KUADROTEK – Cooling the cabinets of the inverter stations for the 35 MW Ashalim photovoltaic plant, in Israel.

The plant includes the world’s tallest solar tower

The Ashalim power station is located in the Negev desert near the kibbutz of Ashalim, in Israel. The station will provide 250 Megawatt of hybrid PV-solarthermal electricity (2.5% of the Israeli consumption), which makes it the largest of its kind in Israel and one of the largest in the world. The station will combine 3 kinds of energy: solar thermal energy, photovoltaic energy, and natural gas. The PV plant has been connected to the grid in January 2018. Pfannenberg’s cooling units have been mounted in Kuadrotek’s cabinets for inverter stations.

The Customer

Kuadrotek SA, from Tarragona, is part of the Spanish Elektra Group. It specialises in the design, development and implementation of electric switchboards and control panels for the automation of installations and industrial processes in the automotive and energy industries.

Kuadrotek has delivered the electrical cabinets for the inverter stations of the 35 MW photovoltaic plant. Pfannenberg’s cooling units will ensure the perfect thermal management and operational safety for their components.

The Application

PV power plants are built across the globe, including areas of high altitude, extreme temperature, proximity to the sea, and desert areas impacted by sand and dust.

The inverter is the heart of every PV plant; it converts direct current of the PV modules into grid-compliant alternating current and feeds this into the public grid. At the same time, it controls and monitors the entire plant.

Controlling the temperature inside the electrical cabinets – and therefore guarantee the health of its components – it’s a crucial task.

The Solution

After taking into consideration different options of the competition, Kuadrotek chose Pfannenberg’s Outdoor Type 3R/4 side mount cooling units – model DTS 3161 230 V – because of the high protection level (comparable to IP 56) together with the reliability of working in extreme conditions. It offers a cooling capacity of 1235 W in a very compact design – 395 x 748 x 237 mm only.

It is available in 3 models; DTS 3141 (NEMA Type 12) for indoor use, DTS 3161 (NEMA Type 3R/4) designed for outdoor use, and the stainless steel DTS 3181 (NEMA Type 4/4x) designed for washdown applications.

The full DTS 3000 series was designed utilizing high temperature compressors and larger condensers to best perform in outdoor applications which require a maximum ambient temperature of 55 °C – such as roadside, rooftop or desert locations.

NEMA rating can be compared with IP rating – although there is no direct correspondence – but the first one is more complete and also includes other factors such as the protection from corrosion. NEMA Type 3R/4 is equivalent to IP 56. Moreover, Pfannenberg cooling units from NEMA series are UL listed.

 

“Our relationship with Kuadrotek is strengthened thanks to the reliability of the products already used in other large photovoltaic plants in the world. This is also why Kuadrotek continues to choose our products over our competitors.” Xavier Pedescoll – Sales Area Manager. Pfannenberg Iberia

 

Facts at a glance

  • Task: Control cabinet cooling in the Negev desert, Israel.
  • Application: Ashalim power station, a PV-solarthermal plant
  • Solution: n.12 DTS 3161 230 V cooling units
  • Success factors:
    • high quality products
    • highest level of protection for extreme outdoor conditions
    • long term agreement with Pfannenberg regarding warranty and worldwide support.

CASE STUDY: SICIM – Outdoor Cabinet Cooling in Extreme Environments

Paywelders Equipped with 4/4X DTS 3081 Cooling Units

 

Paywelder machines at work in a desert environment

The Customer

SICIM is a Construction Company established in 1962 and offering all types of services related to the installation of pipelines and relevant ancillary facilities for the transmission and distribution of oil, gas and water on an international basis. The experience gained as result of operating for the most important international Oil & Gas Companies in all types of logistic, climatic and environmental conditions, has allowed SICIM to continuously modify and perfect all the relevant operating procedures and adapt them to the specific technical and contractual requirements.

Application Requirements

SICIM has an impressive fleet of machinery that can be mobilised anywhere around the globe. Thousands of machines, including pipe-layers, paywelders, excavators, bulldozers and boring machines, used to tackle the many challenges the company faces in the implementation of its projects. These machines operate in very harsh environments such as deserts and high mountains where they must face high temperatures, humidity, saltiness, sand, etc. on a daily basis. They also have onboard control cabinets requiring temperature control in these outdoor conditions.

The Solution

Due to the need for high reliability in critical outdoors installations, plus compact size to minimize vibrations and fit the small cabinet, SICIM has successfully applied the Pfannenberg 4/4X stainless steel cooling unit DTS 3081, 694 W. The perfect and reliable functioning and the full satisfaction of the given requirements convinced the customer to standardize the solution on each and every paywelder in its fleet.

 

 

 

 

 

 

 

This is an application that has been tested for several years in the most difficult weather conditions, a welldeserved success that once again underlines the robustness, efficiency and reliability of our outdoor air-conditioning solutions. Andrea Pavarani, Sales Area Manager. Pfannenberg Italia srl

Facts at a glance

Task: Outdoor compact cabinet cooling for harsh environments

Application:
Paywelder machines for oil, gas and water pipes

Solution:
~ 70 pcs DTS 3081 4/4X cooling units in 5 years

Success factors:

• efficiency and reliability in harsh environments
• low maintenance
• user friendly installation

Control cabinet and Pfannenberg cooling unit on a SICIM paywelder machine

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.

Pfannenberg’s Chillers Keep Chocolate Tasting Great


Pfannenberg’s Chillers Keep Chocolate Tasting Great

Chocolate plays a major role in many of our holidays as Valentine’s Day or Easter! Whether it’s a box of chocolates or Easter eggs filled with various sweets – there is an extensive process that goes into making these enjoyable treats!

The manufacturing process of chocolate is a delicate procedure. Temperature control of the equipment and the product is important to producing a flavorful and scrumptious chocolate. All processes related to making chocolates are temperature regulated.

A major aspect of chocolate manufacturing is the conching step. Pfannenbergs’ packaged chillers are an ideal solution for the temperature regulation in this process.  Conching is the step in which the chocolate receives its flavor and smooth characteristics! At this stage, the addition of other ingredients is introduced as metal mixers/rollers mix the ingredients together.  This step generates its own heat, which is integral to keep the flavor and the proper consistency of the liquid state.  This chocolate has to be kept at average of 175°F throughout the process (temperature will vary depending on the type of chocolate).  The length of this process will vary depending on the flavor of chocolate.  Typically the average time spent conching is between 4-6 hours; gourmet chocolate brands will spend 30+ hours at this stage.

Following conching, the next step in the process is tempering.Tempering gives chocolate a distinctive shine and color; adding additional flavor.  It is crucial to have strict temperature control.  For tempering, a cooling tunnel is used to take the ambient air; cooling the air to approximately 50°F.  The air then needs to be heated to ambient air temperature.  Pfannenberg’s process chillers have been used successfully in the production of candy and chocolate.  At this stage it is crucial once again for strict temperature control.  If the temperature of chocolate begins to harden and then is heated to become a liquid state – the chocolate is ruined. For chocolate to receive its distinct flavor, look, and texture – the temperature of the chocolate and the air it is produced in is critical.

Next time you eat a piece of chocolate, be sure to appreciate the process it takes to produce such a sweet indulgence!

>> Click here to discover our complete range of chillers!


About Pfannenberg…

By keeping electronics in enclosures from overheating, Pfannenberg provides an invaluable service to companies, keeping their machinery and processes consistently operating.  By developing and producing products which are designed to save energy and other resources, Pfannenberg operates by their business philosophy – Protecting man, machine and the environment.


Topics: Cooling UnitsNorth AmericaPackaged ChillersFood & BeverageChillers

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

The Technology of Cooling Part 3: Cooling with Closed Loop Cooling Units


Pfannenberg cooling units operate on the principle of the Carnot cycle. This means that the cooling units function 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 indoor NEMA Type 12 applications, NEMA Type 3R/4 outdoor applications and NEMA Type 4/4x stainless steel for washdown applications are required – closed loop cooling can maintain the NEMA Type rating of the cabinet.

Properly sizing a cooling unit

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

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.

 

 

 


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 units 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.

In harsh environments involving high temperatures, wash-down requirements, heavy particulate matter or the presence of chemicals capable of damaging components (NEMA 4 or 12 environments), ambient air must be kept out of the enclosure. Pfannenberg Cooling Units seals out the ambient air, cooling and re-circulating clean, cool air throughout the enclosure.

Pfannenberg offers Critical Thermal Management Solutions for Maximum uptime and efficiency.

Find the previous articles of this “Technology of Cooling” serie: Cooling with Filterfans® and Cooling with Closed Loop Air to Air Heat Exchangers.

Read the last part of this “Technology of Cooling” serie: Closed Loop Liquid Cooling Solutions

 

Topics: Enclosure CoolingCooling UnitsThermal Management

The Technology of Cooling Part 2: Cooling with Closed Loop Air to Air Heat Exchangers


Closed Loop Cooling and particularly Air to air heat exchangers are used when the complete separation between the enclosure and the environment is required and the internal enclosure temperature to be cooled can be higher than the ambient. The air to air units have a rating showing how much heat can be removed based on the difference in the ambient and the internal temperatures. This is traditionally rated on W/°C which is the watts of heat that the unit can remove per temperature difference in °C.

How do I know if an air to air heat exchanger is the right product for my application?

  • If the ambient temperature is lower than the desired temperature inside the enclosure.
  • If a total separation between ambient air and enclosure air is required.

Properly sizing an air to air heat exchanger

To properly size an air to air heat exchanger you must know the required cooling capacity in Watts, target temperature rise over ambient and the dimensions of the heat exchanger and enclosure.


Utilizing performance curves to properly size air/air heat exchangers:

> Pfannenberg utilizes watts of heat that the unit can remove per temperature difference in °C.

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


PAI_drawing.jpg

Important information when utilizing air/air heat exchangers:

  • The max ambient is 35 °C (95 °F) and the max internal temperature that the system can take is 45 °C (113 °F).
  • Can be used when the temperature difference is 10 °C.
  • If you apply this temperature difference to the rating of the air to air unit you will get the total amount of heat that can be removed.
  • A unit rated 100 W/°C could remove 1000 Watts (100 x 10) of heat under these conditions.

Closed Loop Cooling with air to air heat exchangers is the most efficient cooling solution as cooling with ambient air is the most economical type of cooling!

Pfannenberg εCOOL Air to air Heat Exchangers feature an energy efficient, minimal maintenance design. Installation and maintenance of these units requires much less time compared to other closed loop Thermal Management solutions.

Click here to read the 1st part of this “Technology of Cooling” serie: Cooling with Filterfans®
Click here to read the 3rd part of this “Technology of Cooling” serie: Cooling with Closed Loop Cooling Units

Topics: Enclosure CoolingCooling UnitsThermal Management

Selecting the Proper Equipment for Food and Beverage Applications


Proper thermal management is key for saving resources and keeping electronics (and equipment) up and running on a consistent basis. It is important to understand the various types of cooling methods available and how the ambient conditions may effect the product chosen.  Choosing the wrong method may lead to a solution that is undersized or oversized, or fails prematurely due to being specified for incompatible ambient conditions.


Selection of the preferred thermal management method, based on various environmental conditions:

Click here to view our thermal management selection guide.


With products that include fans, heaters, packaged air conditioners, air-to-water heat exchangers, packaged process chillers, and signaling devices, Pfannenberg offers a full range of thermal management solutions for the food and beverage industry. Standard options such as stainless steel materials, NEMA 4/4X enclosures, and washdown duty construction allow these time-tested products to be seamlessly incorporated into even the most demanding food and beverage processing applications.


Have a question regarding which equipment is best for your application? Ask Us Here.

Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!

Topics: Air Water Heat ExchangersFilterfansCooling UnitsThermal ManagementHeatersFood & BeverageChillersAir Air Heat Exchangers

Pfannenberg’s Cooling Units Help Support Bottling Inspection


We understand as a consumer that it can get aggravating when you purchase a bottled beverage and the packaging is either defective or the container is not filled properly. It is crucial that beverage and food manufactures implement an inspection system – not only for sanitary reasons, but also for product quality.  Once quality is compromised, the manufacturer loses brand reputation.

Common Problems:

  • Fill Level is Over/Under Target
  • Cracked Cap/Seal
  • Missing Cap
  • Broken/Tampered Band
  • Wrong Cap Color

Pfannenberg’s NEMA Type 4/4X DTS Washdown Stainless Steel Cooling Units fit in perfectly with inspection machines. Inspection equipment (vision systems and x-ray equipment) generate a lot of heat that needs to be managed.  As products move rapidly down the line the inspection machines have to quickly provide an alert when a defective product is detected and signal removal of the defective product.  These inspection machines have hi-res cameras and stainless steel housing to be compatible with the high speed filling lines that need to be cooled.  Pfannenberg’s DTS units are a perfect fit for this equipment and come in various sizes and capacities depending on the requirements.

DTS Series Cooling Units:

  • The wide fin spacing is less susceptible to clogging from dirt buildup which can cause the unit to work harder and hamper efficiency
  • NEMA Type 4/4X Stainless Steel to repel contaminants in food grade applications and to provide for easy washdown
  • High temperature models can operate in ambient temperatures up to 140 °F (60 °C)

As consumers, when we make a purchase we expect the product to be perfect – both taste and overall look (packaging). Nothing would be more upsetting then paying for a beverage and having it filled half full or damaged.  Without the cooling necessary for these inspection systems, the quality of the final product would suffer.


Click here to learn more about Pfannenberg’s DTS Cooling Units.


Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!

Topics: Cooling UnitsFood & Beverage