Marine Vienney

The Technology of Cooling: Cooling with Closed Loop Cooling Units

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Pfannenberg Cooling Units operate on the principle of the Carnot cycle. This means that the cooling unit functions as a heat pump that “pumps” the thermal energy transferred from the electronic cabinet (heat dissipated from the components) up to a higher level of temperature (the ambient temperature can reach levels as high as + 55 °C). The air inside the enclosure is cooled down by the evaporator and at the same time dehumidified.

How do I know if a cooling unit is the right product for my application?

> If the ambient temperature is greater than the target internal temperature of the enclosure, active cooling is required.
> If a NEMA Type 12 to 4x rating is required – closed loop systems can maintain the NEMA Type rating of the cabinet.

Properly sizing a cooling unit:

To properly size a cooling unit you must know the required cooling capacity in Watts, mounting requirements (side, integrated or top mount) and the dimensions of the unit and enclosure.

{PC = PD – PR }
> Pc [ Watt ]: Refrigeration capacity of a cooling unit.
> PD [ Watt ]: Dissipation Loss: Thermal power generated inside a cabinet by the dissipation loss of components.
> PR [ Watt ]: Radiant heat gain/loss: Heat transfer through the skin of the enclosure (insulation factor not included).

{PR = C x A x ∆T }
> C [  W/m2 °C ]: Coefficient of heat transmission.
> A [  M2 ]: Surface area of electronics cabinet.
> ∆T [ °C ]: Difference in temperature between the ambient air and the air inside the electronics cabinet.

Utilizing performance curves to properly size cooling units:

Pfannenberg utilizes the DIN standard 35/35 °C when rating our cooling units. Many other companies use 50/50 °C, which provides a higher, non-usable value.

Customers should use their own application temperatures to determine the proper cooling capacity of the system.

To properly size your Cooling Units you can also use Pfannenberg’s PSS Software which will guide you through the sizing process, to calculate the correct product for your application.


Important information when utilizing cooling units:

  • The refrigeration capacity should exceed the dissipation loss from the installed components by approximately 10%.
  • The enclosure should be sealed to prevent the inflow of ambient air.
  • Use the door contact switch to impede operation with open doors and consequent excessive accumulation of condensation.
  • Use cooling units with maximum clearance between air inflow and air outflow to prevent poor circulation.
  • Make sure that the air inflow and air outflow in the external circuit is not hindered, preventing proper heat exchanging at the condenser.
  • When using top-mounted cooling units, make sure that components with their own fans do not expel the air directly into the cooling unit‘s cool air outflow.
  • Make sure unit is level.
  • Setting the temperature to the lowest setting is not the optimal solution due to the condensation issues. The value we have preset on the cooling unit is a sound compromise between cooling the inside of the enclosure and the accumulation of condensation.

Click here to discover our complete range of Cooling Units!

Topics: Enclosure Cooling, Cooling Units, Thermal Management

Marine Vienney

New Thermal Management Solutions with Cloud-Based Remote Monitoring

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On the way to Industry 4.0 with Pfannenberg’s innovative Thermal Management Solutions

Pfannenberg will unveil its Thermal Management Solution with cloud-based remote monitoring at Europe’s leading exhibition for electric automation, SPS IPC Drives in Nuremberg, Germany.

Communication is provided by a compact device with an integrated SIM card, which receives the relevant data from the connected cooling units via Modbus – a Building Management Protocol – and transmits it to the cloud over a secure mobile telecommunication link without any need for access to the company’s IT infrastructure.

The solution developed in cooperation with T-Systems enables users or systems to retrieve status data, diagnostic information and alarm notifications from the cooling units, live and independent of location, through a web browser, or to integrate the data directly into their applications.

From November 24-26th,  visitors will have the opportunity to see a working model on display at Stand #339 in Hall 5, and discuss this innovative Thermal Management solution with experts from Pfannenberg to learn more about its functionality and deployment options.

“The smart factory is the wave of the future. As an innovative medium-size company with over 190 patents worldwide, making our cooling solutions fit for networked products is a natural choice”, says Andreas Pfannenberg, Managing Director of the Pfannenberg Group. “With the premium controllers of the newest generation, our cooling units are able to provide a wealth of relevant data. Thanks to the cloud solution, employees in production management, the service department or the maintenance department, as well as higher-level monitoring systems, receive information about possible malfunctions or imminent failures promptly, wherever they are. This enables them to respond quickly before a serious incident occurs, which helps increase machine availability.”

Next-generation of Thermal Management

The Thermal Management demo system on display at the trade show will consist of a two-compartment switchgear cabinet with a semi-recessed DTI cooling unit on one side and a semi-recessed PWI series Air to Water Heat Exchanger on the other side, each equipped with a premium controller. There are three heaters in each cabinet compartments, which can be turned on individually at the front using door-mounted switches to simulate heat loads. On an external monitor visitors will be able to observe how the Enclosure Cooling Unit reacts to changes in the heat load or when opening the cabinet door.

Contact us today to learn more about this innovative solution!

Topics: Air Water Heat Exchangers, Enclosure Cooling, Cooling Units, Thermal Management

Marine Vienney

Top-Mounted Cooling Units for Electrical Enclosure Cooling

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Pfannenberg’s Top-Mount Cooling Units meet all industry demands for costs, space and energy savings.

Proper cooling is essential for temperature regulation in electrical enclosures. Our Top Mount Cooling Units provide 100% protection against condensate with their unique, patented condensate management.

Why choose Pfannenberg’s Top Mount Units :

Compact size
Ideal for narrow production lines, electrical enclosures that are placed tightly together in a row and areas that are required to be kept obstruction free. Their top positioning keeps them protected from mechanical damage.

Energy Efficiency
New Proven, Energy Efficient Micro-Channel Technology (an environmentally friendly solution that using 50% less refrigerant than standard coils). The additional Energy Savings Mode allows the unit to automatically switch off the internal motor.

100% condensate protection
Main features of the DTT’s innovative condensate management include re-positioning of the cooling circuits. Moving the cold area up prevents the cold bridge to the electrical enclosure and also enables a problem-free drainage of condensate. An extensive separation of air flow and evaporator stops the formation of twirling droplets. Lastly the integrated air outlet nozzle makes the use of conventional air hoses unnecessary, minimizing the condensation risk.

Unique Design
The compact, top-mount design allows you to save valuable space to use for other purposes. Its low energy consumption reduces your energy costs. Our DTT Top Mount Units have a unique, revolutionary patented condensate management design. The innovative position of the cooling circuits challenges the traditional design of top mounted units, preventing condensate from penetrating the electrical enclosure.

Flexible
The DTT series are available in three installation sizes and six performance classes – from 500 W to 4,000 W, providing the optimum enclosure cooling from every manufacturer.
Additionally the product range of filter media covers virtually every area, for example aluminum filters for air containing oil or aerosols or fluted filters for highly dusty environments. Pfannenberg’s DTT top mounted cooling units comply with the protection class up to IP54 level of protection for control cabinets.

Service and maintenance friendliness
> Easy, tool-free installation thanks to quick fastening clips on the bottom of the unit.
> A removable cover that can be taken off the front allowing for quick access to the components.
> A Tool-free filter change requiring no screws that can be carried out in seconds.
> Uses the same filter media found in our DTI/DTS series door-mounted and side-mounted cooling units.

Click here if you need more information about our Top-Mounted Cooling Units!

Topics: Enclosure Cooling, Cooling Units, Thermal Management

Marine Vienney

Pfannenberg becomes a proudly member of BEMA association

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BEMA (Bakery Equipment Manufacturers and Allieds) is an international, non-profit trade association representing leading Bakery and Food Equipment manufacturers and suppliers, whose combined efforts in research and development have led to the continual improvement of the baking and food industries.

This affiliation confirms our commitment to the Baking Industry with our specifically designed Liquid Cooling Solutions perfectly adapted to aggressive ambient air environments and systems that require a very high IP class (up to IP 65).

To avoid operations grinding to a halt, specifically those with flour and high particulate in the air, Pfannenberg’s PWS Series Air to Water Heat Exchangers are an ideal solution for efficient, trouble free cooling for electrical enclosures.. Use an existing glycol or cool water source already available in the factory to cool your electrical cabinets.

If you need a cool liquid source, Pfannenberg also has a complete line of Chillers to complement our Air/Water Heat Exchangers.

 

Click here to learn more about the BEMA association

 

Topics: Air Water Heat Exchangers, Enclosure Cooling, Thermal Management, Company News & Annoucements

Marine Vienney

Pfannenberg Water-Cooled Solutions for Greater Energy Efficiency

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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. To keep these processes running, Industrial Cooling is critical.  When ambient conditions are at their worst liquid cooling is an ideal efficient solution.

The Challenge…

One of our machine tool customers needed a customized solution adapted to their customer’s environment allowing their industrial electronics to operate at optimal efficiency. Industrial cooling was needed for a grinding machine requiring cooling control accuracy. This is especially important as it significantly influences the grinding tolerance. The machine sands parts to remove all irregularities before sending them off for further assembly (gear manufacturing), the required control accuracy or hysteresis is up to +- 0.1 K in active units and up to +- 0.5 K in passive units.

The goal was to cool the machine with available water using a passive enclosure cooling unit at a flow temperature of 22°C. The main requirement for this project was that the water from the return flow (returning to the water ring) had to be at least 9°C warmer to match the customer’s own energy efficiency requirements.

The Solution…

After an analysis of their needs, Pfannenberg’s PWW Water to Water Heat Exchangers appeared to be the best solution. Our water-cooled solutions are designed with durable components to ensure the effectiveness and longevity of the critical cooling process at hand.

   

We installed our new passive PWW 6000 into our compatible EB 60 WT Chiller housing which is extremely flexible. Passive water cooling makes sense if the flow temperatures are not too low and if a water circuit is available. This solution works reliably at a temperature difference of more than 5°C between the water circuit and the chiller.

To support this new solution for our customer, Pfannenberg provided 2-days of on-site training bringing “live initial operations” online.

Thanks to the success of this installation, our customer secured 10 more projects using our PWW Water to Water Heat Exchangers with one in China.

Click here to get more information abour our PWW Water to Water Heat Exchangers.

Topics: Enclosure Cooling, Cooling Units, Thermal Management, Water Cooling

Marine Vienney

Pfannenberg Cools Customers Worldwide

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Pfannenberg’s North American headquarters are based in Lancaster, NY but the company serves customers around the globe with plants in Germany, Italy, China and recently Brazil.

Our internal company motto is “Sharing Competence” which allows worldwide teams to work together for a better understanding of our customers, providing dedicated service and solutions for projects globally.“This is the basis for our culture of innovation. We work closely with our internal teams, suppliers and customers to share information, developing an internal company know-how,” said Blaine Witt, Chief Sales Officer. “This process allows us to develop products and solutions based on what the market really demands.”

This strategy has not only contributed to receiving recognition as one of  “Western New York’s Fastest Growing Companies” for 2015 but also to global recognition as a recipient of a “Red Dot Award” award, won for our PYRA-MA Flashing Sounder.

Having manufacturing centers worldwide “allows our teams to work together to support the customer’s needs on every continent,” Witt said. “Looking forward, as technology evolves, our innovation will allow us to build new products that are intelligent and able to communicate with other systems.”

Our global presence and market know-how is a real competitive advantage as our Enclosure Thermal Management products help some of the largest companies worldwide stay cool and safe, protecting and keeping electronic equipment running to avoid costly downtime. We also manufacture visual and audible signaling devices for security, industrial fire alarms, building, industrial process, disaster warning, hazardous areas, light art and illumination.”

Click here to read the full article!

Topics: Enclosure Cooling, Cooling Units, Thermal Management, North America, Company News & Annoucements

Marine Vienney

Pfannenberg’s Micro-channel AC cooling units for electronics cooling

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Micro-Channel cooling is a proven cooling technology that has been used in the Automotive and HVAC industry for over 25 years. Pfannenberg was the first company to introduce micro-channel condenser technology to the industrial process and electrical enclosure cooling industry.

Our extensive 34X1 DTS range features our dual condenser fans with ultra efficient micro-channel condensers designed to meet all industrial environment expectations with products compatible with US regulations as Nema Type 12 indoor, Nema 3R/4 outdoor and Nema Type 4/4x stainless steel for washdown applications.

Pfannenberg’s DTS range of Cooling Units offer a smaller footprint, improved heat transfer efficiency while also providing an environmentally friendly solution by using 50% less refrigerant than standard coils!

Greater Efficiency

The micro-channel condenser coils utilize an ultra-efficient design providing up to 40% more heat rejection thanks to multiple channels
within the tube and a brazed joint between the tube and fin. This improves the transfer of heat from the refrigerant into the ambient air.

Single Row, Less Clogging & Fouling

The single row air flow path of the micro-channel condenser allows for a condenser air flow path that clogs less and is significantly easier to clean during general maintenance.

Corrosion Resistant & Less Weight

The 100% aluminum design with zinc coating increases the corrosion resistance – versus conventional copper tube and fin condensers – and significantly reduces the weight of the product.

Increased Durability

The Cooling Units design provides for a condenser coil that is harder to damage during transit and general handling of the cooling unit.  Fin combing is not required to maintain proper airflow channels.

Cost Effective Design

Machine production of the condenser and the reduced material cost of using aluminum vs copper tubing creates a significant savings over conventional copper tube and fin designs.

Uses 50% Less Refrigerant

In an age where many companies are required to account for and pay fees based on refrigerant usage, having a system that provides the same cooling capacity using 50% less refrigerant is a life saver for plant managers.

Topics: Enclosure Cooling, Cooling Units, Thermal Management

Marine Vienney

Afraid to Use Water to Cool your Electronics?

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Afraid to Use Water to Cool Your Electronics? You Shouldn’t Be:
Air Conditioners have condensate management precisely to handle the water that is already in your enclosures. Many enclosure cooling devices for industrial thermal processing are designed to handle environments where water is present. The off-the-shelf systems incorporate condensate management to handle water in your enclosures. What is that? There is no water near your electronics? That is where you are wrong: The water is hidden in the vapor form in the air. Fortunately when managed correctly it has no effect on the components inside the enclosure.

Learn more about not only managing the water correctly but how to also use Pfannenberg’s Liquid Solutions™ such as chillers and air to water heat exchangers to cool with water. Check out the article written in Process Cooling by Pfannenberg’s Mitchell Wheeler.

Afraid to Put Water Cooling Near Electricity – Process Cooling September 2014 WEFTEC Issue

Topics: Thermal Management, Water Cooling

Marine Vienney

Enclosure cooling. But how and where?

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Pfannenberg Paper Featured in May Design World:

When it comes to keeping electronics cool, you have several choices. For enclosure cooling, industrial air conditioners cool internal electrical components. The conditioners mount directly to the enclosure and are selected based on the amount of heat gain, interior air temperature requirements and, since the heat from the interior is rejected by the condenser of the air conditioner into the area adjacent to the enclosure, are also selected based on the ambient air conditions in the immediate vicinity.

Many industrial applications involve harsh environments including air laden with dust, grit, and/or oil mist, packaged air conditioners are not always easily applied and a remote cooling solution is required. Remote cooling moves the enclosure heat to a location away from its installation site – allowing the control enclosure to be sealed against the operation environment.

Remote cooling may involve using the air conditioner with a remote condenser or “split” refrigeration system. Here, the refrigerant compressor and evaporator remain packaged in the locally installed air conditioner. But the condenser is located in a more environmentally favorable location. Because the refrigerant gas from the compressor must be sent to the remote condenser, and the condensed refrigerant liquid must be returned to the conditioner’s evaporator, the piping between the local and remote components becomes an important part of the split system. If piping size and geometry are not properly engineered, the cooling system will be under capacity and the potential for problems with lubrication can cause premature compressor failure. Split systems also require charging the cooling circuit with refrigerant in the field and one remote condenser for each local condition is needed.

Another option for remote cooling involves equipping the control enclosure with an air to water heat exchanger that uses chilled water and a fan to condition and re-circulate the air within the cabinet. In this case, the entire refrigeration system is installed in a remote location and chilled water or a water-glycol combination is circulated to the enclosure-mounted device to remove the heat. Circulating a single-phase fluid makes the connecting piping a less critical element of the system.

An air to water heat exchanger can be beneficial for industrial applications. Because the heat exchangers use chilled water instead of vapor comp-ression refrigeration, it provides a sufficient cooling in a small package. In some cases, a single air-to-water heat exchanger can take the place of two or more air conditioners.

Air-to-water remote cooling can also offer increased energy efficiency when compared to using local air conditioners in environments where high ambient temperatures result in high refrigerant condenser pressures. As the refrigerant condensing pressure increases, the energy input for the compressor increases resulting higher operating costs. Contaminate-laden ambient air contributes to this situation by fouling the condenser coil and reducing its heat transfer efficiency. These problems are avoided by using a system where the refrigeration source is remote. If the chiller is located outdoors, there are additional efficiency gains to be made when seasonal changes in ambient air temperature allow lower refrigerant condensing pressures and lower operating costs.

The remote chiller-based system allows several enclosures to be cooled with a single chiller reducing equipment and installation costs. The chillers are selected to circulate the water flow rate required by the total number of air to water heat exchangers and programmed to maintain a fixed water temperature. Each enclosure-mounted heat exchanger controls the amount of coolant that it receives from the common coolant loop based on its own local temperature controller. The controller can be programmed to either maintain a fixed temperature or a variable temperature relative to the dew point temperature inside the enclosure to avoid condensation.

This coolant loop setup also provides an easy method of increasing reliability through redundancy. A second full-capacity chiller, installed in parallel with the primary chiller will provide up to 100% back-up for the cooling system. Simple controls are available to allow the back up chiller to be brought on line automatically in the event of a cooling failure. These controls can also rotate the lead and lag chillers to provide even duty cycles and ensure that the off line chiller is always ready.

Click here for more info on our Chiller range!