Spring Cleaning – 3 Steps you Can Take to Prepare your Cooling Units for the Stress of the Summer Heat

With hotter temperatures just around the corner we’ve put together this Preventative Maintenance Video to help you prepare your enclosure cooling units for the stress of summer heat.

To avoid any critical component failure, follow the 3 simple steps below to help ensure your enclosure cooling units stay up running all summer. Don’t Wait Until it’s Too Late!

STEP 1: Make Sure your Condenser Coils are Clean

The condenser coils are one of the most important components of your Cooling Unit, they ensure the reliable, cost efficient and long-term operation of your unit. When dirt, dust or debris builds up on your condenser coils, it can have a major effect on the performance of your cooling unit.

STEP 2: Check your Fan Motors and Inside/Outside Electrical Components

In order to prevent failure, the cooling unit’s fan motor and fan blades need to be inspected to determine wear and damage.  All the electrical components in the control box also need to be checked to make sure all connections aren’t damaged or loose.

STEP 3: Set your Unit to the Recommended Proper Temperature

Pfannenberg sets the dip-switches on the control board to 95°F/35°C in the factory, and recommends that the dip switch settings are not altered.

*Having the dip-switch temperature set to a lower point can cause damage not only to the cooling unit, but to the composure as well.  Changing the set point can cause the cooling unit to run excessively, possibly causing damage to the compressor and other components.  It can also cause the enclosure to produce condensate, possibly damaging electrical components inside the cabinet.


Contact us for recommended spare parts or getting your orders in now for new or replacement cooling units.

3 Solutions to Protect your Electrical Enclosures From Condensation and Humidity

What is condensation?

Formation of condensation is one of the biggest dangers for electrical enclosures. Condensation is caused by hot, humid air coming into contact with a colder surface than the air dew point.

With Springtime’s typical variable weather conditions, outdoor enclosures are even more exposed to the risk of condensation. Condensation can also occur indoors if the humidity is too high.

When the humidity is high is does not take a large change in temperature to cause condensate to form inside the cabinet.

How to prevent condensation?

The most efficient solution is to combine Filterfans® and Heaters with control devices such as Hygrostats and Thermostats. Fan Heaters are typically used in outdoor applications where ambient temperature can threaten sensitive electronics. Radiant Heaters are often used to reduce humidity and control condensate within the enclosure.

1. Filterfans® + Rainhoods

Filterfans® are the ideal solution for clean, non-hazardous environments with an acceptable ambient (outside the enclosure) temperature range.

Designed for use with standard Filterfans®Pfannenberg’s new Rainhoods (Patent Pending) protect your application from harsh environments like rain, water spray, snow or fluids from being drawn into the enclosure.  This product feature a robust design rated to NEMA TYPE 3R/4/4x and IPx6 when used with Pfannenberg Filterfans®.

Adding a Heater to your Filterfan® + Rainhood solution will ensure a proper humidity control. This combination is the optimum solution for the economical and energy efficient cooling of electrical enclosure components.

2. Fan Heaters

Pfannenberg Heaters prevent condensate build up and therefore protect against corrosion.

Compact fan heater with thermostatFan HeaterMini radiant heaterThe PFH-T Fan Heaters with Thermostat are designed to protect electronics from the effects of low temperatures such as corrosion, freezing or condensation, which can damage critical components within a control enclosure.

The PRH-M Mini Radiant Heaters are ideal for small outdoor enclosures, preventing condensate formation.

The FLH Heaters are ideal for use in larger electrical enclosures.

3. Thermostats / Hygrostats

Industrial ThermostatHygrostat FLZ 600

Pfannenberg’s Hygrostats allow you to effectively control the humidity level inside the enclosure. These devices are used to start the heater or filterfan® if the predetermined humidity threshold is reached.

When combining a Pfannenberg Thermostat with a Filterfan®, the fan can be controlled to turn on and off based on the temperature inside the cabinet.

The benefits to this combined system are:
• Extended fan life.
• Reduced energy consumption.
• Reduced consumables and maintenance.

As a system; Filterfans, Heaters, Thermostats and Hygrostats will ensure that the environment within the enclosure is ideal for the performance and service life of the critical electronics.

 

Pfannenberg’s Air/Water Heat Exchangers withstand dust, dirt, and even sterile environments

Pfannenberg’s Air/Water Heat Exchangers offer a solution to fix your thermal management problems in washdown areas, areas with high amounts of particulate or even sterile environments.

Built for both harsh and sterile environments:

The sealed cabinet provides contaminant-free component cooling without adding heat to the local environment. It provides an excellent economic solution where plant water is available or when used in conjunction with a process chiller.  It’s sealed design and available stainless steel, NEMA Type 4/4X construction provides a maintenance free solution with no exposed fans or maintenance of filters required.

With IP 56 protection, our Air/Water Heat Exchangers satisfy the toughest environments. They are available with a corrosion protected hood in brushed stainless steel with epoxy-coated copper pipes and condensers; they offer reliable protection against alkaline solutions and acids. As a high-temperature model, they are also suitable for use in hot environments with temperatures ranging up to 140 °F (60 °C).

Customized solution for Pharmaceutical Industry

Customer Requirement

A system integrator contacted Pfannenberg looking for a thermal management solution for their customer’s plant expansion project. The original design called for building a control panel with supported thermal management for a pharmaceutical application. The challenge was that this system would be located in a Class I, Div II environment, meaning the enclosure and components had to be explosion proof. To remain competitive in price, the system integrator needed an alternate solution to an explosion proof AC unit.

The Pfannenberg Solution

Our engineering team worked closely with the system integrator to develop a solution. The pharmaceutical plant did have water available (60°F at 7gpm flow) and there were no size constraints. Our solution was a customized PWS Air/Water Heat Exchanger.

The solution included:

  • Increasing the overall envelope of the panel
  • Mounting a customized PWS Air to Water Heat Exchanger directly inside the panel
  • The enclosure remained sterile and explosion proof because everything remained inside the cabinet

Customer Benefits

Installing the thermal management product inside the enclosure meant reduced installation and maintenance costs for the customer. In addition the end user also saves money as their available water is used to cool the enclosures. The Air to Water Heat Exchanger provides sustainable efficiency and reliable performance in harsh environments.

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.

Case Study: Pfannenberg Thermal Management Solutions for Harsh Marine Environment


Customer Requirement

An OEM machine builder in the Marine industry needed a thermal management solution that was NEMA Type 4/4X rated, but also resistant to highly corrosive salt spray (fog).  In an industry that encounters very harsh environments, it is crucial to be able to have a product that will be able to withstand such conditions.

The Pfannenberg Solution

To meet the customer’s specific requirements, we provided our PWS Air to Water Heat Exchangers with the 316 Stainless Steel option.

We offered a unit:

  • Which is very resistant to corrosion and oxidation (316 Stainless Steel) compared to the 304 Stainless Steel
  • That can be configured with a different heat exchanger when salt water is used for the cooling supply water
  • With an “easy to mount” seal, no elaborate reworking of the mounting cut-out
  • With an integrated thermostat and solenoid valve for temperature control

Customer Benefits

The customer was satisfied with these highly resistant units that are perfectly adapted to marine environment. Thanks to Pfannenberg’s Air to Water Heat Exchangers the customer was able to reduce downtime and maintenance costs.


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.

Drinktec 2017: Pfannenberg to exhibit for the first time

Pfannenberg, the specialist for industrial thermal management solutions and signaling technology will be exhibiting for the first time at Drinktec, the world’s leading trade fair for the beverage and liquid food industry to be held in Munich from 11 to 15 September 2017.


Pfannenberg will be at stand 138 in Hall B3 showing tough, efficient thermal management solutions and signaling technology for the beverage and liquid food industry.

Visitors will be able to see the latest signaling technology and thermal management solutions for the food and beverage industry at stand 138 in Hall B3. Exhibits will include cooling units with corrosion resistant stainless-steel covers and robust signaling devices with high IP classifications. These products are designed for the toughest environments and are therefore suitable for use where liquids are processed and in production systems which require frequent cleaning.

A demo stainless-steel cabinet demonstrating these features will show a NEMA cooling unit, an air/water heat exchanger including a water jet test, a DTT top-mount cooling unit, a stainless steel rainhood and filterfans in stainless steel design.

“Food production places great demands on manufacturing technology. Our efficient, reliable and tough cooling and signaling technology guarantees maximum machine availability in the fast-cycling and highly dynamic processes in the food and beverage industry, starting with raw material processing through manufacture and quality control to packaging,” explains Annarita Amadei, Industry Group Manager Food and Beverage at Pfannenberg.

IoT-enabled packaged solution
The communication-enabled cooling units in the εCool X series that will be exhibited are ideal for companies wanting to make their production fit for Industry 4.0 and at the same time improve machine availability. These thermal management solutions for electrical enclosures can be integrated directly in the user’s automation systems. If required, they can also provide relevant device parameters via the Cloud for remote maintenance. Users benefit from customized maintenance, cost-efficient service and better machine availability thanks to preventative maintenance.

Reliable cooling
Modern production systems such as filling lines are usually permanently in operation. The cooling units and filterfans from Pfannenberg are fitted with IP 56 housing and corrosion-proof stainless-steel covers which makes them the optimum solution for the economical cooling of electrical enclosure technology.

Exhibits at Drinktec will include the new compact 6301C cooling units from the εCool 6000 series. Their power, and their compact design in particular, make them suitable for use in a wide range of applications.

Despite their space-saving design they offer the same energy efficiency, service friendliness and cut-out compatibility as the standard models: they cut energy consumption compared to traditional cooling devices by up to 43%, with a further 10% reduction in standby operation.

Tailor-made process cooling
In particularly sensitive areas of food and drink manufacture, the maintenance-free air to water heat exchangers and the EB series industrial chillers allow economic system solutions which work independently of the ambient air. Typical areas of application are filling lines and packaging systems. Pfannenberg chillers – with cooling capacities from 3.2 to 148.8 kW – cool sophisticated electronic systems. Both standard ready to-use units and fully customized ones can be provided.

This will be demonstrated at Drinktec with the EB 95 WT. Starting from the compactly designed, highly efficient and easy to service standard unit, this chiller can be equipped with several additional features to match specific applications.

For example, all devices can be equipped with a hydraulic bypass, a SMP55 controller with error messages panel and a ASI communication module enables the unit to be integrated the in the customer’s system. The EB devices are UL certified and can be used at ambient temperatures from -20 °C to +45 °C. All chillers in the range allow users to benefit from lower energy and operating costs, space-saving installation, high reliability and long machine life.

Robust signaling technology
Signaling-2.jpgWith high levels of ambient noise, the manufacture of beverages and liquid food makes serious demands on signaling technology. The status of packaging, laser inscription or filling machines and lines must be permanently displayed so that response times can be optimized and costly downtime minimized. Warning lights and acoustic alarms must signal hazards, risks or technical faults immediately, even in the vicinity of noisy conveyors operating at full capacity. Against this background, combinations of visual and audible signaling devices are the best choice.

Signaling technology suitable for operation in production environments such as these will be exhibited:

  • The BR 50 stacklights: This device is of a modular construction and uses sound and flashing, blinking or solid lights to signal statuses and dangerous situations reliably
  • The QUADRO and LED-HI multi function lights
  • the PYRA sounder/flashing light combinations
  • the PATROL and DS sounders

All of which are suitable for use in the demanding conditions of the drink and liquid food industry, will also be exhibited.

Topics: Thermal Management, Industrial Safety & Signaling Solutions, Trade Show

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.

 

Case study: Pfannenberg Cooling Units to meet Wood Manufacturing needs

An end user turned to Pfannenberg for assistance with managing their enclosure temperatures in a particularly harsh environment. The company produces high-quality construction and installation materials from wood fiber.

Customer Requirement

The customer current system was facing system failures and downtime due to severe soiling from wood dust and rust particles from diesel-powered fork lift trucks and heavy equipment. The current thermal management solution used conventional point-of-entry filters and top-mounted filterfans. The current cabinet system had to be completely changed as it needed to be reliable despite severe air contamination from wood dust and exhaust gas, plus provide energy savings and service friendliness.

The Pfannenberg Solution

As a first step, all the switch cabinets were wet cleaned, both inside and outside.  To rule out any repeat soiling, the top-mounted fan combination was replaced by partially recessed cooling units: DTI 6301 Model.

Special features of the cooling units are:

  • Uniquely high energy-efficiency rating (EER)
  • Significant energy savings/operating costs reduction
  • Condenser with wide fin spacing for highly effective protection against contaminated ambient air
  • Large distance between intake and exhaust vents (to eliminate hot spots)
  • Perfect ease of servicing
  • New service interface for easy retrieval of parameter settings/history (Pfannenberg Plant software necessary)
  • Optional filter can be retrofitted in a few seconds
  • Energy-savings mode in the Multi Controller integrated as standard

Customer Benefits

Use of the new DTI 6301 cooling units led to reliable system operation and to the highest possible amount of machine up time. The environmental and cost balance sheets demonstrated considerable reductions with regards to energy costs and CO2 emissions, as well as reduced service requirements and repair times.


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.

Topics: Enclosure CoolingCooling UnitsThermal Management

Pfannenberg Top-Mounted Cooling Units meet the need of OEM Milling Component Manufacturer

Customer Requirement

An OEM Milling component manufacturer which develops processing centers for the precision boring and milling high-precision components needed critical thermal management for their machine’s control electronics. The systems are designed using relatively tall electrical enclosures to minimize that installation space. This compact design fosters the development of heat pockets.

 

The customer needed a space-saving thermal management solution to keep the manufacturing footprint compact. To minimize the formation of heat pockets, the solution needed to promote very efficient air circulation. Another requirement was absolute protection against condensate and assurance of top-level machine availability – even under difficult environmental conditions.  Thermal management with compact cooling units proved to be unreliable so far because of the problems with condensate.

The Pfannenberg Solution

Our revolutionary DTT series top-mounted cooling units met the requirement for maximum reliability, space savings design and 100% protection against condensate.

The DTT top-mounted cooling units provide unique, four-fold condensate protection:

  • Zero sweat guarantee
  • No overflow of condensate into the electrical enclosure
  • Managed water droplet control
  • No air hoses, which are otherwise at risk of condensation

Further benefits:

  • High-volume air delivery via the integrated nozzles to accelerate cold air movement right down to the bottom of the cabinet
  • Filter media for any area (contaminated ambient air)
  • Controller with energy-saving mode to maximize energy-efficiency (optional feature)

Customer Benefits

Switching to the DTT series top-mounted cooling units successfully allowed the OEM to provide a competitive design to their customers. The units are compatible with all makes of electrical enclosures and are available in 3 sizes and 6 performance levels. Because of its cUR approval and versions with 230V and 400V voltages, the milling processing centers can be used worldwide.


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.

Topics: Cooling UnitsThermal Management

How to Choose the Best Heater for your Electrical Enclosure?

Condensation is one of the biggest dangers for electrical enclosures. As long as the components operate under load, their own warmth prevents water from condensing. If the process is switched off, the electronics cool down. This is where Pfannenberg control cabinet radiant heaters and fan heaters provide additional protection for your electronics.

 

How to Choose the Best Heater for your Electrical Enclosure?


Radiant Heaters
Pfannenberg PRH-M Mini Radiant Heaters (10 to 30 Watts) are ideal for smaller enclosures or for the heating of isolated spots in sensitive areas. These heaters use natural convection to heat the cabinet and prevent condensate formation. FLH series of Radiant Heaters (up to 150 Watts) are used in combination with a thermostat or hygrostat, mainly to avoid excessively low temperatures or high humidity into the enclosure.


Fan Heaters
Ideal for use in larger electrical enclosures with higher heat requirements, Pfannenberg FLH series of Fan Heaters (250 to 400 Watts) have an integrated fan that assists the natural convection and provides fast distribution of the heat in the electrical enclosure. The fan heaters are used in combination with a thermostat or hygrostat, and are designed to protect electronics from moisture or corrosion caused by high humidity, low temperatures or condensation caused by rapid temperature change.

Need more than “just” a Heater?


Pfannenberg also offers a range of fan heaters with an  integrated thermostat: PFH-T (200 – 1200 Watts) dedicated to larger enclosures and with flexible mounting options. These fan heaters with adjustable thermostat are especially designed to protect electronics from the effects of low temperatures such as corrosion, freezing or condensation, which can damage critical components within a control enclosure.

To provide the best Thermal Management for your electronics, using a thermostat or hygrostat results in greater reliability of your production process:

  • Pinpoint distribution and constant temperature in the control cabinet
  • Reduced energy consumption and optimization of the efficiency of the heaters.
  • Additional savings on energy, materials and time.

Pfannenberg’s heaters, thermostats and hygrostats  detect and keep ambient conditions above dew point to avoid the harmful effects of condensation on your electronics. They can be used as a standalone product or in partnership with our Filterfan® and Cooling Unit product lines for a complete Thermal Management of your electrical enclosures.

Topics: Thermal ManagementHeaters