Pfannenberg EB Chillers: Tailor-made Solution for a Rail Component Manufacturer


Customer Requirement

A rail component manufacturer needed a solution to eliminate downtime caused from the overheating of their track drilling unit.  The current system used 2 undersized chillers, unable to keep up with the cooling requirements, especially when the ambient temperatures in the plant rose due to the hot afternoon sun.

The Pfannenberg Solution

An analysis carried out on location with the customer revealed that the cooling capacity of the two chillers no longer corresponded with the current requirements.  The cooling system needed to be redesigned.

Taking the temporarily intermittent high ambient temperature in the factory into account, the choice fell on our high performance EB 90 chiller.  This unit has an integrated control module which allows for precise temperature control of the cooling medium.EB_Chiller_drawing.jpg

The solution excels due to:

  • Separate cooling and hydraulic circuits
  • Control module to program small hysteresis of the oil temperature
  • Use at ambient temperatures of up to +40°C
  • Sturdy steel housing with thick powder coating

Customer Benefits

As a result of our plant audit, the customer was able to invest in a new solution that was tailor-made to meet their current needs instead of spending money on a temporary, expensive and insufficient repair of their old chiller system.  The new solution ensures the desired machine uptime even during those days affected by the hot sun.  A new maintenance contract was signed to support the optimum functionality of the equipment for the long term.


Have a question regarding which equipment is best for your application? Contact our engineering team for more information!


Pfannenberg, Inc. is a global manufacturer of Thermal Management, Liquid Cooling Solutions and Signaling Technologies.

Pfannenberg is proud to provide solutions as a single source to its customers. Our business philosophy – Protection for man, machine and the environment.

Reliable Enclosure Cooling for Commercial Bakeries

Customer Requirement

Pfannenberg worked with a bakery end user to develop a cooling solution for their control cabinets.  Most of the OEM equipment installed in the bakery called for air conditioners to cool the drives. PLCs and additional electronics. Most times Cooling units can be a convenient and effective method for cooling electronics, except when located in dusty, humid areas within the plant.

These AC units failed regularly and had to be replaced. This was not a sustainable solution as the customer had constant issues with clogging coils and overheating panels.

Once a panel overheated they had to either: not operate the machine, or operate the cabinets with the doors open. This would let all the contaminants that were hurting the AC units into the cabinet, damaging the drives and other components.

The Pfannenberg Solution

To use the chilled Glycol that was already present for other machine processes to provide the cooled liquid source for our PWS Air to Water Heat Exchangers.

The solution included:

  • A reliable cooling solution designed for harsh environments
  • Reduced maintenance.  Once installed the units only have just one moving part, so regular maintenance is not necessary
  • Eliminating equipment failures, means greater uptime
  • Reduced energy costs with the PWS units
  • UL Tested NEMA Type 4/4X – washdown

Customer Benefits

Pfanneneberg’s PWS Series Air/Water Heat Exchanger was the precise solution for the problems our customer experienced. Incorporating Air/Water Heat Exchangers improved performance, reduced maintenance, was energy efficient, and prevented unplanned repairs.

 

Customer Success: Chiller Solution Saves Significant Water Costs for Ink Manufacturer

Choosing the best chiller for your application is not always as simple as picking a product from a catalog. When sizing a chiller it is important to know the environment it will be in. For example, if you need a 5 ton chiller you have to determine 5 tons at a certain ambient and a certain leaving water temperature. When you change either one of these parameters you change the capacity of a chiller. For instance a 5 ton chiller operating at 65°F leaving water temperature in an ambient of 90°F will become a 4 ton chiller if operating at 50°F leaving water temperature and 90°F ambient. The same holds true for higher ambient. The capacity will be reduced significantly when the ambient increases 10°F.

Application Example: Reitech EB 800 WT Chiller Startup

Pfannenberg chiller experts went to perform a startup of an EB 800 WT Packaged Chiller at Reitech. The company manufactures all different types of inks for printing. The application consists of 3 milling machines that grind raw pigment into liquid inks. The grinding process produces heat which must be cooled to maintain the process.

Customer requirements

The company was looking for a more cost effective solution as they were using city water to cool the milling machines. After the process was cooled this water went down the drain. Since the water was not reused in the process, the customer’s city water bill was extremely high and needed to be reduced.

Pfannenberg Solution

Pfannenberg packaged chillers achieve top grades in energy consumption. First, properly sized chillers help to avoid extra costs, as an undersized chiller will never be able to properly cool your application while an oversized chiller will be inefficient due to excessive power consumption.
Then, a chiller is a looped system which uses a refrigeration cycle to remove  heat from a circulating liquid. As the liquid moves through a system of tubes and pipes it absorbs the heat generated by equipment and processes. This generated heat is then transferred by the liquid back to the chiller where it is dissipated. Fluid is cooled and sent back into the system which resulted in a significantly reduced water bill for the customer.

Customer Benefits
The Pfannenberg chiller and installation cost was 25% less than the city water bill leaving the customer with a ROI of 8-10 months.


Need help sizing a chiller? Nothing more simple! You can start by referencing our Chiller Sizing Guide, but if this is not enough to help you choose the best option for your application, you can use our new Chiller Quote Request Form. We’ve created this new web form to allow you to easily enter detailed information about your project, connecting you directly with one of our chiller experts.

CLICK HERE TO REQUEST A CHILLER QUOTE


Topics: liquid cooling

Need help sizing Chillers? Pfannenberg is here for you!

Do you have a need for liquid cooling? Do you have an old chiller that needs to be replaced? Are you unsure of your liquid cooling options? We are here to help!

Correctly sizing a chiller is crucial on many points. An undersized chiller will never be able to properly cool your application while an oversized chiller will be inefficient due to excessive power consumption.

You can start by referencing our Chiller Sizing Guide, but if this is not enough to help you choose the best option for your application, you can use our new Chiller Quote Request Form. We’ve created this new web form to allow you to easily enter detailed information about your project, connecting you directly with one of our chiller experts.

CLICK HERE TO REQUEST A CHILLER QUOTE


Pfannenberg is your expert source for liquid cooling products and helping you choose the correct chiller. We offer packaged chillers from fractional tonnage to over 30 ton. Need more capacity? We can talk about a modular design using multiple chillers. We can also offer installation and commissioning of your new Pfannenberg Chiller.

>> Click here for more information about Liquid Cooling Solutions!

Topics: Chillersliquid cooling

The 6 Step Guide to Choosing the Best Chiller for your Application

Heat is a single common by-product of today‘s manufacturing machines that include the advanced automation technology required for both high speed operation and high precision. Components such as spindle motors, variable frequency drives, laser and x-ray sources all require cooling to operate properly and reliably – most often in the very adverse manufacturing environments.

With manufacturing space at a premium, machine packages have become smaller and liquid cooling has emerged as the most efficient and economical means of removing process heat.Liquid cooling is especially well adapted to hot, dirty environments, where it provides a method of removing the heat from the machine and not contributing additional heat back into the environment.


A quick guide to choosing the correct chiller:

As each industrial environment is different, Pfannenberg designed a 6-steps guide to help you select the proper chiller for your application:

Step 1: Determine the Heat Load

It is important to determine the heat load of your application to ensure the chosen chiller is big enough for the intended application.There are several ways to determine the heat load (in BTU) but understanding the process is essential to calculating an accurate heat load.


Step 2: Determine the Coolant Type, Temperature & Flow Rate

When the heat load is known, the next step is to determine the coolant, its target temperature and the flow rate that the chiller must provide to the process. This is determined by the method from which the heat is transferred from the process to the coolant and the type of coolant being used. For example, water has different characteristics than oil.


Step 3: Identify Installation Environment

In what environment the chiller will be installed? Indoor applications for example can see high temperatures and dirty atmospheres, while outdoor installations can experience both low and high ambient temperatures. This can effect chiller sizing and require accessories such as air filters, sump heaters, etc.


Step 4: Use Chiller performance curves

Now use the chiller performance curves available to select a chiller model that meets or exceeds the required capacity based on the chilled water supply temperature and the highest expected ambient air temperature. Consideration should be given to the safety margin of the application with respect to available frame sizes to maximize the value of the chiller selection. Find all Pfannenberg Chillers Performance Curves on our New Thermal Management Catalog.


Step 5: Check Pump performance curves

Check the pump performance curves available to ensure that the pump will provide enough pressure at the design flow rate to satisfy the application. Some liquid cooled systems have small coolant flow paths or longer distances that can have higher than average pressure losses.


Step 6: Final Selection

Finally, consider that the remaining application requirements such as power characteristics, control options, footprint, agency listing, color, etc. are met by the selected standard Pfannenberg chiller. Choosing a standard chiller will bring you greater reliability, easier service with common spare parts and global support.

>> Click here to download the PDF version of this guide.


Pfannenberg offers a versatile range of packaged chillers, ranging in sizes from less than ½ Ton to 30 Tons insuring the proper capacity available for most applications. These packaged chillers are ready to use requiring only piping and power to install as part of your solution for process cooling applications – we‘ll even provide the coolant. Ethylene & Propylene Glycol coolants, with proper corrosion inhibitors are available in a variety of packaging options – both full strength and pre-mixed. Each chiller model includes the pump, tank, refrigeration system and controls required for simple installation and reliable, efficient operation.

Our knowledgeable applications staff is always on hand to discuss the application and to make sure that a proper selection is made. With our many available equipment options we can easily customize our standard chillers to meet specific application requirements.

Contact our engineering team for more information!

Topics: Chillersliquid cooling

Pfannenberg’s enclosure cooling units installed in the Gotthard Tunnel


Under construction for 15 years, the 35 mile long Gotthard tunnel located in Switzerland is due to open in 2016.

The Gotthard Base Tunnel impresses with many outstanding features:

  • It is the longest railway tunnel in the world at 57 km and its tunnel run, with all the transverse and connection tunnels, stretches over 154 km.
  • From 2016, passenger trains should have a top speed of 250 km/h, reducing the travelling time e.g. between Milan and Zurich to under 3 hours and should almost double the haulage capacity on the Swiss North-South Axis to 40 m tons of goods.

Operating a tunnel poses a huge challenge for engineers and operators. All products and solutions have to meet the highest requirements and have to work perfectly even under harsh ambient conditions. In particular, this applies to electrical enclosures and their thermal management, which are subject to extreme alternating pressure loads, temperature differences and are also exposed to dust and moisture.

In close collaboration, Swibox and Pfannenberg have developed a special climate control concept for tunnel applications. Robust Swibox electrical enclosures with a pressure body which was developed especially to protect the cooling circuit and the side mounted cooling units with integrated controller and heater from Pfannenberg guarantee a high system uptime which are situated, in the 176 cross passages amongst other places.

These electrical enclosure cooling units ensure that the thermal pressure of the electronic components integrated inside the electrical enclosures does not become too high and that they work safely and reliably throughout their whole service lives.

 

Electrical enclosures withstand every alternating pressure

The largest technical challenges were the high requirements to the system of protection of the electrical enclosure, IP65, and also the high alternating pressure load which is caused by the trains passing through. When entering the tunnel, the train pushes the air ahead of it, causing overpressure until the train passes by the cross passage where the electrical enclosures are standing. As soon as the train has passed, the overpressure transforms suddenly to a corresponding under-pressure.

All the electrical enclosures and the installed cooling units are exposed to the load of this alternating pressure of up to +/- 5 kPa. It had to be ensured that all devices can withstand this alternating pressure mechanically, simultaneously implementing the high system of protection.

It was possible to meet these requirements, thanks to the mechanical unit custom construction developed especially in cooperation with the company Swibox. This construction ensures a leak-proof separation of the surrounding (outer wall of the unit) and the inside of the electrical enclosure (unit inside), also under pressure load. A special feature here is the developed pressure body inside which the components of the inner cooling circuit are housed. Therefore, it was not enough to use reinforced sheet metal: the selection of a suitable material and the increased material thickness in combination with specially installed stiffening plates led to the desired compressive strength.

Climate control concept of electrical enclosures does not only mean cooling

Another challenge in tunnels is the ambient air. Large temperature differences ranging from -20 °C to +40 °C, maximum humidity of 100%, and ferrous abrasion of brakes, rails and contact lines in the ambient air increase the risk of corrosion and show how different a tunnel application is compared to standard applications.

Therefore, a special enclosure climate control concept had to be established for specifically this application. In addition to the cooling units, which are predominantly used inside the mountains (ambient temperatures up to +40 °C), Pfannenberg heaters also had to be installed in the portal sector (ambient temperatures to -20 °C). These heaters ensure that the temperature inside electrical enclosures does not fall below the so-called dew-point (the temperature that moist air has to drop to – by unchanged pressure – so that the amount of water dissolved in the air is precipitated as condensate). At the dew-point, the relative humidity is 100%; that means that the air is saturated with water vapour.

Pfannenberg’s new generation of controllers, designed especially for this project, were also installed. This is especially important to prevent unplanned failures and downtime and, by planning maintenance works in advance, to guarantee a high level of system uptime. The controllers are not only used directly inside the cooling units. The climate controller was also integrated into 500 other electrical enclosures without a cooling unit. This makes a temperature monitoring system possible, which, like the climate control units, can communicate with the tunnel control system and, if necessary, can be replaced with such, without having to reinstall the data transfer.

In 2010 the first cooling units were delivered to the company Swibox. In the meantime, all units have been delivered and will be installed one by one, together with the electrical enclosures, in the 176 cross passages of the Gotthard Base Tunnel. They have already been able to prove their reliability every day, as the various test phases started a while ago and will continue until the start of the scheduled railway operation on 2016.

Click here to read the full Case study!

Happy National Manufacturing Day


Today October 3, 2014 marks National Manufacturing day. This is a day for manufacturers to support young people pursuing careers in manufacturing and engineering. This past week Pfannenberg exhibited at WEFTEC which is a show that focuses on products and services targeting the Water Industry. As I walked the mile long exhibit floor it was amazing to see the number of manufacturers exhibiting innovative products that were developed and manufactured here in the USA. My hope is that here in America we continue this innovation and manufacturing traditions. As manufacturers we have to inspire young people and make them aware of the types of jobs that are available in science, math, technology and engineering.

Pfannenberg is proud to support an organization that promotes this initiative locally, Dream It Do It WNY. Dream It Do ItWNY, works with local manufacturers to open their plant doors to showcase their exciting and modern manufacturing plants and inform participants of the many excellent careers that are available in manufacturing. Their message is simple: “Whatever energizes young people — be it cars or computers, music or movies, outdoors or outer space — they can find a great career doing it in today’s manufacturing.”

Safest Way to Cool with Water



Electronics Cooling with an Air to Water Heat Exchanger

Water is the most efficient form of heat removal. Using an air to water heat exchanger allows you to safely cool your electronics using water, while also keeping external contaminants from entering your enclosure. Air to water heat exchangers also offer the advantage of being low maintenance while using significantly less energy than traditional methods.


Advantages of Pfannenberg’s Air to Water Heat Exchangers:

How do we safely cool with water?

#1: Bulkhead fitting for condensate drain providing superior ingress protection.
#2: Solenoid valve – controls liquid flow for capacity control and energy conservation.
#3: Color-coded water lines easily identify water supply & return lines.
#4: Air flow path designed to prevent condensate water from entering the enclosure.
#5: Internal design guarantees  full separation of water lines from airflow paths.
#6: Electronic thermostat for more accurate control of temperatures. Manual purge feature eases winterization.
#7: One-piece cover with sloped top for better protection of internal components and easy cleaning in wash-down applications (not pictured).


CONCLUSION:

Water has been used for years around sensitive electronics.  There’s no reason to be afraid of using water to cool your electronics. This is a great option to consider when your looking for safe and efficient solution to manage your cooling.


Pfannenberg Illuminates the Tallest Christmas Tree in Paris


Flashing lights make the “Place de la Concorde” shine

Hamburg, December 2012 – The tallest Christmas tree in Paris, which stands at 35 metres high, has been shining at the Place de la Concorde since the 6th December.

Equipped and illuminated with Pfannenberg 52 Quadro F12 flashing lights and inaugurated in an official opening ceremony by Paris’ mayor, Betrand Delanoë, the extraordinary light spectacle can be admired by inhabitants and visitors for a whole month longer.

Once again, Pfannenberg has proven that it is a competent partner in terms of art illuminations. As early as 2003, 20,000 Pfannenberg flashlights put the Paris landmark, the Eiffel Tower spectacularly in the limelight. Pfannenberg as a Hamburg company it was an absolute must to illuminate the Hamburg City Hall in 2004. And in 2008 9,500 flashing lights illuminated the Trinity Bridge, the television tower and the summer night sky in St. Petersburg.The French company SAF MAGNUM was commissioned by the City of Paris and is thus responsible for the Parisian Christmas Tree illuminations. The company is, amongst other things, a specialist for the illumination of events. Whilst searching for a manufacturer of flashing light circuit boards, SAF MAGNUM encountered the Quadro flashing light used in the Parisian Eiffel Tower which was produced by Pfannenberg. SAF MAGNUM then used this to build a prototype for the Paris Christmas tree.

For the flashing lights on the Christmas tree the circuit boards of the flashing light Quadro F12 were built into a plastic ball with a diameter of 50 cm. The ball is then, in addition, illuminated permanently from the inside by 12 red high-performance LEDs. The red permanent glow of the balls is made to sparkle by the Pfannenberg flash circuit board by means of a white flash once every second. This light generates 13 joules flash energy, 140 candela light intensity and an internal random generator creates a unique champagne pearl effect.

Click here to see raw video of the tree lighting.