Blog

Adding intelligent motion controls (IMC) to your fan or blower design can maximize your system’s performance. There are several types of IMC solutions available to add functionality to your fans and blowers. Four of the solutions include a rotation detector, life detection, DC voltage signal control, and current source signal control. In this post, we will discuss each of these solutions.

Solutions

Rotation Detector (Complement)

The rotation detector (complement) (RDb) control is an open collector with hardware similar to the frequency generator (tachometer) (FG) control #2a. The output signal is HIGH when the fan is rotating, but when the fan is stopped or powered OFF the output signal is set to LOW. The output can be connected in parallel to the RDb of a series of fans that end at a single alarm device, which provide a warning if any single fan has stopped working. The RDb control is an external violet wire.

Life Detection

Similar to the RDb, the life detection (LD) control is also an open collector with the same hardware as the FG control #2a. The output signal is HIGH under the fan’s normal rotation, and it is set to LOW when the fan’s rotation speed is below 70% of the device’s rated target speed. Slow rotation may be a sign of aging or wear of the fan or blower, or it could mean there is reduced power supply voltage. The LD control is a brown external wire.

DC Voltage Signal Control

The DC voltage signal (VPWM) control adjusts speed by applying an external DC voltage signal. The voltage input “Vin” can have a value ranging from 1V to 20V, with standard values of 1V to 5V. The fan speed varies linearly, is proportional to the percentage change of the “Vin” value, and corresponds to the same percentage change of the maximum speed. The constant speed (CS), inrush current protection (IR), and current limit (CL) controls are included.

The part number is followed by an additional identification entry, such as V 1 5 20 100 C 500. That number indicates that the fan speed is 1000 RPM (20%) at 1V and 5000 RPM (100%) at 5V. Additionally, the fan maintains the minimum speed if Vin is less than 1V and it stops if Vin is less than 0.5V (Mode “C” operation). The maximum fan speed is 5000 RPM, with a stop point typically set at 20% of the maximum. The VPWM control is an external white wire.

Current Source Signal Control

The current source signal (IPWM) control adjusts speed through the application of an external current source signal. The current input “Iin” may have values ranging from 4mA to 50mA, with standard values of 4mA to 20mA. The fan speed varies linearly, is proportional to the percentage change of the Iin value, and corresponds to the same percentage change of the maximum speed. The constant speed (CS), inrush current protection (IR), and current limit (CL) controls are included.

The part number is again followed by an additional identification entry, such as I 4 20 20 100 A 500. That number indicates the fan speed will be 1000 RPM (20%) at 4mA and 5000 RPM (100%) at 20mA. The fan maintains the minimum speed if Iin is less than 4mA (Mode “A” operation). The maximum fan speed is 5000 RPM, and the IPWM control is an external white wire.

Discover the IMC Solution That’s Best for You

Pelonis Technologies will help you find the perfect IMC solution to your fan or blower designs. We offer rotation detector, life detection, DC voltage signal control, and current source signal control. Learn more about our products and services on our website, where you can also contact us or request a quote.

 

Related Products

The direct current fans, or DC fans, are powered with a potential of fixed value such as the voltage of a battery. Typical voltage values for DC fans are, 5V, 12V, 24V and 48V.

In contrast, the alternating current fans, or AC fans, are powered with a changing voltage of positive and of equal negative value. In general, this changing voltage has sinusoidal shape. Worldwide, the usual value of this sinusoidal voltage may vary in size and in frequency, such as 100VAC, 120VAC, 200VAC, 220VAC, 230VAC or 240VAC, and with frequency (cycles per second) of 50Hz or 60Hz.  

In the past, big AC fans were typically less expensive compared to big DC fans. Today however, their price difference is negligible due to their payback advantage. We will try to point out differences between the above fan types, to help you choose and purchase the correct fan type for your application.

The Pros and Cons of DC fans

DC technology has become much more sophisticated in recent years, and it can now be applied to both residential and industrial ceiling fans. DC fans have motors that rely on permanent magnets in order to attract and repel a rotor around the axis using electronic switching. DC technology is much newer than AC technology, which means there are fewer options available.

PRO: Consumes less power

DC fans are widely regarded as the most efficient type of fans. They consume significantly less power than AC fans. In fact, DC fans consume up to 70 percent less energy to produce the same output as traditional AC fan types.

This means, that a 25-watt DC-driven yields the same results as 100-watt AC fan. This is ideal for commercial settings, like restaurants, allowing you to keep fans running all day without incurring astronomical electric bills.

PRO: Minimal electromagnetic interference

Due to low power used as well as the application of sophisticated electronic switching, the electromagnetic interference of DC fans is minimal. Sensitive electronic devices often use DC fans to prevent electromagnetic interference.

For example, computer applications and equipment rely on DC fans, to prevent overheating while still minimizing electromagnetic interference that could negatively affect sensitive applications.

PRO: Acoustically Quieter

DC fans make use of a new type (sin180) of electronically commutated motor (ECM). Not only are these motors ultra-efficient, they are also incredibly quiet. Because they are so quiet, DC fans are an excellent option for applications such as medical instruments, telecom switches, or car entertainment systems, where noise could be a nuisance.

PRO: Lower voltage

DC fans generally use less voltage than AC fans. The majority of DC fans are low-voltage fans. For example, you can typically find 5V, 12V, and 24V versions of DC fans. Larger models of DC fans, such as 119mm to 172mm fan models, are typically available in 48V. In comparison, most AC cooling fan models are available in 115V, a much higher voltage. Lower voltage also makes DC fans potentially less dangerous.

PRO: Water-Resistant

The DC fans can be used in applications of severe environmental conditions. It is imperative to employ a reliable, high-quality water-resistant model to ensure the safety of your equipment and staff.

Read More: Water-Resistant DC Fans for Harsh Environments

Pelonis Technologies, Inc. (PTI) has been designing, developing, and manufacturing industry-leading AC axial fans and brushless DC fans for more than 25 years. This includes a wide range of severe weather and water-resistant fans, which offer unparalleled dust and water protection while meeting military and NASA material specifications, USP certifications, and UL certifications.

Our harsh weather fans feature an eco-friendly proprietary conformal coating with excellent properties and corrosion resistance, allowing the fans to easily withstand dust, moisture, water exposure, and even full water immersion. Our DC fans also undergo a rigorous vacuum sealing process, enabling them to operate during submersion.

PRO: Intelligent Motion Control

The use of Intelligent Motion Controls in select model DC brushless fans and blowers has already arrived. With Intelligent Motion Controls, the movement of air is now smarter. 

The inclusion of full-wave-in-board circuit design and multiple features leaves no doubt that intelligence has enhanced air movement.

PRO: Variable flow

With minimal additional cost, the DC fan can offer a variety of speed control functions, so that the fan can meet the airflow target of a given application. The fan can be controlled by:

• Voltage
• Current
• Temperature
• Resistance
• PWM signals

By controlling the fan speed according to what is needed, the life of the fan can be increased and its acoustical airflow noise can be kept to the minimum necessary.

CON: May require an AC to DC converter

The AC fans are powered by an alternating voltage source. The DC fans are powered by a constant voltage source. This means that, the DC fan must have an AC to DC converter, either externally or included internally in the DC fan to convert AC to DC Voltage to power the DC fan.

The Pros and Cons of AC fans

AC fans are commonly used because the AC outlets are readily available in our houses.

CON: Variable flow

The speed control of the AC Fans is not easy matter. The AC fan’s speed depends on the line frequency and partially on the amplitude of the AC Voltage source.

To change the frequency of the AC Voltage is totally not practical due to its very high conversion cost. To vary the amplitude and maintain the waveform of the AC Voltage source is also expensive and certainly not practical to meet the target cost of a speed-controlled AC fan.

Less expensive “Capacitor” speed control methods, influence the power factor of the fan. Finally, economical “Phase Control” speed control methods introduce electromagnetic noise.

CON: More energy consumption

AC fans do consume more energy than DC fans. You need up to $3 worth of electricity using a DC Fan and you need $10 worth using an AC Fan to achieve the same airflow result.

CON: More electromagnetic interference

AC fans have more electromagnetic interference than DC fans, when they use “Phase Control” speed control methods.

AC vs. DC: Which Fan Is Right for You?

 

The bottom line is that the right fan for you will depend on your specific needs. Prior to deciding between an AC and DC fan, you will need to carefully weigh the pros and cons of each type of fan.

Pelonis Technologies offers fan technologies for a variety of industries and applications. To evaluate which one is right for you, view our guide on how to select the right cooling fan for you.

If you need further assistance in choosing the right fan for your project and/or application, don't hesitate to reach out the Pelonis Technologies team and we'll be more than happy to assist you!

 

Related Products

Operating in harsh conditions can present serious challenges for companies across various industries, but deadlines must be met no matter how extreme the environment. Severe weather, in particular, can affect all types of industrial processes and equipment.

Power supply equipment, for instance, is especially susceptible to extreme weather conditions, as is heating, ventilation, and air conditioning (HVAC) equipment. Without the proper equipment and guidelines in place, industrial facilities run the risk of increased downtime, added costs, and worker injuries. To ensure efficiency and minimize downtime and unnecessary expenditures, precautions must be taken to protect equipment and keep workers safe in hazardous areas.

Hazardous-Area Classification

The National Electrical Manufacturers Association (NEMA), Underwriters Laboratories(UL), the National Fire Protection Association (NFPA), and a number of other industry organizations publish standards classifying areas that are considered hazardous.

A “hazardous area” refers to any area, indoors or outdoors, with — or with the potential for — harsh conditions, such as gases in chemical and petrochemical plants, dangerous fumes in food processing facilities, or the intermingling of fluids with electrical components.

Download our data sheet to learn about weather resistant fans suited

for the most demanding applications

Equipment Protection in Harsh Environments and Hazardous Weather

Equipment used in harsh environments, which can even include indoor applications in certain circumstances, must be designed to withstand dust and other contaminants — especially those that are flammable — as well as moisture, including water vapor, and direct water or liquid exposure.

Water-Resistant DC Fans

When DC fans must be used in these types of severe conditions, it’s imperative to employ a reliable, high-quality water-resistant model to ensure the safety of your equipment and staff.

Pelonis Technologies, Inc. (PTI) has been designing, developing, and manufacturing industry-leading axial AC and brushless DC fans for more than 25 years. This includes a wide range of severe weather and water-resistant fans, which offer unparalleled dust and water protection while meeting military and NASA material specifications, USP certifications, and UL certifications.

Our harsh weather fans feature an eco-friendly proprietary conformal coating with excellent low friction properties and corrosion resistance, allowing the fans to easily withstand dust, moisture, water exposure, and even full water immersion. Our DC fans also undergo a rigorous vacuum sealing process, enabling them to operate during submersion.

Learn More

PTI’s severe weather fans are ideal for a wide range of applications, including control equipment, emergency response vehicles, field and ground support equipment, indoor and outdoor cooling and ventilation applications, marine products and vessels, medical systems, military and mobile units, and security cameras.

To learn more about the importance of having the proper equipment in place for harsh weather conditions, or to discuss how PTI’s water-resistant DC fans can help ensure reliability and safety in your facility, contact the team today.

As summer’s temperatures reach their peak, keeping your facilities cool is important for maintaining comfortable working conditions. Cooling commercial spaces properly means finding the right balance for employee comfort, temperature/humidity control, and energy use. In manufacturing operations where additional heat is generated by machinery, and in warehouses where goods must be stored in constant environmental conditions, cooling systems are vital mechanisms.

Optimizing Cooling Systems

Although summer is in full swing, it’s not too late to take steps to make sure HVAC systems are running efficiently. By optimizing cooling systems, energy consumption is reduced. Bringing down utility costs makes for a more sustainable and green environment. HVAC systems basically consist of condensers, fans, and thermostats and all must be in good working order to perform optimally. If any part is failing, your facility or warehouse may be uncomfortably hot.

Cooling Systems Maintenance: What Needs to be Done

To be sure your system is performing at its best, take the time to perform some basic preventative maintenance:

• System checks: Ensuring that all parts of the cooling system are working to peak performance begins with regular inspections. Performing regular checkups and inspections keep the system working well and will help you find potential problems before they cause a serious breakdown.
• Sensors and thermostats: As the brains behind the mechanics, sensors and thermostats must be working properly to maintain accurate indoor temperatures. Calibrate the instruments to ensure the temperature readings are correct and make sure they respond accurately to rising and falling temperatures.
• Filters and external equipment: Staying on top of filters and changing them regularly helps cooling units work efficiently and keeps the air as clean as possible. Check external units for dirt, debris, or damage from environmental conditions that could prevent the units from running smoothly.

How to Select a Cooling Fan

When choosing cooling equipment, look for the highest quality components. Since fans are integral components for all cooling systems it is important that this component be well made, durable, and reliable. If fans are improperly sized or inefficiently designed, the cooling system will not be able to maintain optimal temperatures.

It is often difficult to know if you are choosing the right fan for a specific application. To choose the fan that will meet performance specifications we have developed an eBook titled “How to Select a Cooling Fan.” This informational guide will help you choose a cooling solution that meets the needs of your operation.

As the leader in manufacturing high-quality AC and DC fans, PTI has the expertise to provide information on how to achieve the ideal temperatures in your facility. With a wide range of sizes available, we also have custom capabilities to meet the specific requirements. Our innovative technologies provide the right solutions for numerous industrial applications.

 

The question of how to provide the best cooling for industrial applications has been around since the earliest days of the industrial revolution.  When equipment is functioning at a high level, it often produces heat that needs to be dissipated, and today, facilities are using systems that are more advanced than ever. 

With the advances in technology that are so commonplace in today’s industrial landscape, many systems are being designed to provide the greatest power possible in the smallest possible space.  These systems can run the risk of overheating if they are not designed with an appropriate cooling mechanism. 

Overheated equipment can pose many risks, including poor performance of equipment, early component and lubricant deterioration, overall system malfunction, and ultimately the possibility of fire and other safety risks for users and operating personnel. 

In order to avoid these problems, design engineers need to select the appropriate cooling unit for these systems.  One popular and economical option is the use of cooling fans.  Cooling fans are available in a wide array of options according to the temperature needs of the project.  Some considerations that a designer needs to think about when choosing the best cooling application include the size of the unit, voltage, and how much noise is involved.        

Different Sizes for Different Applications

Just as mechanical systems can come in all different sizes, the dimensions of cooling fans also vary greatly in order to ensure the best temperature stability.  This process is usually begun by thermal analysis, which is used to ascertain how much heat is generated inside systems in order to find out how much cooling is necessary. 

After this has been determined, a design engineer can then choose the proper sized cooling unit.  The exact size needed can be determined according to the sizing and density of the individual application.  For instance, cooling units for computers often need to be placed in very small spaces, and therefore will need to be designed to run at a high speed. 

By calculating the space available and how much cooling is needed, the appropriate fan can be chosen or designed as needed.  Knowing the desired temperature is also necessary for choosing a fan for large scale applications.  Larger fans can be used in applications such as locomotive engines that need a large volume of air constantly blowing to keep the engine and engine fluids cool. 

Fans of this size are not only used to keep equipment cool, but also to maintain comfortable temperatures for personnel working in industrial environments.  Cooling fans for HVAC systems can ensure that all workers are safe and comfortable, and usually are required on a large scale.

High or Low Voltage

The power supply used for a fan will influence its size and many other aspects of its operation, and must be taken into consideration when choosing the best cooling system.  The voltage that a fan requires will be dependent on its size and speed.   The parameters that best represent the voltage needed can be found in a fan performance curve. 

A performance curve graphically represents a variety of parameters that relate to the construction of fans.  These include the fan space, static pressure, airflow quantity variation, and required current for any specific fan voltage.  This tool is essential for design engineers to pick fans that have the correct voltage to cool systems sufficiently. 

Certain models, such as DC fans, are built directly proportionate to voltage, making them highly efficient in regard to energy consumption.  These models can also be designed with circuits that reduce voltage spikes in operation, providing efficient and smooth cooling results.

Noise

There are many different factors that can influence the noise level associated with fan operation.  The amount of noise that comes from a fan is determined in part by how big the fan is and how fast it spins.  Essentially, the faster a fan operates the more noise it produces. 

A larger fan running at lower speeds can produce the same energy with less noise than a smaller fan running at a high speed.  However, these types of size adjustments are not always practical, depending on the size requirements of the design engineer’s specific application.  The type of fan employed also affects the amount of noise generated.  The two primary types of industrial fans are axial and centrifugal, and they vary when it comes to noise. 

Axial fans work similarly to an airplane propeller, and while they tend to be compact, inexpensive, and light, they are noisier than centrifugal fans.  When noise is a concern, alterations can be made to fans, and these include insulation of the duct, installing material that dampens sound, or mounting the fan using soft materials such as rubber. 

Some noise will be inevitable when operating fans, but certain fan types, installation options, and designs can minimize noise as much as possible.

Many Determining Factors

For buyers and designers in the market for cooling systems, the above factors represent some of the major concerns associated with acquiring fans.  There are other aspects to consider as well.  The exact sources of heat, fan performance, reliability, and cost all need to be taken into account. 

When determined early in the system design process, the correct cooling system will help keep hardware and personnel safe while increasing the longevity of important equipment.  By acquiring high quality cooling fans, buyers and designers can easily ensure that even the most advanced, dense, and heat generating equipment can be operated with the utmost safety and efficiency.