Project Snapshot
Application : 24/7 Heavy Machine Control Panel Cooling
Industry : Industrial / Factory
Existing System : Dedicated Panel Air Conditioners
New Cooling System : 2 × 1.5 HP Ducted Split Air Conditioners
Operating Strategy : Alternating operation for continuous 24-hour machine use
Airflow Control : Individual damper for each ducted air conditioner
Electrical Arrangement : Separate air-conditioning power supply with individual MCB protection
Installation Condition : Cramped, dusty and high-temperature area beside burner machinery
Project Scope : Air-conditioning installation, ducting, dampers, support brackets and electrical works
The Challenge
The burner machine operates continuously 24 hours a day, and its controller equipment requires continuous cooling.
The factory had previously been using panel-type air conditioners installed specifically for the machine controller DB. Repeated breakdowns and servicing difficulties eventually led the customer to look for a more conventional and maintainable air-conditioning solution.
Another important consideration was reliability.
Using only one air-conditioning unit would mean that any breakdown or maintenance requirement could leave the machine controller without its intended cooling.
The factory engineer therefore requested a two-unit system that could be operated alternately.
The Solutions
CrystalAir installed:
- 2 × 1.5 HP ducted split air conditioners
- Separate duct connections to the machine controller cooling area
- Individual air dampers for both air-conditioning units
- Independent electrical supply arrangement
- Individual MCB protection for each air-conditioning unit
- DOL starter/control arrangement
The two air conditioners can be operated alternately to support the factory’s continuous operating schedule while reducing dependence on a single cooling unit.
Key Design Features of this Project:
Dual 1.5 HP Ducted Air Conditioning: Two ducted split air conditioners were installed to provide cooling for the heavy machine controller area operating continuously for 24 hours.
Alternating Operation: The two air conditioners can be operated alternately, reducing dependence on a single unit and allowing one system to remain available when the other is resting or undergoing servicing.
Individual Airflow Dampers: A damper was installed for each ducted air conditioner to prevent cooled air from flowing backward through the standby unit when only one air conditioner is operating.
Independent Electrical Supply: Instead of tapping power directly from the machine controller DB, a separate supply arrangement was used to reduce the risk of an air-conditioning electrical fault affecting the production machine.
Individual Electrical Protection: Each air conditioner was provided with its own MCB together with the DOL starter/control arrangement for clearer circuit protection and isolation.
For commercial and industrial air-conditioning servicing and cooling solutions, learn more about our commercial air conditioner maintenance and cooling services.
Technical Specifications & Installation Details
Below are some details for this project
Application: Heavy industrial burner machine controller cooling
Operating requirement: 24-hour continuous machine operation
Air-conditioning system: Daikin ducted split type
Quantity: 2 units
Capacity: 1.5 HP per unit
Model: FDBC35AV1M9 / RC35BV1M
Refrigerant: R32
Damper: G.I. VCD with Quadrant Handle
Operating strategy: Alternating operation to support continuous machine cooling
Airflow control: Individual damper for each air-conditioning unit
Electrical arrangement: Separate power supply from the machine controller DB
Electrical protection: Individual Schneider Single Pole 10A MCB for each air-conditioning unit with 0.7kW DOL starter/control arrangement
Installation scope: Air-conditioning units, ducting, dampers, support brackets and electrical works
Site condition: Cramped, dusty and high-temperature area beside operating burner machinery
Challenging Installation Environment
Although the air-conditioning capacity itself was relatively small, the physical installation was not straightforward.
The installation area beside the burner machine was:
- very limited in working space;
- dusty;
- exposed to significant heat generated by the operating machine; and
- difficult to access for bracket fabrication and installation.
Constructing and positioning the supporting brackets in the confined area required careful site work to ensure that both air-conditioning units could be installed securely while maintaining access for future servicing.
This was an important consideration because one of the customer’s reasons for replacing the original panel air conditioners was to achieve a cooling system that would be easier to maintain and repair in the future.
Watch the Project Walkthrough
Installation walkthrough of two 1.5 HP ducted air conditioners for a 24-hour industrial machine controller cooling application, including alternating operation, airflow dampers and independent electrical protection.
The Result
The completed system provides the factory with a more conventional and serviceable cooling arrangement for its machine controller area.
Instead of depending on a single specialised panel air conditioner, the factory now has two ducted split air-conditioning units that can be operated alternately, with individual airflow control and electrical protection.
The project also demonstrates that industrial air-conditioning design is not only about selecting the required HP.
For continuous production environments, redundancy, airflow control, electrical separation, maintenance accessibility and operating reliability should also be considered as part of the complete cooling system.
Need a Cooling Solution for Industrial Equipment or Factory Applications?
CrystalAir provides cooling, ventilation and air-conditioning solutions for commercial and industrial applications.
If your factory has equipment rooms, machine controllers or production areas requiring a customised cooling arrangement, contact us to discuss the operating requirement and site conditions.