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3 Solutions to Protect your Electrical Enclosures From Condensation and Humidity

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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 Spring’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.

 

Marine Vienney

Success Story: DTS Cooling Unit back for service after 15 Years of use!

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At Pfannenberg, we are delighted to learn how satisfied our customers are with our products. When we received an old DTS Cooling Unit back for service after 15 years of use, we could do nothing but offer a full-service repair on the unit!

This DTS Unit was sold by Pfannenberg to an integrator back in 2004. The final customer, a manufacturer of fencing, railing and hardware has been a Pfannenberg customer since 2011 and has always been satisfied with this product. This DTS Cooling unit is used to keep the blow-molding machine cool and operational.

The reason for returning the unit to Pfannenberg was not to upgrade to a newer product, but to perform routine maintenance on the unit.  After a full evaluation, our service technician replaced all defective components to get the unit back to full running status, meeting a good refrigeration delta temperature condition. Additionally, preventative measures were taken by replacing fan motors, capacitors and relays, as well as a thorough cleaning of the condenser coil for proper heat dissipation.

 

This success story demonstrates once again the robustness and service-friendliness of Pfannenberg Thermal Management products. Pfannenberg customers can rely on reliable products and customer service to keep their application and processes up and running, even after 15 years.

Contact us for Preventative Maintenance on your units or recommended spare parts!

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Filterfan 4.0 New Video

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Trust in the Original

Otto Pfannenberg’s invention of the Filterfan® in 1958 was a milestone in the area of industrial thermal management. From generation to generation, our world-class engineers have been working on the continuous technological development of Pfannenberg Filterfan® products. Numerous improvements are continuously made including several breakthroughs, so valuable that they required international patents. All in all our Filterfans 4.0™ contain 11 field-proven patented features!

Discover below our New Video presenting the great features of our Filterfans 4.0™ line: quick and easy to install, to maintain or to replace and still no tools are required!

Important for the use of Filterfans®:

  • Use Filterfans® to force the surrounding air into the electrical enclosure, so that a slight overpressure builds up inside the enclosure.
  • The surrounding air enters the electrical cabinet exclusively via the Filterfans®, which ensures that it is filtered.
  • Install the Filterfans® in the lower third of the electrical enclosure and the exhaust filter as close to the top as possible. This assists the natural convection of the air and avoids hot spots within the enclosure.

Is your enclosure located in a wash-down area? Then Pfannenberg’s Rainhoods are your to-go choice! Their direct spray barrier and high air-flow baffle allow for superior protection from overspray entering the cabinet while minimizing airflow loss, more info here!

 

Marine Vienney

Pfannenberg concludes exclusive agreement on thermal management solutions with the BMW Group

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Thermal management specialist Pfannenberg has concluded an exclusive agreement with the BMW Group on thermal management solutions for the production plants at all sites worldwide.


Picture Source: BMW AG

Pfannenberg’s energy-efficient, low-maintenance and long-lasting thermal management solutions as well as our global presence were decisive in the conclusion of this partnership. Depending on site, environment and application, we offer a wide range of thermal management solutions – from filterfans® and air/air heat exchangers to air/water heat exchangers and cooling units.

The perfect cooling solution for any requirement

Whether painting or assembly work, manufacturing in the automotive industry uses many different processes at the same time and production efficiency is a top priority. Cooling requirements vary depending on the application, and a precise analysis of the needs is necessary to define the appropriate performance. Otherwise, an oversized system can lead to higher energy consumption. In this area, Pfannenberg offers the right thermal management solution for every cooling requirement and ensures an energy-efficient and smooth production sequence. In particular, Pfannenberg’s ECool series cooling units stand out for their high performance, intelligent control and exceptionally easy-to-maintain design.

Translated with www.DeepL.com/Translator (free version)

“We are very pleased about this cooperation and look forward to the coming years as a partner of the BMW Group. Thanks to the outstanding cooperation of the technical team, the customer service and our account managers, we can offer the BMW Group a convincing all-round package” says Jan Lautenschläger, Germany Sales Director at Pfannenberg. “In the production area, an energy-efficient cooling concept is becoming increasingly important and here in particular regarding the CO² emissions along the production chain. Major customers such as BMW are demanding a respective company-wide solution with a sustainable concept for the future. Here, the focus is clearly on energy efficiency and perceivable quality.”

Convincing energy efficiency and ease of maintenance

BMW group’s main requirements were focused on energy efficiency and maintenance needs. Thanks to the installation of test Cooling Units, Pfannenberg convinced in particular with the εCOOL series. A realistic energy consumption analysis facilitated the simulation of the expected energy consumption in various production sites. This analysis showed that due to low ambient temperatures, the real environment will often not require the unit to run at full power. This is where the Pfannenberg’s intelligent energy-saving mode comes into play, with the “cooling mode” being triggered when the required cabinet temperature is exceeded. In addition, the standardized installation dimensions and housing cutouts allow easy replacement of cooling units and quick adaptation to changing environmental conditions and applications.

Marine Vienney

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

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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.

Watch the Full Video Now!

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

Marine Vienney

Pfannenberg to Showcase New PKS 3000 VFD Control Panel Cooling Technology at EASA 2019

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Visit booth #561 to see more efficient, high-performing air to air heat exchanger

Pfannenberg will highlight their advanced Pfannenberg Kinetic System™ Series Air to Air Heat Exchangers for removing heat from VFD control panels at booth 561 at the 2019 EASA Convention in Las Vegas, NV, held from June 30th to July 2nd.

Additionally, Pfannenberg will be presenting their new PKS system and how this solution could improve the reliability of VFDs while reducing energy consumption and maintenance compared to other thermal management products on Monday July 1st at 2:30 PM at the New Product Theater.

Perfect Solution for VFD control panels Cooling

Pfannenberg’s PKS Series Air to Air Heat Exchangers use a revolutionary next generation cooling technology (Pfannenberg Kinetic System™) to remove heat from VFD control panels while preventing ingress of contaminants into the enclosures. These environmental parameters within the VFD cabinet, temperature and dust, could determine the service life of the VFD.

A VFD running at 18°F above its recommended ambient temperature could lose up to 50% of its expected service life. Industrial air conditioners are typically the go-to solution for cooling VFDs and other critical electronics housed in sealed enclosures. However, a cooler ambient environment could also be used to help control the temperature within the cabinet. Lightweight and easy to install, the PKS technology takes advantage of a cooler ambient environment to remove heat from within the enclosures while sealing against gas, humidity, and dust. The patented technology, unlike industrial air conditioners, does not utilize a refrigerant cycle that has a high energy consuming compressor, making it more efficient to operate from a uptime reliability and energy savings standpoint.

PKS Series Air to Air Heat Exchangers

PKS Series Air to Air Heat Exchangers are designed for indoor (NEMA Type12), outdoor (NEMA Type 3R), and washdown (NEMA Type 4X) applications that require protection from harsh ambient conditions.

They are also ideal for keeping water and dust from sensors and drives on outdoor systems, and protecting against corrosion and contamination in the food and beverage industry.

This is a perfect solution for those looking to reduce the energy, maintenance and footprint associated with traditional enclosure cooling units. This new technology offers considerable saving compared to a traditional AC unit.

In addition, with only two mechanical elements, PKS Series Air to Air Heat Exchangers require less maintenance and ensure greater uptime!

Visit booth 561 or Click Here to learn more!

About Pfannenberg

Established in 1954 by Otto Pfannenberg in Hamburg Germany, Pfannenberg is recognized as a leading global manufacturer of thermal management technologies within the Electro-technology Industry. In 1958 we invented the Filterfan®, which continues to be recognized worldwide as a leading product to help manage the temperature in electrical enclosures. Our business philosophy: Protecting Man, Machine and the Environment.

Marine Vienney

Why Pfannenberg’s Cooling Units Do Not Need A Filter

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Pfannenberg’s ‘service-friendly’ DTS cooling units provide effective cooling for tough industrial or outdoor applications. Their closed-loop designs ensure that ambient air, dust, and humidity are not passed to the interior of the enclosure, thereby keeping sensitive and critical electronics safe from contamination and in prime operating condition.

Pfannenberg’s DTS Cooling Units filter-less design reduces the amount of required maintenance needed for operation in dirty environments. Indeed, if a dirty filter is not cleaned or replaced, it can become clogged which severely limits its efficiency and result in poor performance.

Filter-Less Design

  • High Airflow Backward Curve Impeller Fan
    Provides high airflow in a long lasting, single bearing design. Higher airflow pushes dirt through wider fin spacing allowing for less clogging which avoids system failure.
  • Large Fin Spacing
    Large condenser fin spacing allow for longer maintenance periods, even without an additional Nano coating. They are less susceptible to clogging from dirt buildup which can cause the unit to work harder and hamper efficiency.
  • Corrosion Protection
    The DTS Outdoor and wash-down units have a special coating on pipes and coils on the ambient side of the unit to provide maximum protection from saltwater, sour gas, and other corrosive substances.
  • Self-Protected Electronics
    Our unit is uniquely designed to protect itself in NEMA 3R, 4, and 4X environments. An example of this is the location of our control electronics within our dry, cool interior circuit.

 

How to Avoid System Failure

As with any unit located in a dirty environment, the components around the external air circuit require periodic cleaning. To avoid any critical component failure, follow the 3 simple steps below to help ensure your enclosure cooling units stay up running:

  • STEP 1: Make Sure your Condenser Coils are Clean
    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
    The fan motor and fan blades need to be inspected to determine wear and damage.  Also make sure electrical components aren’t damaged or loose.
  • STEP 3: Set your Unit to the Recommended Proper Temperature
    Pfannenberg recommends the dip-switches on the control board to 95°F/35°C in the factory.

All maintenance should be performed by qualified personnel, following all safety procedures. To help you perform your preventative maintenance, Pfannenberg realized a simple video following the 3 above steps: Watch the Full Video Now!

 

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Stronger than the elements – Pfannenberg’s DTS 3000 series Outdoor Thermal Management Devices

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When conditions are harsh you can count on Pfannenberg’s DTS 3000 series cooling units to protect your electronics in extreme heat, cold, wet or dusty environments.

System integrators and planners often struggle with the thermal management of electrical enclosures in outdoor applications: extreme temperatures, moisture and dust are particularly challenging with some applications exposed to the elements 24/7. Pfannenberg, the world leader in the Thermal Management of electrical enclosures, has designed a range of cooling units which represent a solution to providing protection in these harsh environments.

DTS cooling Units

Pfannenberg’s DTS 3000 series Cooling Units, cooling capacity from 300W to 6.3kW, are suitable for use in demanding outdoor locations. These products are categorized in protection classes NEMA Type 4/4X and IP 66. Pfannenberg also offers heaters, thermostats and hygrostats to prevent the formation of damaging condensation.

Typically, these cooling units are used for applications in demanding environments such as deserts or extreme cold, in buildings, traffic and energy technology, in sewage and water treatment plants and in metal production/processing. They are also found in other harsh manufacturing systems for cement and building materials, the timber industry, wind,  water power generation and photo voltaic applications. Users even rely on these versatile devices in mobile equipment. Pfannenberg’s DTS 3000 series cooling units are therefore making a contribution to the energy transition.

“Pfannenberg is focusing on the growing global market for demanding outdoor cooling systems. We have have a name in the thermal management of electrical enclosures for indoor applications and with an extremely broad portfolio of devices which also meet the NEMA standard, we can cover almost every application scenario,” says Jörg Achenbach, Regional Product Manager, Thermal Management for Pfannenberg EMEA.

“Outdoor conditions are often extreme: wildly fluctuating weather situations like rain, frost and heat all present problems as do a high concentration of particles in the air, hail, snowstorms, aggressive vapors and cleaning with powerful water jets and cleaning materials. Pfannenberg offers solutions in the DTS 3000 series for all these environmental conditions, with models that can operate in temperatures ranging from -40 °F to maximum 140 °F”, explains Achenbach.

 

Robust and reliable

Pfannenberg’s DTS 3000 series offer powder-coated NEMA 3R/4 but also Type 4/4X 304 Stainless Steel units for use under the toughest conditions. A hermetically sealed cooling circuit not only ensures prevention of leaks, but also makes topping up with coolant unnecessary. Systems to protect against thermal overload, corrosion and excess pressure ensure that these outdoor cooling units have a longer operational life.

 

Dust and moisture remain outside

To prevent ingress of foreign bodies, dust or water, Pfannenberg’s outdoor cooling units meet the requirements of IP 56 and N3R protection classes as standard. Also, the DTS 3000 outdoor units condensers fins are 3 mm apart which makes them less likely to trap dust. One of the advantages of this design is that the units are almost completely maintenance free – even with very high concentration of particulate in the air.

 

Low Ambient (LA) equipment package for low temperatures

The Low Ambient (LA) anti-frost package has an integrated enclosure heater and an intelligent fan control system to ensure that the machinery operates without interruption and provides excellent protection from condensation at temperatures as low as -40 °F. The extracted moisture evaporates in the device before it can cause damaging short circuits in the enclosure. The package also includes a safety overflow and a thermostat which can be installed in the enclosure. The LA package is available with cooling capacities from 700W to more than 5kW for the DTS 3000 cooling units. The integrated electrical enclosure heater, which is very easy to install, is offered in versions up to 3kW.

 

High Temperature (HT) package for extreme heat

The High Temperature (HT) package has a temperature-stable compressor and a large condenser for reliable protection of enclosure components at exceptionally high temperatures up to 140 °F. The HT package is available for compact 700W cooling devices and also for large, powerful solutions up to 3200W.

 

Even better equipped

Compact fan heater with thermostat

As a useful addition to the outdoor cooling devices, Pfannenberg offers 10W – 1200W supplementary heaters, thermostats and hygrostats for monitoring relative humidity levels. Depending on the application, this additional equipment offers further protection from condensation and corrosion and helps to optimize the energy/cost ratio. 

As a system: cooling units, heaters, thermostats and hygrostats will ensure that the environment within the enclosure is ideal for performance and service life of the critical electronics.

 

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.

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

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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.
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CASE STUDY: SICIM – Outdoor Cabinet Cooling in Extreme Environments

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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