indoor climate controls also provide extensive options for managing humidity, ventilation, air filtration, and even demand-sensitive controls to adapt quickly to process changes or occupancy fluctuations. Residential systems generally offer basic temperature and humidity settings, sometimes with optional IAQ upgrades, but lack the adaptability of commercial or industrial HVAC designs.
Due to their scale and operational intensity, industrial air conditioning systems require highly engineered drainage solutions. These may involve complex pipelines, multiple condensate pans, and monitoring devices to prevent clogs, water overflow, or moisture buildup that could hamper system performance. Effective condensation management is critical, especially in industrial operations where moisture damage or environmental compliance is a concern. While both residential and industrial systems must remove excess water, only industrial applications necessitate large-scale drainage infrastructure and proactive flood prevention strategies.
Industrial air conditioning maintenance is essential for preventing unexpected failures, optimizing efficiency, and safeguarding productivity. Service intervals for industrial and commercial HVAC systems are frequent—monthly, weekly, or even daily—depending on operational load and facility type. Leading industrial air conditioner manufacturers offer dedicated customer support, technical maintenance teams, and equipment monitoring programs to ensure proactive servicing and timely parts replacement. Failure to maintain commercial HVAC equipment can result in higher energy bills, regulatory non-compliance, costly repairs, or catastrophic operational interruptions.
For homeowners, maintenance of residential air conditioning is typically annual or biannual, focusing on cleaning filters, checking refrigerant levels, and ensuring system safety. While basic, these check-ups are vital for energy efficiency and unit longevity. Regular maintenance helps prevent breakdowns, ensuring cooling comfort during peak seasons and minimizing unexpected repair costs.
In summary, industrial and residential air conditioning systems differ fundamentally in size, complexity, capacity, customization, and maintenance demands. Residential HVAC units focus on comfort, cost-effectiveness, and simplicity for buildings with predictable occupancy and standard cooling requirements. Industrial HVAC systems, by necessity, offer advanced features, robust engineering, modular scalability, and customized design for challenging spaces, critical operations, and large commercial facilities.
Choosing the right air conditioning solution depends on accurately assessing the environment, cooling load, usage patterns, and risk tolerance. If your focus is home comfort, a well-installed, appropriately sized residential air conditioning system will offer ongoing value and peace of mind. If your facility faces variable climate needs, high cooling loads, or mission-critical operations, partnering with an experienced industrial HVAC design and installation specialist is essential. To further explore your options or schedule a professional assessment for your property, consult a trusted local HVAC contractor or industrial air conditioner manufacturer.
The selection of an industrial air conditioner begins with the system’s manufacturer or manufacturer’s representative that provides service and support during the selection process. It is essential and important that the process begin with the expertise and knowledge of manufacturers and service providers. Manufacturers have a team of experts dedicated to guiding their customers to the perfect system that meets a customer’s requirements.
Unlike the installation of a residential air conditioner, there are several parameters that have to be examined in the selection of an industrial air conditioner, which are far beyond the square feet of a facility or its location. At the center of the process is the collection of data that describes a location and its purpose.
To ensure the proper performance of an industrial air conditioner, it must be the correct size. The calculations necessary to make that determination takes time, study, research, and investigation. Although the process is time consuming, the benefits lead to comfort and lower operating costs.
The size of industrial or commercial air conditioners is rated in tons that increase in increments of a half-ton. A one-ton air conditioner removes 12,000 BTUs of heat per hour. As all air conditioning experts know, cooling is the removal of heat. The calculations for determining the right industrial air conditioner for a location is partly related to the measure of a location's cooling load, the amount of heat a cooling system must remove. There are numerous factors that affect the cooling load, some of which are structural design, exposure to sunlight, occupants, machinery, and processes.
Cooling loads are divided into external and internal. The external aspect of the cooling load refers to the weather conditions of a location. The external load for Arizona is drastically different from the cooling load of Michigan or Minnesota that have weather conditions that bring heat and cold. The external load is also influenced by the design of a structure and its insulation.
The internal load includes the people, equipment, lighting, windows, air circulation, and various other factors that professionals assess. Each aspect has an influence on the cooling load and the required air conditioner tonnage.
As with residential air conditioning, the calculations for an industrial air conditioner begin with the square footage of the space. In many industrial locations, the height of the ceiling exceeds the traditional eight-foot ceiling of residential properties and offices. The height of ceilings is one of the reasons that industrial air conditioners have to be so powerful in order to accommodate the vacant space.
The initial calculations for an industrial air conditioner begin by dividing the square footage by 500 and multiplying the answer by 12,000, the number of BTUs. Each person that works in a space requires the addition of an additional 380 BTUs per person. Each window is worth 1000 BTUs.
Using this method of calculating, a 5000 square foot space with four workers and three windows would require an air conditioning system of approximately 124,520 BTUs. Since the size of air conditioning systems is measured in tons, the 124,520 BTUs would need to be divided by 12,000 to determine the tonnage of the system. In this example, the tonnage would be between 8 and 10.
As is indicated by the mathematical calculations, it is essential to consult with an industrial air conditioning professional when shopping for an air conditioning system. There is a great deal of difference between installing a residential air conditioner and an industrial one. The expense of the process necessitates the involvement of professionals who understand the challenges of cooling large spaces.
The Air Conditioning Contractors of America provide manuals, guidelines, and literature that detail sizing methods and system designs. Included in their literature are four considerations for industrial air conditioner installation.
The careful selection of an industrial air conditioner is a critical decision. The installation of a system that is too small will cause the system to overwork, place stress on components, and require costly repairs. On the other side, the installation of a system that is too large can lead to 1poor air quality, excess humidity, discomfort, and increased costs. Only a trained industrial air conditioning specialist can provide the data, consultation, and guidance to ensure a successful air conditioning choice.
The high-quality performance of an industrial air conditioner requires that all the parts and components of a system work together. A general knowledge of the components can help in assessing malfunctions in a system and prevent larger issues. Although many of the components of an industrial air conditioner are the same as those of residential air conditioners, the complexity and intricacy of industrial air conditioners requires components to be robust, highly durable, and long lasting.
The compressor is the heart of an industrial air conditioner. It circulates the refrigerant between the condenser coils and the evaporator. Compressors change the refrigerant from a gas to a liquid before it enters the condenser coil. It compresses the refrigerant to turn it into a high-pressure gas.
The control panel determines the temperature for each zone or section of a structure. It is usually set by maintenance personnel and closely monitored. Fluctuations in zones are detected by the control panel, which activates the system to increase or decrease cooling. The size of the control panels varies and can include several high-performance sections with complex technological controls or be a single touch screen control. The variations in the size of control panels are due to the different types of industrial air conditioners that are custom designed to fit the requirements of a location.
Industrial air conditioning control systems may have direct digital controls (DDC) for improved energy efficiency. DDCs have sensors that monitor temperatures. Systems provide system updates, detect problems, and request maintenance. Although a DDC system is expensive, it can be cost effective in the long run. Regardless of the type of controls, simple or DDC, they help realize energy savings of 5% up to 20%.
Industrial condensers condense the refrigerant back to a liquid. They transfer the heat from the refrigerant as it is changed to a liquid phase. The type of application for which the condenser is used determines the type of condenser since different applications require the handling of different pressures and levels of temperature. The cooling process for condensers can be air or water depending on the air conditioning system design.
The thermal expansion valve controls the amount of refrigerant that enters the evaporator. It regulates the heat of the refrigerant. In the condenser, refrigerant is condensed to a high-pressure liquid by removing heat from it and transferring it into the environment. As the refrigerant moves from the condenser to the evaporator, it is restricted by the expansion valve that reduces the pressure and allows isenthalpic, a process where the liquid expands but retains its level of heat, back to the vapor phase for absorbing heat.
The sensing bulb of the thermal expansion valve is connected to the output of the evaporator and senses the temperature of the refrigerant leaving the evaporator. The gas pressure in the sensing bulb provides the force for opening the TXV, which adjusts the flow of refrigerant into the evaporator.
From the expansion valve, the refrigerant enters the evaporator at low pressure. In the evaporator, the refrigerant goes from a low-pressure liquid to a low-pressure gas, which allows the refrigerant to absorb heat. As air passes through the evaporator, it gets cooler and loses its heat. The cooled air is pushed out into the facility by ductwork or an air handler. After absorbing heat, the refrigerant returns to the compressor and the air conditioning cycle begins again.
The ductwork of an industrial air conditioning system delivers and removes air. The many forms of ductwork include round or rectangular, metal or fabric. Metal round or rectangular ductwork is used the most with industrial air conditioners due to their ability to fit in limited space and their high durability. They allow for even and controlled air flow, ensuring efficient system operation.
Round ductwork allows air to move smoothly due to its ability to transition for varying degrees of angles. In addition, unlike rectangular ductwork, round ductwork has less friction and turbulence, which further enhances airflow. Since round ductwork can move higher volumes of air, it has lower energy costs.
A common addition to industrial air conditioners is an air filter that cleans the air and removes particulate matter. Depending on the level of air quality required by a facility, the air filter may be a high efficiency particulate air (HEPA) filter, which removes the smallest of contaminants. Although the primary role of filters is to clean the air, they also keep a system clean and free of large particles that can interfere with a systems operation.
Aside from HEPA filters, the other types of filters include large pleated filters and fiberglass filters. UV filters are a special type of filter that captures airborne viruses and bacteria using ultraviolet light. They are not effective at capturing dust, dirt, and particles.
Most industrial air conditioning systems operate like a residential system but are larger and more dynamic. In the simplest form, the compressor compresses the refrigerant, increasing its pressure and temperature. From the compressor, the refrigerant moves to the condenser, which liquifies it. Before entering the evaporator, the expansion valve lowers the pressure of the liquid and cools it before releasing it into the evaporator that transforms the refrigerant cool liquid into a warm gas.
The above description is the basics of an air conditioning system. Other features may be added for extracting heat or cooling the refrigerant. An industrial air conditioner may be part of an interconnected system that involves a furnace, heater, and air handler. As with all aspects of industrial air conditioners, the addition of components depends on the system's design.
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A shell and tube heat exchanger (STHE) is a type of heat exchanging device constructed using a large cylindrical enclosure, or shell, that has bundles of perfectly spaced tubing compacted in its interior. Heat exchanging is the transfer of heat from one substance or medium to a similar substance or medium...
A water chiller, or chilled water system, is a type of refrigeration system which uses water as a secondary refrigerant. They are used for larger, more complex, heating, ventilating, air conditioning, and refrigeration (HVACR) applications...