For industrial production environments, central air conditioning is not only a facility to ensure employee comfort but also a crucial infrastructure for maintaining stable production processes and guaranteeing product quality.

A well-designed, efficient air conditioning system can save a company significant operational costs, while a poorly planned replacement project can lead to countless subsequent issues.

I. Preliminary Assessment: Laying the Foundation for a Successful Replacement

Precise Load Calculation: Beyond Simple Formulas

Industrial factory load calculations are far more complex than those for office or commercial spaces. Besides basic area parameters, it is essential to consider a comprehensive range of factors:

Height and Volume: The air flow organization and temperature stratification in tall spaces significantly affect load calculations.

Equipment Heat Output: The power density of production equipment and the operational schedule have a decisive impact on the cooling load.

Personnel Density & Activity Intensity: Significant Differences in Heat Dissipation Among Workers of Different Work Intensities

Building Envelope: Wall Materials, Insulation Performance, Window Size and Orientation

Special Process Requirements: The electronic workshop requires constant temperature and humidity control (such as)±1°C), the spray painting workshop has specific requirements for temperature and humidity.

2. System Compatibility Analysis: The Key to New and Old Matching

Before selecting a new host, it is essential to comprehensively assess compatibility with the existing system.

Terminal Equipment Compatibility: Verify if the operating parameters of the existing fan coil units and air handling units can be matched with the new main unit.

Water System Compatibility: Confirm the pressure and flow capacity of the cooling towers, pumps, and water pipeline network to meet the new main unit's requirements.

Power System Assessment: Verify the matching of distribution capacity, voltage levels, and control methods to prevent secondary renovations due to insufficient power.

3. Balancing Energy Efficiency and Costs: A Long-Term Perspective

When selecting equipment, one should consider both initial investment and long-term operational costs.

Energy Efficiency Priority: Variable Frequency Units Show Significant Energy Efficiency Advantages at Part Load, Ideal for Long-Operating Factories

Cost Considerations: Significant Variations in Parts Availability and Technical Support for Different Brands and Models

Incentive Policies: Understand local subsidies or tax incentives for high-efficiency equipment to lower investment thresholds.

Installation and Implementation: Professional Construction Ensures System Performance

1. Host positioning and installation

The installation location of outdoor units directly impacts system performance and lifespan.

Ventilation Conditions: Ensure sufficient space on all sides (adequate distance when multiple units are placed side by side)≥1.5 meters), to avoid air flow short-circuit

Inspection Channels: Retain ample maintenance space for convenient daily maintenance and emergency repairs.

Vibration and Noise Reduction: Utilizing professional shock absorbers and dampers to minimize vibration transmission and noise pollution

2. Pipeline Operation Standards

Pipe construction quality directly affects system reliability:

Welding Process: Nitrogen gas shielded welding must be used to prevent oxidation and impurities from forming on the inner wall of the copper pipes.

Pressure Test: System Pressure Retention Test Recommendations for Refueling4.0 MPa nitrogen, pressure maintained for over 24 hours, pressure drop does not exceed standard.

Cleanliness Control: Dust prevention measures must be implemented during construction to ensure the cleanliness of the system interior.

3. Drainage and Insulation Systems

Drainage Slope: Condensate pipe slope is ensured.≥1%, and set appropriate water seals to prevent air backflow.

Insulation Continuity: The insulation must be continuous without any breaks, with the thickness meeting local climate conditions (usually)≥30mm）

Electrical Safety Regulations

Cable Separation: Power and signal cables are laid separately to prevent interference.

Ensure Reliable Grounding: Ensure that the main unit and control systems are properly grounded, and surge protectors should be installed in areas prone to lightning strikes.

Section 3: Wind System and Water System Optimization

Air System Evaluation and Optimization

Replacing the main unit is a great opportunity to optimize the entire air distribution system.

Air Duct Inspection: Check for leaks, dust buildup, or damage to the insulation in existing air ducts

Airflow Organization Optimization: For large-scale factory buildings, side supply air outlets should be arranged on the short sides of the room to optimize the air supply range.

Terminal Cleaning: Clean or replace fan coil filter, check fan operation status

2. Water System Cleaning and Protection

In order to connect the new main unit to the existing water system, it is necessary to:

System Cleaning: Utilize professional chemical cleaning agents for a cyclic cleaning process to thoroughly remove scale and rust particles.

Water Treatment: According to the local water quality characteristics, corrosion inhibitors and scale inhibitors are added to the water treatment chemicals.

Filtering Equipment: Install a full water treatment system or an electronic descaling device throughout the installation process to prevent subsequent scaling.

Four: Commissioning, Acceptance Testing, and Long-term Operation and Maintenance

System Debugging Process

Pre-operational debugging steps required prior to official launch:

Vacuum Drying: Ensures no moisture within the system, achieving and maintaining the required vacuum level.

Pilot Run Monitoring: Records key parameters such as return air temperature, supply air temperature, operating current, high and low pressure, etc.

Control Logic Verification: Check temperature and humidity control accuracy, sequential start/stop function, and alarm protection function

2. Standardized Acceptance Criteria

Upon inspection, the following documents should be obtained and reviewed:

Completion Drawings: Including system schematics, pipeline layout plans, and control system diagrams

Debugging Report: Comprehensive Data Record and Analysis of the Pilot Run

Warranty Documents: Clearly Define the Scope and Duration of Warranty for the Main Unit and Installation Projects

User Manual: Comprehensive Guide to System Operation, Maintenance, and Troubleshooting

3. Long-term Operations Maintenance Plan

To ensure the system operates continuously and efficiently, a regular maintenance schedule should be established:

Routine Maintenance: Clean or replace air filters monthly; check condensate drain for proper flow.

Quarterly Maintenance: Clean heat exchanger surfaces, inspect fan belt tension, and ensure electrical connection tightness.

Annual Maintenance: Complete condenser cleaning, check refrigerant pressure and compressor oil level/color, calibrate sensors