Free Cooling is a process that can be achieved using air-cooled chillers when the outdoor air temperature drops. With this mechanism, cooling can be performed in industrial or HVAC systems without operating the chiller’s refrigeration cycle or compressor.
In fact, during cold seasons or when the outside air is cool, an additional or integrated air-cooled condenser (installed separately from the refrigeration cycle of the chiller) can use ambient air to cool the circulating water in the system. Today, Free Cooling is widely applied in both residential and industrial HVAC systems, eliminating the need for the chiller's compressor to create cooling.
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Applications of Free Cooling Systems
When the outdoor temperature is lower than the indoor temperature, this system uses outside cold air to chill the water (without using the chiller’s compressor), providing cooling to specific spaces or equipment. In this scenario, it replaces the chiller’s refrigeration cycle and still achieves the desired cooling effect.
This technology is used in HVAC systems during colder months or in industrial settings for cooling continuous-operation machinery.
Generally, Free Cooling systems are used in the following scenarios:
- Buildings requiring both heating and cooling simultaneously in different zones; for example, shopping malls where crowd density raises the indoor temperature and cooling is needed even during colder seasons.
- Industrial factories that operate all year round, such as plastic injection molding machines, pharmaceutical plants, etc.
- Server rooms or data centers where year-round cooling is essential.
How Free Cooling Works
Free Cooling is typically used in air-cooled chillers. When the outdoor temperature is lower than the indoor temperature and the set point of the system, a triple valve bypasses all or part of the chiller water to the free-cooling coils installed on the main condenser. The returning water then exchanges heat with the outdoor air. The cooled water is used for process cooling (equipment) or HVAC cooling coils (AHUs or fan coils). When ambient air is colder than the water required for cooling, the chiller compressor shuts off, and the Free Cooling system provides all cooling.
Key Points:
- In warm seasons, when the outdoor temperature rises, the triple valve directs the water flow straight to the chiller’s evaporator, bypassing the Free Cooling system.
- Free Cooling is generally not used with water-cooled chillers, since these systems naturally cool the cooling tower water using outdoor air, which then circulates to the fan coils or air handling units.
Free Cooling’s Impact on Chiller Power Consumption
As mentioned, Free Cooling produces chilled water without using the chiller compressor. It can be especially effective in temperate regions during late fall, winter, and early spring. Since the compressor’s operation is reduced or eliminated, Free Cooling significantly reduces power consumption in HVAC and industrial cooling systems. Lower use of the air-cooled chiller’s refrigeration cycle leads to major energy and cost savings.
Ideally, the only energy consumption in Free Cooling mode is from blowers and fans. By eliminating the compressor, power use can drop by up to 75%, depending on the climate. Additionally, reduced compressor wear extends the chiller’s service life.
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Free Cooling in Brief
Free Cooling is a method that utilizes the lower outdoor air temperature to provide cooling in HVAC or industrial systems without running the chiller’s compressor. This is achieved by diverting the system’s water through coils mounted on the air-cooled condenser, where it exchanges heat with the outside air. When the outdoor temperature is below the system’s set point, a triple valve redirects the water flow to the free cooling coils, allowing the compressor to shut off. This process significantly reduces power consumption and extends the compressor’s lifespan. Free Cooling is primarily used in air-cooled chillers and is most effective in temperate climates during colder seasons.
DamaTajhiz, the first and most trusted source for HVAC and building system equipment since 2004 (with 3 valid business licenses), offers various air-cooled chillers and hundreds of other products with guaranteed authenticity, after-sales service, and official warranty. If you need help selecting and comparing brands, feel free to contact our technical experts during business hours at +98-21-88822550.
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