Shows the Fluid Dynamic Airflow to explain Optimal Air Circulation for Enclosures
Ian Johnston

Considerations for Selecting an Electrical Enclosure Cooling Solution

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Optimal air circulation in an enclosure is key to protecting critical components

 

Curious about what to consider when selecting a cooling solution for your electrical enclosure?Fluid Dynamic Airflow image of the inside of an electrical enclosure.

Our experts have the insights and tools you need to make the best decision for your application.

Electrical enclosures house critical components that generate heat during operation. Proper air circulation can make or break an electrical enclosure. Inadequate air circulation can lead to isolated temperature accumulation, running the risk of system malfunctions, reduced component lifespan, and compromised reliability.

To select the best cooling solution for an electrical enclosure, consider such factors as the unit’s proximity to operators, whether it will be installed in a temperature-controlled facility, and the type of airflow inside the enclosure. Read on in Panel Builder US for an overview of electrical enclosure cooling challenges, a review of tools that can be used to simulate and optimize airflow patterns within the enclosure, and considerations for designing electrical enclosures for optimal air circulation.

 

For more infomation and explanation check out our Whitepaper here.

Service review of plant - thermal audits
Ian Johnston

Crafting Proactive Thermal Management Plans for Electrical Enclosures

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Excess Heat in Electrical EnclosuresCooling Unit on enclosure with air flow

Excess heat in electrical enclosures is a high-stakes problem. These enclosures often contain vital electronics that are not only critical to production, but also expensive. Failing to effectively manage heat buildup can degrade enclosed electronics, leading to costly replacements. It can also shut down systems, leading manufacturers to incur even more costs from unnecessary downtime.

The high stakes of excess heat makes proper cooling crucial for effective and efficient production. Proper cooling requires manufacturers to consider heat load, ambient temperature, particles and debris, enclosure location, material, and other complex factors. Most manufacturers lack effective thermal management plans for electrical enclosures, risking significant financial losses that can easily be prevented with proper cooling.

Developing a Thermal Management Plan with Pfannenberg

Manufacturers looking to reduce costs and improve uptime by developing proactive thermal management plans for enclosures can benefit from Pfannnenberg’s 70 years of expertise. Pfannenberg can help determine if a manufacturer employs the correct cooling solutions for their unique facilities and craft a thermal management plan. The plan activities include verifying that the size of cooling methods meet the thermal loads of enclosures, identifying critical equipment, and recognizing thermal technology that may be underperforming due to poor maintenance putting steps in place to reduce downtime  Pfannenberg can also help develop a preventive maintenance plan and recommend the correct thermal technology for challenging applications.

Executing a Thermal Management Plan with Pfannenberg Solutions

Pfannenberg offers thermal management solutions for diverse manufacturing environments. These solutions can be a critical component of a thermal management plan by delivering high performance and precision.

The PKS 3000 Series Air/Air Heat Exchangers use Pfannenberg’s Kinetic Cooling System™ to remove heat from electrical enclosures using ambient air. These exchangers suit environments with cooler ambient air or dirty air. They offer reduced maintenance and robust performance across indoor, outdoor, remote, and washdown applications that demand a closed-loop system for electronics protection.

Pfannenberg’s Air/Water Heat ExchangerThermal management for electical enclosures s serves environments with high ambient temperatures or washdown areas with significant particulates. Designed for both internal and external installation, these exchangers are maintenance-free and energy-efficient, using a supplied water source to achieve cooling capacities ranging from 2,218 BTU to 34,121 BTU. This ensures safe and efficient cooling of enclosure electronics, making these exchangers ideal for a wide range of industrial applications.

Pfannenberg Cooling Units provide a closed-loop system that seals out ambient air and recirculates clean, cool air into the enclosure, which prevents overheating and critical temperature fluctuations. These units help maintain internal temperature at or below ambient levels, and also provide higher ingress protection when surrounding air is contaminated with oil or conductive dust.

For less demanding environments, Pfannenberg’s Filterfans® offer a cost-effective thermal management solution. With tool-free installation, superior airflow, and extended filter lifespan, Filterfans® provide Type 12 or Type 3R protection. This makes Filterfans® particularly suitable for clean, non-hazardous environments where ambient temperature outside the enclosure is lower than internal temperature.

Proactive Plan + High-Performance Products: An Ideal Thermal Management Solution

In fast-paced manufacturing environments, crafting a proactive thermal management plan for electrical enclosures keeps operations running smoothly and avoids costly downtime. Pfannenberg’s  experience and market-leading solutions provide manufacturers with tools they need to protect their vital electronics and optimize efficiency. By partnering with Pfannenberg, manufacturers ensure they have the right cooling systems in place, improving performance, reducing costs, and increasing reliability. Taking proactive steps in thermal management with Pfannennberg helps secure more efficient and dependable operations for years to come.

Learn more here about our service and maintenance options here.

Ian Johnston

Pfannenberg USA Launches X-Series Cooling Units

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Introducing the X-Series Cooling Units

We are excited to announce our new X-Series cooling units. The innovative X-Series marks a focus in energy efficiency and operational effectiveness for industrial cooling applications.

Designed to meet the demanding needs of modern industries, the X-Series units feature an optimized control algorithm using inverter technology, developed from years of expertise. This allows for the precise adjustment of cooling power required to maintain the temperature within the enclosure. This reduces the start and stop cycle present in other cooling units, significantly reducing energy consumption. The X-Series guarantees very precise temperature control within a tolerance of +/- 0.1 K, preventing risks associated with overheating, thus protecting sensitive electronic components.

Maintaining the Pfannenberg time tested design, the X-series has a large distance between the hot air intake and cold air outlet to prevent short cycling. Using top of the line fans, it provides high airflow to push through densely packed enclosures, preventing hotspots. The X-series units will be available in the standard side or surface mount, where there is no intrusion inside the cabinet, as well as the recessed mount, where the unit is mounted on the enclosure door, ideal when space is limited around the enclosures.

The X-Series includes two models: the 6X1E, covering a power range from 1,000 W to 2,800 W, and the 6X2E, ranging from 2,000 W to 4,500 W. These units are set to deliver superior performance with unparalleled efficiency. Both units offer robust flexibility, equipped with a RS 485 interface and Modbus RTU protocol as standard, ensuring seamless integration into existing systems for real-time monitoring and control.

“The X-Series Cooling Units are Pfannenberg’s latest innovation in industrial cooling technology,” says James Wong, Director of Product Management. “These units provide optimal protections to machines and the environment without compromising total cost of ownership to the end user.”

Additionally, the units are designed for quick and easy mounting using our patented “click & fit” method, enabling rapid deployment and minimizing downtime. Its cut-out compatibility allows easy replacement of existing Pfannenberg units without the need for new cut-outs, facilitating effortless upgrades and integration. This compatibility extends to the UL-certified safety of the X-Series, ensuring it meets global standards for quality and safety. The X-Series aligns with our commitment to innovation and its dedication to providing solutions that enhance efficiency and reliability in industrial applications.

Click here for the X-Series product flyer.

PTF1200 Top Mount Filterfan
Ian Johnston

Pfannenberg USA Introduces the PTF 1200 High CFM Top Mount Filterfan®

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PTF 1200 Intro Graphic

We are proud to introduce our new PTF 1200, an industry leading high CFM top mount filter fan designed to redefine cooling solutions for various industries. This compact yet powerful innovation boasts an unimpeded airflow rate of up to 589 CFM, making it a game-changer in the realm of cooling solutions.

The PTF 1200’s exceptionally high heat removal capacity is matched by its durability, featuring a robust full metal housing enclosure that ensures longevity, even in challenging environments. With a protection class of IP 54/NEMA 12, this top-mounted filter fan guarantees effective protection against dust, dirt, and moisture, maintaining optimal performance under diverse conditions.

One of the standout features of the PTF 1200 is its energy-efficient EC centrifugal fan, delivering optimum airflow and uniform temperature distribution. Its energy-efficient centrifugal fan translates to low power consumption, contributing to sustainability efforts.PTF1200 Top Mount Filterfan

The PTF 1200’s long service life is due to its EC fan, which provides a soft start and stop, reducing wear and tear on vital parts. The result is an impressive 70,000-hour average lifetime which is also complemented by the ease of filter changes, reducing maintenance costs and downtime. Filter replacements don’t require skilled labor and are quick, ensuring minimal downtime during servicing and making it an ideal choice for maintenance managers seeking efficiency.

The convenience of the unit is further elevated by its compact size, saving valuable space without compromising on cooling efficiency. Unlike traditional top mounts that often require expensive palletized shipping, the PTF 1200 ships in an easily transportable cardboard box, directly to your door, minimizing costs and delivery times.

Designed with the end-user in mind, the PTF 1200 comes with 4 mounting through holes in the cabinet. This eliminates the need for advanced cut-outs during installation, providing easy mounting options and allowing users to achieve a quick install.

The introduction of the PTF 1200 unlocks a new configuration of filter fans for the market, addressing the unique needs of purchasing agents, electrical engineers, project managers, and maintenance managers. This top-mounted filter fan offers a higher airflow rate than side mounts, ensuring efficient heat removal and surpassing competitors with its airflow range.  The industry leading airflow allows for the possibility of using a passive system in lieu of a small air conditioner, yielding substantial energy savings and reducing costs. Its ease of installation and cost-effective shipping make it an attractive solution for professionals seeking high-performance cooling solutions.

 

Click here for the PTF 1200 product flyer.

Outdoor Filterfan
Ian Johnston

Selecting a Filter Fan for Outdoor Applications

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What are filter fans?Image of Filter fan application and exhaust filter on an enc;losure with the air flow.

Filter fans protect electrical enclosures from external environmental damage. From heat control to mitigating the ingress of liquid and solid objects, filter fans provide another layer of protection for the electrical equipment housed within enclosures. Filter fans protect critical equipment by reducing thermal load and filtering out airborne particles larger than 5 microns. The dual fan and filter composition keeps electrical equipment running at optimal temperatures while mitigating the amount of dust and other particulate matter from causing buildup and damage.

When selecting a filter fan for an enclosure, it’s important to consider the application’s heat load, optimal temperature, and environmental conditions in which it will be operating. Environmental considerations are particularly important for outdoor enclosures, as rain, snow, ice, and sunlight all pose risks to electrical equipment.

Challenges for outdoor applications

Filter fans are necessary for a wide range of outdoor electrical equipment. Some applications, however,  require intentionality and extra consideration when choosing the appropriate filter fan. These include irrigation pump panels, water and waste water, lighting control boxes for traffic signals or fields and stadiums, outdoor communication and information technology structures, energy storage and charging systems (such as in electric vehicles), and transportation systems, including bridges, toll stations, and electrical rail equipment.

When properly designed and integrated, outdoor filter fans can provide an energy efficient solution for heat load maintenance while also protecting enclosures from dust, ice, water, and sunlight. However, many filter fans on the market do not effectively protect critical electrical equipment. When improperly designed, filter fans can be subject to ice and dust buildup or damage from UV radiation and rainwater. These conditions can cause short circuiting within the enclosure. While there are workarounds for water infiltration, such as adding a rainhood, these additional steps increase space requirements and initial investment costs.

Tips for selecting the correct filter fan for outdoor applications

Given these challenges, there are some tips to keep in mind when selecting a filter fan for an outdoor electrical enclosure.

Consider heatload and environment

Selecting an outdoor filter fan begins with determining the application’s heatload and airflow requirements while considering environmental exposure. Electrical enclosures in dry, hot weather require different filter fan needs than those used in areas with snow, ice, and highly variable temperatures. For applications where environmental conditions cannot be determined ahead of time, a filter fan that can accommodate each of these possibilities is best.

While determining application needs, it is beneficial to consult with an expert to help determine specific risk factors. An expert can help with considerations around which airborne particulates are present and if they are corrosive, as well as what ambient temperatures can be expected and how direct or indirect sunlight can affect operating temperatures.

Outdoor Rated Filterfan ApplicationThe Pfannenberg Outdoor Rated Filterfan® (NEMA 3R rated) is designed for outdoor weather where direct sunlight and extreme weather, like rain and ice formation, are important factors. This filter fan utilizes UV-resistant plastics to prevent premature degradation from direct sunlight. Additionally, the filter fan’s design protects against the ingress of falling dirt, rain, sleet, snow, and even external ice formation.

Weigh maintenance needs

Filter fans generally require little maintenance outside of regular filter replacement. However, it is crucial to change the filter as specified by the manufacturer as filter clogs reduce airflow, causing extra strain on the fan and increasing the potential for overheating.

Well-designed filter inserts, including the filter for Pfannenberg’s Outdoor Rated Filterfan® described above, provide longer service life. Pfannenberg’s fluted filter-mat enables longer mean time between maintenance, delivering three times longer service life than standard designs. It accomplishes this with its increased dust holding capacity. As a result, the need for service is reduced, saving maintenance time, costs, and stress, which is especially helpful for electrical enclosures located in remote areas.

Balance protection, airflow, and initial investment costs

Filter fans for outdoor applications require a design that balances airflow optimization with low initial investment. A filter design that minimizes maintenance needs should also ensure unrestricted airflow throughout the fan’s service life. However, it must do so without compromising on water and dust protection capabilities. Combining a filter that fits these needs with a filter fan housing design that does not require metal rain hoods, achieves an excellent balance of protection, airflow management, and minimizing upfront costs.

Conclusion

Filter fans are critical for protecting electrical equipment from overheating, water, and airborne debris so the equipment can run safely and efficiently. In outdoor environments, this task is particularly challenging. Finding a filter fan suitable for outdoor environments without significant drawbacks requires careful research. By considering heatload, environmental conditions, and maintenance needs before selecting a filter fan, it is possible to keep costs low. In applications ranging from pump panels and lighting control boxes to communication technology and energy storage systems, well-designed filter fans keep outdoor electrical equipment functional and safe.

Thermal solutions
Ian Johnston

Why is a Thermal Mangement Plan for Enclosures Important?

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Thermal Management Plan for Electrical Enclosures 

Manufacturing facilities have many electrical enclosures housing hundreds of thousands of dollars in high performance drives and electronics that are critical to production processes.  These critical electrical components generate a significant amount of heat and if not managed properly the high heat leads to premature aging and eventually failure, shutting down systems and resulting in downtime.  No manufacturing facility can afford downtime.

 

While having thermal management for your enclosures is important, having the correct cooling technology for your specific application that takes into account the cooling requirements and the ambient conditions is critical  The considerations to appropriate thermal management include heat load, ambient temperature range, the presence of particulates or debris, enclosure location and material among others.  Unfortunately, most manufacturing facilities lack a proper Thermal Management Plan to protect and extend the life of their equipment.  As a result, manufacturers suffer significant financial losses each year as a result of enclosures overheating. In many cases, this is preventable with a well-designed Thermal Management Plan.

Pfannenberg can Help Develop a Thermal Management Plan

Pfannenberg has over 65 years of experience keeping enclosures cool with our thermal management solutions and working with manufacturers to reduce costs and improve up time.  A good thermal management plan starts with a plant survey or thermal audit to evaluate the needs of the specific facility. Our Service and Support team offers a number of programs to gather the required information to determine if the correct cooling technology is in place and functioning properly to meet the needs of that particular facility.  A thermal management program from Pfannenberg can help:

Dirty Inside of Unit

  • Verify that the sizing of the A/C meets the thermal loads of your enclosures.
  • Reduce electrical costs caused by poorly maintained air conditioners.
  • Create a Preventive Maintenance plan specifically for your team and facility to keep industrial cooling(A/C) running.
  • Provide the correct thermal technology for challenging applications.
  • Identify critical equipment and put steps in place to reduce lost production time.

If you want to reduce the amount of unscheduled downtime due to enclosure overheating and extend the life of expensive drives, electronics, and industrial air conditioners reach out to us.  Either at service@pfannenbergusa.com or submit a request here.

 

 

 

Ian Johnston

Get Ready for Summer! 3 Steps to Prepare Your Enclosure Cooling Units for the Stress of the Summer Heat

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Don’t Wait Until it’s Too Late!

With the summer heat just around the corner we want to help you prepare your electronics enclosure cooling units to stay up and running.

We put this Preventative Maintenance Video together to help you get ready.

Avoid critical component failures by following these 3 simple steps to ensure your enclosure cooling units stay up and runing all summer.

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 negative effect on the performance of your cooling unit leading to increased run time and energy consumption.

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 enclosure 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.

Edge computing graphic
Ian Johnston

Thermal Management Protection Solutions For Edge Computing Environments

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By Jonathan LaPorta, Pfannenberg USA

Select the right option to ensure continuous operation of senstive electronics

Edge computing – placing application logic as close to the source of data as possible – reduces latency, optimizes bandwidth usage, and minimizes costs, all while increasing visibility and control, speeding up processing, and enhancing user experience. The challenge is that enclosures used to protect distributed computer equipment from the immediate environment oftentrap heat generated by the electronics. Read on to learn about thermal protection solutions that ensure continuous operation of sensitive electronics in edge computing environments.

Edge computing graphic

 

Benefits of Edge Computing Fuels Explosive Growth

The adoption of edge computing is accelerating for mission-critical computer components in factories, warehouses, retail stores, hospitals, and college campuses – and indeed in most other sectors. The explosive growth is fueled by megatrends like digitization, the internet of things (IoT), and automation.

Key examples include high-definition video cameras that generate masses of data; machine vision systems used in manufacturing to perform imaging-based automatic inspections; hospitals, which have to store and process medical sensor data and digital health records; and warehouses and retail stores running inventory and point-of-sale systems.

All that data needs to be processed somewhere, and it is usually much faster and more efficient to do it close to the edge where people and things produce and use that information. Keeping and processing data at the edge can also enhance reliability, security, and privacy by minimizing the transmission of sensitive information and exposure to network failures and malicious attacks.

 

Protecting Distributed Components is Critical

In edge computing environments, computing equipment is located outside of a climate-controlled data center. Servers and networking gear are often placed in crowded factory floor spaces, up in warehouse rafters, or in closets. They may be located in inhospitable environments, with high ambient temperatures, or dust- and oil-filled air. That is why distributed computer equipment is typically placed in enclosures for protection. Unfortunately, the enclosures themselves trap heat generated by the electronics, so they require protection from overheating.

 

Simple, Proven Cooling Solution 

A variety of cooling methods have proven effective for thermal management of electrical enclosures. Filter fans are an economical solution when the ambient temperature is always lower than the temperature required by the computer components inside. One example is Pfannenberg’s new Datawind Filterfan®, which has a temperature indicator and is mounted externally to the enclosure to enable full use of all racks within the bays.

 

More Challenging Cooling Applications 

Some applications require enclosures specially designed for challenging environments, from weather and impact-resistant outdoor enclosures to tightly sealed stainless steel enclosures for food production facilities that must withstand high pressure cleaning.

A closed loop cooling system is required when the interior air of the electrical enclosure must be protected from the exterior environment. Air to air technology is one of the more energy efficient technologies to use when there is a temperature difference between the internal target temperature and the surrounding temperature (∆T≥10°C). Pfannenberg’s Kinetic System™ (PKS) Series Air to Air Heat Exchangers remove heat from inside of the enclosure to the cooler environment using the least amount of energy while still providing a closed loop ingress protection.

If the electronics generate a high heat load and/or the ambient air is too warm to provide adequate cooling, an active cooling system such as the Pfannenberg DTS Series of side mounted cooling units may be required. These air conditioning systems utilize a compressor for cooling in a closed loop design that isolates the interior of the enclosure from the exterior environment.

Ideal for extremely demanding industrial and outdoor applications, Pfannenberg’s DTS units provide NEMA 4 level of protection from washdown conditions and caustic air and can operate in ambient temperatures up to 140° F (60° C).

By implementing the optimal cooling solution for distributed components operators can take advantage of edge computing’s many benefits while protecting mission critical IT infrastructure from overheating.

 

Jon LaPorta

Active and Passive Cooling Methods – A Simple Way to Calculate Cooling Requirements

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By Jon LaPorta, Pfannenberg USA

Here is a simple way to calculate cooling requirements for both active cooling and passive cooling methods.

Active Cooling Rule of Thumb

VFDs are typically sized in horsepower (HP) and cooling systems are measured in British Thermal Units (BTU, or BTU/h for BTU hours). But how do you convert from HP to BTU/h?

Here is the rule of thumb for air condition and water cooling:

75 BTU/h is required for every 1 HP

In other words, for a 100 HP VFD drive, 7500 BTU/h of cooling is required.

This rule of thumb is derived as follows:

  • 3% of the electrical energy in a VFD is converted to heat
  • 1 HP = 746 watts
  • 746 watts x 3% heat loss = 22 watts of heat loss per 1 HP
  • 1 watt = 4 Btu/h
  • 22 watts x 3.4 BTU/h = 75 BTU/h per 1 HP

Passive Cooling Rule of Thumb

For passive cooling solutions, such as the Pfannenberg Datawind Filterfan®, the rule of thumb is

4 CFM is required for every 1 HP to maintain 10°C above ambient in the enclosure

In other words, for a 100 HP drive, 400 CFM is required.

This rule of thumb is derived from the following equation

1 CFM = 1.82 x watts of heat loss / Δ Temp (°C)

 

These rule of thumb guides provide a general guide for selecting a cooling method and for sizing the cooling load requirements. For more precise calculations that account for ambient temperature and humidity and other critical considerations, we provide Pfannenberg Sizing Software at no charge.

By simplifying the calculation of cooling requirements, we hope that the adoption of VFD technology will continue grow rapidly, and that users will benefit from maximum performance and service life.

Marine Vienney

Pfannenberg’s Cooling Units Used to Ensure Efficiency and Uptime in Vaccine Production Settings

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How Cooling units maintain proper operating temperatures for automation system components

Vaccine production requires highly precise temperature and humidity control at all stages of production: manufacturing, packing, and storage. During production of pharmaceuticals, precise temperature control is essential so that temperature fluctuations do not interfere with the manufacturing process. Throughout the process of manufacturing, distributing and storage, it is essential that downtime is eliminated and repair costs are kept to a minimum. To carry this out, vaccine producers relied on Pfannenberg’s cooling units which can operate 24/7 and on the Pfannenberg team, which offers the highest degree of service quality.

Pfannenberg’s DTS 3245 Series Cooling Units have been installed in COVID vaccine production settings to ensure efficiency and maximal uptime by providing critical cooling to electrical components of automation systems in mass vaccine production.

The Pfannenberg DTS 3000 Series cooling units offer superior capacity, more efficient design, and a robust build to ensure a longer service life of the cooling unit. Customizable to pharmaceutical environments like vaccine production, the DTS 3000 Series features a sealed cabinet that 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.  Its 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.

The DTS 3000 Series Cooling Units are designed to take up less space while delivering greater cooling capacity. These units boast the highest power to cooling ratio available on the market. These cooling units are built with a sealed, yet “open design,” so critical components can be accessed easily for maintenance purposes. The refrigeration system is totally redesigned with longer and more robust service life in mind helping end-users focus on uptime and prevent disruption in operation.