Workshop “Kühltechnik” Peter Bachmann 23.04.2012

Übersicht Modul A Peter Bachmann 3. Modul C Alle 1.1. Einleitung, Wärmequellen und Auswirkungen 1.2 Die richtige Kühllösung 1.3. Dimensionierung, Berechnung und Auswahl 1.4. Produktübersicht, Produktvergleich 1.5 Gewinnen gegen den Wettbewerb 1.6 McLean, Kühlgeräte aktiv verkaufen 2. Modul B Rudolf Buchta 2.1. McLean, Verfügbare Daten im Internet/Intranet 3. Modul C Alle 3.1. Musterbesichtigung, Feedback sowie Fragen und Antwort 4. Modul D Ying Augenstein/Jon Reddemann 4.1. Service and Trouble shooting

Electronics Cooling Market Drivers Faster, more powerful devices produce more heat Higher density of electronic devices used in control applications Devices not hardened to environmental extremes advancing technology There seem to be two main factors driving the market. First, advancing technology: newer, more powerful devices generate more thermal output; more heat. There’s also a trend toward squeezing more electronic devices into enclosures; which creates higher densities of heat. And most of these components are not hardened to environmental extremes. They’re designed for smaller temperature ranges and can’t handle temperature extremes. The other factor driving the market is the increasing awareness of what happens when equipment overheats. Customers are seeing more conclusive results that there is, indeed, a relationship between high performance, temperatures & reliability. They also understand what equipment failure can mean to their bottom line, and are receptive to insuring against those failures. Relationship between high performance & temperatures & reliability Customers seek ‘insurance’ solutions to protect from costly shutdowns. increased awareness of temperature vs. reliability

Heat Stresses Electronics Every 10 °C / 18 °F rise over room temperature cuts electronic life expectancy in half 1) According to a DEC study, the life expectancy of electronics is cut in half for every 10° C / 18° F in which they operate over room temperature.

Resource of damaging heat Heat can come from sources inside the cabinet . . . Indoor Industrial, Telecom & Data Networking AC power supply Controllers (PLCs) Drives & servos Transformers Processors Inverters Contactors & relays Radio equipment Battery back-up Server racks

Resource of damaging heat . . . outside the cabinet . . . Indoor Industrial & Telecom Welding process Paint oven Blast furnace Foundry equipment Solar heat gain

Resource of damaging heat . . . from the electronics themselves . . . More electronics going into same size or smaller enclosures Datacom, telecom demanding higher performance More server functions mean more heat Today’s engineers are packing more electronics performance into existing or smaller cabinets. Greater performance means more data processing, which leads to increasing server functions, which generates more heat. Telecom, radio broadcasting, wireless, digital media are processing more bits. Packed airwaves equals more heat.

Effect of damaging heat . . . as performance increases . . . “Semiconductor transistor density and performance double every 18-24 months.” Moore’s Law Named for Intel founder, Dr. Gordon Moore 1) Moore’s Law (named after Named after Intel founder, Dr. Gordon Moore): “Semiconductor transistor density and performance double every 18-24 months.” 2) Ninety percent of engineers expect demand for electronics cooling to stay the same or increase in the future (Source: McLean Survey, Spring 2008).

Effect of damaging heat At extreme temperatures . . . Catastrophic failures Properties of silicone materials change Drive performance is de-rated I/C based devices may experience intermittent fluctuations in output and voltage migration Mean Time Between Failure (MTBF) decreases exponentially

Over $500,000 Effect of damaging heat What does it cost to shut down an automotive assembly line for 1 hour? Over $500,000 What is the cost of not addressing the heat within the enclosure. Well, the automotive industry provides a great example of the cost of equipment failure. Shutting down an assembly line for just one hour can cost the company as much as half a million dollars.

Effects of damaging heat Consider the costs associated with the following . . . Productivity losses of plant/line shutdowns Labor Scrap Opportunity cost Component costs In warranty – processing costs, labor Out of warranty – out of pocket costs Material & Labor Customer satisfaction costs Missed ship dates That figure comprises productivity losses, component costs and customer satisfaction costs. Productivity losses come from having an idle workforce, increases in products that have to be scrapped because they were ruined when equipment failed, and there’s the cost of lost opportunities. Equipment failure also means paying for repairs or replacement. Even if equipment is under warranty, there may still be processing and labor expenses involved. And when equipment is out of warranty, the cost of repairing or replacing equipment goes up exponentially. Customer satisfaction may also be jeopardized by equipment failure when it means ship dates are missed.

The Benefits of Cooling Cooling electronics can: Extend operational life Instill smooth performance Maintain valuable equipment warranties Prevent catastrophic failure Maintain productivity Cooling is essential to protecting electronics and maintaining performance. Electronics cooling can help extend the life of electronics and keep it performing smoothly. Electronics manufacturers often warrant components and systems only up to a maximum operating temperature. Cooling controls the enclosure’s temperature to help keep that warranty coverage in place. The major benefits are preventing catastrophic failure and maintaining productivity.

+ = Auswahl der optimalen Kühllösung Lösung Umwelt (Außen) Gehäuse, Schrank (Innen) Komponenten (Innen) Lösung + = So now that we understand the problems and available solutions, how do we find the right specific solution for each customer application? Finding the right thermal management solution involves analyzing three primary variables: the environment, the enclosure and the equipment inside the enclosure.

Vorraussetzungen und Bedingungen Umwelt (Außen) Schrank, Gehäuse (Innen) Umgebungsbedingungen - direkte Sonneneinstrahlung - korrosiv - nass, staubig, schutzig etc. Aufstellort - Im Gebäude oder im Freien Umgebungstemperatur max./min. Schutzart(IP) Standards UL, Nema, Gost Art der Aufstellung Abmaße (H x W x D) Material Installierte Verlustleistung Schrankinnentemperatur max.

Die richtige Kühllösung ja Filterlüfter e.g. filter fan ja ≥ IP 54 wichtig? ja Luft/Luft Wärmetauscher - PROAIR - CLIMAGUARD Voraussetzungen no Kühlung mit Luft 19“-Lufteinschübe Schrank (Innen) Ti > TU Umweltbedingungen ja Luft/Wasser Wärmetauscher LHX Serie raum-unabhängig? nein Thermoelectric Cooler Peltier nein - V-Series - SPECTRACOOL - T-Series - PROAIR nein Kühlgeräte

Leitfragen zur Auswahl

Leitfragen zur Auswahl

Kühltechnik Datenblatt

Kühlung Leistungsdiagramm

Beispiel Leistungsdiagramm Thermoelectric

Beispiel Schaltschrank 2000 x 600 x 600 PS = A x ∆T x k QO = PV - PS TU 45 °C ∆T: maximale Temperaturdifferenz ∆T = Ti – TU PS = A x ∆T x k PS = 4,34 m² x (-15) °C x 5 W/(m² x K) PS = -325 A: effektive Schaltschrankoberfläche gemäß DIN 57660 Teil 500 k: Wärmedurchgangskoeffizient bei ruhender Luft zwischen Ti und TU QO = PV - PS QO = 800 W + 325 W = 1125 W  V-Series  Model / Arbeitspunkt UMWELT 1. Umwelt- / Umgebungsbedingungen: schmutzig, staubig, ölig 2. Aufstellort: im Gebäude 3. Umgebungstemperatur: TU = 45 °C GEHÄUSE 1. Schutzart: IP 55 2. Art der Aufstellung: 3. Größe: 2000 x 600 x 600 mm 4. Material: Stahlblech gepulvert 5. Installierte Verlustleistung: Pv = 800 W 6. Schrankinnentemperatur: Ti = 30 °C Ti 30 °C

30°C Innentemperatur

McLean Online Selection Tool Go to www.McLeanCoolingTech.com Provide inputs regarding: Environment Enclosure Equipment V-Series will be integrated soon

Auswahl und Dimensionierung für Outdoor Anwendungen Von Dr. Adam Pawlowski Klimatechnik Dimensionierungsprogramm

30°C Innentemperatur

Thermoelectric Cooler Produktübersicht Kühlgeräte Wärmetauscher Peltier V-Series Genesis Spectracool T-Series PROAIR PROAIR2 CLIMAGUARD Thermoelectric Cooler NEW NEW Applications Indoor , Industrie X Korrosive und stark belastete Umgebung Hygiene, Lebensmittel, abwaschbar Outdoor Telekom

Produktübersicht – Hauptmerkmale Kühlgeräte Wärmetauscher Peltier V-Series Genesis Spectracool T-Series PROAIR PROAIR CLIMAGUARD Thermoelectric Cooler NEW NEW SPECIFICATION / FEATURES Kühlleistung L35L35 300W bis 2000W 234W bis 1582W 1260W bis 5656W 235W bis 13810W 410W bis 2080W 7W/°C bis 151W/°C 25W/°C bis 151W/°C 60W, 100W, 200W Betriebstemperaturbereich +20°C bis +55°C +10°C bis +52°C -40°C bis +55°C -29°C bis +60°C -40°C bis +65°C -40°C bis 55°C Spannung 230V 115V, 230V, 460V 115V, 230V, 460V 115V, 230V 115VAC, 230VAC, 24VDC, 48VDC 24VDC, 48VDC Normen CE GOST cUL UL/cUL, Type 12/3R/4 CE, Telcordia GR-487 GOST UL/cUL Type 12/3R/4 CE Telcordia GR-487 GOST UL/cUL Type 12/3R/4 UR/cUR Type 4X GOST UL/cUL UR/cUR CE Type 12/3R GOST UL/cUL UR/cUR CE Type 12/3R/4 Telcordia GR-487 Type 4X GOST UL/cUL recognized Type 12/3R/4 CE GOST

Produktübersicht Unterschiede

Wichtige Zertifizierungen Standards: CE UL / cUL Listed Type 12/3R/4 Telcordia GR-487 GOST R407c and R134a earth-friendly refrigerants Industrial Wash-down Applications Telecommunication/ Outdoor Enclosures Food & Beverage/ Harsh Environment

Air Conditioner Pros: Cons: Use when: Air surrounding cabinet is too hot, dirty and/or corrosive to cool the electronics Temperature inside cabinet needs to be cooler than temperature outside of cabinet Or when humidity control is desired inside the cabinet Below ambient cooling Large capacity cooling Maintains integrity of cabinet seal (closed-loop) Controls humidity in the cabinet Powered by 115, 230 or 400 AC voltages Filterless V-Series Pros: Higher up front investment Higher costs to maintain Can generate condensation Large & heavy sizes High energy consumption Cons: Ambient = air temperature outside of enclosure Example: If temperature in factory is 40°C (ambient), it is possible to cool the enclosure to a temperature below 40°C with an air conditioner.

Air / Air Heat Exchanger Use when: Air surrounding cabinet is too hot, dirty and/or corrosive to cool the electronics Temperature inside cabinet slightly higher than temperature outside cabinet Highly reliable/long life cycle Filterless (low maintenance) Lower up-front & ongoing costs Maintains integrity of cabinet seal (closed-loop) AC or DC power Pros: Does not cool below ambient (Ti>Tu, 5°C) Large size if high heat loads No humidity control in the cabinet Less efficient than fans & blowers Cons: Closed-loop Re-circulates clean enclosure air separately from the ambient airflow system – maintains integrity of cabinet seal

Thermal Electric Coolers Use when: Air surrounding cabinet is too hot, dirty and/or corrosive to cool the electronics Temperature inside cabinet needs to be cooler than temperature outside of cabinet A normal air conditioner may not fit the space A low level of cooling is required (up to 682 BTUs or 200 Watts per hour) Below ambient cooling Compact & lightweight Maintains integrity of cabinet seal No refrigerant Filterless (low maintenance) Powered by 24 or 48 DC voltages Able to heat with reverse polarity Pros: Small cooling capacity Higher cost than filter fans (but provides below ambient cooling) Can generate condensation Energy inefficient in most cases (high power consumption Cons:

Gewinnen gegen den Wettbewerb McLean Rittal Stabiles Stahlgehäuse Montageeinhängewinkel Ausfallsicher und zuverlässig (Feedback von den Distributoren) IP56 Innenkreislauf Betriebstemperatur ab -40 °C Kunststoff Keine Montagehilfe Nicht bekannt, keine Informationen IP54 Innenkreislauf Betriebstemperatur ab -33 °C

COOLING CAPACITY (BTU/Hr) AMBIENT TEMPERATURE (°C) McLean vs Rittal Capacity Claims (586 W) 3000 2500 2000 COOLING CAPACITY (BTU/Hr) 1500 McLean 1000 Capacity Ratings of a 2000 BTU unit, when enclosure temperature is maintained at 35°C McLean: Ambient 35°C/95°F = 2250 BTU/Hr Ambient 45°C/113°F = 1900 BTU/Hr Ambient 50°C/122°F = 1700 BTU/Hr Ambient 55°C/131°F = 1500 BTU/Hr Rittal: Ambient 35°C/95°F = 2083 BTU/Hr Ambient 50°C/122°F = 1195 BTU/Hr Rittal 500 AMBIENT TEMPERATURE (°C) 25 76°F 30 85°F 35 95°F 40 104°F 45 113°F 50 122°F 55 131°F McLean provides more cooling across a wide range of ambient temperatures than competitors When Enclosure Temperature is maintained at 35 °C

Gewinnen gegen den Wettbewerb McLean Pfannenberg Gesamtlösungen, Gehäuse und Kühlung UL gelistet Montageeinhängewinkel Ausfallsicher und zuverlässig (Feedback von den Distributoren) IP56 Innenkreislauf Outdoor Betriebstemperatur ab - 40°C Keine Schrank und Gehäusekompetenz UL recognized (nur teilweise gelistet) Montagehilfe nicht bekannt Nicht bekannt, (keine Informationen verfügbar) IP54 Innenkreislauf Outdoor Betriebstemperatur nicht bekannt. Wenig kompetenz im Outdoor Bereich und kleine Produktpallette.

COOLING CAPACITY (BTU/Hr) AMBIENT TEMPERATURE (°C) McLean vs Pfannenberg Capacity Claims (586 W) 3000 2500 2000 COOLING CAPACITY (BTU/Hr) 1500 McLean Pfannenberg Capacity Ratings McLean: Ambient 35°C/95°F = 2250 BTU/Hr Ambient 45°C/113°F = 1900 BTU/Hr Ambient 50°C/122°F = 1700 BTU/Hr Ambient 55°C/131°F = 1500 BTU/Hr Pfannenberg: Ambient 24°C/75°F = 2000 BTU/Hr Ambient 35°C/95°F = 1795 BTU/Hr 1000 500 AMBIENT TEMPERATURE (°C) 25 76°F 30 85°F 35 95°F 40 104°F 45 113°F 50 122°F 55 131°F McLean provides more cooling across a wide range of ambient temperatures than competitors When Enclosure Temperature is Maintained at 35°C

Competitive comparison Beispiel V-Serie

Warum McLean 30+ years of electronics cooling expertise Broad selection of air conditioners, heat exchangers, thermoelectric coolers, air movers, enclosure heaters, thermostats & accessories Extensive engineering resources—thermal cycle chambers, air flow testing, salt fog booths, high-pressure wash down, sound chamber, rapid prototyping—to ensure robust product designs Modified and custom-engineered cooling solution capability Made with quality in ISO 9001 certified global facilities 1000+ repair technicians and spare part inventories worldwide All the resources of Pentair, a $7.7 billion globally diversified company For more information, visit our web site at www.McLeanCoolingTech.com

McLean USP´s Advantages + Global company + Global availability + Global Service Network + Local support team Schroff + Standards: - UL, Nema Type 12, 3R, 4, 4X - CE, GOST - Telcordia GR-487 capable (Outdoor) + Reliable products, very low failure rate + 2 Year warranty Features + Temperature range ambient: -40 °C to 55 °C + All-metal construction to better-withstand rugged factory and outdoor environments + Corrosion-resistant components + Nano coating  filterless operation + Easy assembling

Active selling of air conditioner Ask about cooling with every enclosure sale Highlight risks and benefits (insurance) Value-added opportunity Gateway to selling enclosures cross selling Combat price by selling solutions Use cooling customers as sales leads for enclosures MRO and retrofit for cooling applications Target global accounts who have already experience with McLean products Utilize online selection tool and offer the best cooling solution Show our McLean product performance and select the best product After sales service

US NEMA Types  IP Schutzart NEMA, UL and CSA Ratings  IP Schutzart Information available at Hoffman or McLean web pages by technical information, standardization

Thermoelectric Temperature Controller: Produktneuheiten NEW V-Series Thermoelectric Temperature Controller: Kühlgeräte Peltier

FAQs Kühlgeräte Malfunction switch => Störmeldung Rotary compressor => Rollkolben Kompressor Head pressure control => Überwachung des Druckes (Hochdruck) (Sicherheitsfunktion) Dual condenser side air movers => Verflüssiger mit 2 Lüftern (Spectracool) Power off relay for door switch => Versorgungsabschaltung über Türkontaktschalter Evaporator => Verdampfer (Wärmeaustauscher auf der Schrankseite) Im K-Laufwerk wird ein Ordner angelegt FAQ McLean, bitte geben sie uns Ihre Eingabe (Fragen, Probleme, Wünsche etc.) bis zum 25. Mai 2012 per Email.

Zusammenfassung V-Serie und 230V Kühlgeräte ab Lager Straubenhardt Die wichtigsten Ersatzteile ab Lager Straubenhardt McLean Hauptkatalog in E-Sprache V-Serie Katalog in E, D, F und R-Sprache Schroff Hauptkatalog mit T-Serie, Climaguard und TE Industriekatalog mit V-Serie, Spectracool und Pro-Serie McLean “online selection tool” mit V-Series 2Q 2012 Datenblätter, Leistungsk. und Betriebsanleitungen im Web World wide service (pre and after sales service)