The STULZ UK Team took a consultative approach to the project and undertook a considered technical consultation to provide an appropriate solution, proposing a modern system to replace the legacy DX system, a hybrid GE solution, which incorporates "DX", "Mix Mode" and "Free Cooling". It was agreed that the use of STULZ CyberAir 3 GE units in a N+1 resilient configuration supported by the appropriate dry air coolers & pump sets, would not only be the best solution, but would provide up to 70% Free Cooling, year-round (based on environmental conditions being appropriate), resulting in a considerable reduction in annual energy costs for Paragon CC. The CyberAir 3 precision air-conditioning system with either Indirect Free Cooling or Direct Free Cooling option conditions the air in data centers and equipment rooms up to 90% more economically than conventional compressor cooling systems.
Based on the capacity for the building, STULZ installed four of the units situated on the roof of the mezzanine, cooled by two 250 kW dry coolers external to the building. STULZ then ducted their units into the roof, distributing the conditioned air into the printing room below. This targets the zones where the majority of the critical printing equipment was, and more importantly, the areas of high-density printing equipment.
Darren Davies, STULZ UK Sales Manager, said:
"Basically, we were taking away all these hotspots and leaving a unified conditioned room which would then allow the machines to work at their maximum operational ability, because otherwise they would cease to function if the temperature rose above a certain point."
The legacy splits in the room were removed because they were leaking and dripping water on to the print area. In addition to supplying the equipment, the STULZ team provided a fully engineered turnkey solution which addressed all the problems within that particular room. STULZ supplied both indoor and outdoor equipment with an additional modification allowing to bring the ambient air in from outside and providing a solution to handle air change rates and mix mode free cooling when ambient conditions allow. This enables Paragon CC to ensure the whole system uses as little energy as possible.
The legacy units were decommissioned, the DX ceiling air conditioning units were removed as part of the full installation programme. Weekly status reports were submitted to the client providing full transparency of the project. All ducting and air distribution sets were installed complete with the installation of the dry air coolers and pump sets.
The Project Team had to manage the perception of the employees within the environment as the facility is used 24/7.
Darren Davies said:
"We had to explain to staff how the air moves and how it is supposed to be. A behavioral shift was needed for the system to work appropriately within the room. Leaving a big warehouse door open for example, was continuously letting in hot air. We undertook a process of educating staff as to how conditioned air is distributed and managed within the building and that was fully embraced by the Paragon CC personnel."
Paragon CC is a significant global business with eight other sites similar to this location in the UK. The STULZ team became a trusted advisor to Paragon CC throughout the project. Other consultations have led to several additional projects with Paragon CC at other sites, from data center cooling with STULZ CyberRow units to sales office air-conditioning supplying products to control temperature and humidity precisely, to ensure efficient, continuous operation.