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Choosing the Right IMC Solution to Protect Fan and Blower Systems

Posted by Sam Pelonis | Oct 9, 2019 11:09:29 AM | 0 Comments

Intelligent Motion Control (IMC) solutions modify the start-up and continuous power in brushless DC fans and blowers. These systems control every element of the equipment's functionality with multi-featured, full-wave, in-board circuit designs to ensure each piece of equipment is protected from abnormal or harmful voltage conditions. Not only can the IMC solution control how much power is run through the fan and blower systems on start-up, but they can also provide early warnings about fan malfunctions and energy usage.

IMC solutions are commonly utilized in green facilities that want to maintain a high degree of energy-efficiency, as well as plants with significant amounts of electronic or heated equipment that needs regular cooling. The benefits of Intelligent Motion Controls include:

  • Better operating efficiency and performance
  • Improved system oversight and maintenance
  • Electronic and fan or blower components that last longer
  • Fewer voltage fluctuations
  • Programmable features to build a customized solution for every facility or application
  • Multi-alarm connections that run multiple fans and detect potential malfunctions quickly

Each of these individual benefits work together to make fan and blower systems perform better, longer, and more safely. It's essential to select an appropriate IMC solution that will optimize each of these benefits for the highest return on investment.

Solutions

Pelonis Technologies provides many IMC control solutions for brushless DC fans and blowers. Four of the most popular control types include:

  • Pulse Width Modulation (PPWM)
  • Over-Voltage (OV)
  • Automatic Temperature Control (TPWM)
  • Manual Variable Resistor Control (RPWM) 

Pulse Width Modulation

PPWM controls allow facilities to directly manipulate signals within fan and blower systems to control how much time they spend operating on high settings. Complex circuitry systems frequently use PPWM systems to vary how much time equipment operates with a high signal. The system is analog and switches the equipment between high or low settings across a consistent period of time.

The control system works by applying a modulated signal with different frequencies ranging from 30 Hz up to 30 kHz. The high setting's pulse height can range from 3V–10V, and the low setting's maximum pulse height is 0.4V. These differences in voltage and signal change the fan system's duty cycle speed proportionally to the same percentage change in the maximum speed. 

PPWM controls also include:

  • Constant Speed (CS) controls
  • Inrush Current Protection (IR) controls
  • Current Limit (CL) controls

PPWM controls ensure that the fan maintains a minimum speed when the duty cycle is less than 25%, and cap the maximum speed at 4,000 RPM. This setting is called Mode "A" operation.  These systems use an external blue wire.

Pulse Width Modulation

Over-Voltage

Inconsistent voltage levels can damage equipment, especially if the voltage surges above a maximum allowable level. Over-voltage systems are protective circuits that detect voltage levels and only allow the equipment to operate when the voltage is below an established safety threshold. This maximum operating voltage is typically set at 20% more than the specific rated voltage, but the level can be customized for different equipment. 

Over-voltage systems either shut down power or clamp the output once it gets too high. The control's voltage range is double the rated voltage of the equipment it's protecting. 

OV controls are built-in tools that don't have an external wire.

Over-Voltage

Automatic Temperature Control

Instead of keeping a facility's fans and blowers on a timer, TPWM systems read the temperature to determine whether the cooling equipment needs to be running at a low or high speed. Operators can customize the upper and lower temperature limits to dictate when the system's settings should change to lower the temperature or hold the temperature steady. 

These systems use a 104J NTC thermistor, which offers 100K at 25° C. Also, the following controls come included in the system:

  • Constant Speed (CS) controls
  • Inrush Current Protection (IR) controls
  • Current Limit (CL) controls

This system has a built-in safety in the event of open or shorted thermistors. In these conditions, the control will tell the fan or fans to run at maximum speeds. Also, the fan's Mode "A" operation will rotate at a minimum of 1,000 RPM in temperature conditions of 16° C (60.8° F) to maintain adequate airflow. These systems use an external green wire.

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Manual Variable Resistor Control (RPWM)

Many applications—including controls for generators, DC motor drives, and electric welding controls—need to have manual control. Manual Variable Resistor Control systems allow operators to adjust the fan or blower speed at varying levels with an external variable resistor. The system's speed will change proportionally to the percentage change of the resistor and in correspondence to the percentage change of the maximum speed. 

The systems come with a resistor with a maximum value allowance ranging from 10–100K. The maximum fan speed is 4,000 RPM. The following controls come included in the system:

  • Constant Speed (CS) controls
  • Inrush Current Protection (IR) controls
  • Current Limit (CL) controls

If the variable resistor drops below 25K, then the RPWM automatically enters Mode "B" operation, and the fan will stop. These systems use external orange and white wires.

Manual Variable Resistor Control (RPWM)

IMC Solutions from Pelonis Technologies

Choosing the right IMC solution to protect your facility's fan and blower systems is essential. Pelonis Technologies can help you select the best fit. Not only do we have a wide range of Intelligent Motion Controls, our products include rotation detectors, life detection systems, DC voltage system controls, and current source signal control systems. 

 

Contact us today to learn more about upgrading your system.

 

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The Different Types of Fans Used in the HVAC Industry

Posted by Sam Pelonis | May 28, 2019 9:45:04 AM | 0 Comments

A fan is a key component of any HVAC system. The most common HVAC fans are axial, forward-curved centrifugal, and backward-inclined, and each is uniquely suited to certain purposes. It’s important to understand each fan’s differences in energy efficiency, cost-effectiveness, and noise considerations. The wrong fan for the job could lead to reduced functionality and higher costs. Here’s what you need to know about the various fans for HVAC systems.

Axial Fans

hvac axial fan

Axial Fans, which include propeller, tube axial, and vane axial styles, move an air stream along the axis of the fan. These fans work like an airplane propeller—blades generate an aerodynamic lift that then pressurizes the air. Propeller fans embody only a motor and a propeller used to drive the airflow. Similar to a propeller fan, a tube axial fan includes a venturi that surrounds the fan propeller and is designed to reduce the air leak

age or vortices created by the spinning prop. A vane axial fan features vanes trailing the rear of the propeller, which straighten out the swirling airflow that occurs when the air is accelerated by the motor. Axial fans are inexpensive, compact, and light, making them a favorite for industrial applications. They are, however, usually noisier than centrifugal fans. Noise can be abated by insulating the duct; mounting the fan on soft materials like rubber or using a spring isolator to reduce the amount of transmitted vibration; or installation of sound dampening material or baffles.

Centrifugal Fanscentrifugal fan

Centrifugal Fans, which are categorized by their radial, forward curved, or backward inclined blade shapes, increase the speed of an air stream with a rotating impeller. The speed increases as the air reaches the ends of the blades and is then converted to pressure. These fans are able to produce high pressures, which makes them suitable for harsh operating conditions, such as systems with high temperatures or moist or dirty air streams. Tip vortices or tip leakage flow produced by the pressure differential across the airfoil section can be problematic with these basic fans.

Forward-Curved Centrifugal Fans, look more like hamster wheels and can create more air pressure. Because of this, they tend to be noisier than axial fans and require more power to run. They are durable, easy to clean and maintain, and have less problems with resistance. Forward-curved centrifugal fans are also called blowers.

Backward-Curved Centrifugal Fans are uncommonly shaped blades, which can be curved or straight, make these fans excellent for high volumes of airflow and variable resistance. They are often used for industrial purposes.

Applications of Fan Types

Though axial fans are usually the least expensive, they’re not the right solution for every situation. Because of their features and capabilities, they are best for compact electronics, automotive products, medical devices, and appliances as well as large applications such as cooling towers, vending machines, outdoor air conditioner compressors, and combustion engine cooling. Axial fans are also ideal as general-purpose fans.

Centrifugal fans are better for larger systems: air-handling units, air pollution and filtration systems, and drying systems. With incredible energy efficiency and versatility, these fans come in a variety of models, so you can find one to fit into a small, hard-to-reach space. They are also great options for dust collection, glass tempering, and incineration systems.

Choosing the right fan for your HVAC system is essential for its efficiency and performance. An axial fan, for example, won’t do as good a job managing the resistance compared to centrifugal fans of the same size in an air filtration system. Using an axial fan for that purpose would make the system perform poorly and likely lead to extra maintenance and repairs. Even though it would be less expensive initially, it would cost you more in the long run and would not function the way you would expect from such a system. Likewise, using a centrifugal fan in a cooling tower where it’s not needed would lead to unnecessary noise and increased costs.

Find the Perfect Fan for Your HVAC System Needs

Even among HVAC fan types, there are a variety of shapes and sizes that will help you narrow down the best option for your project. Take a look at our selection of fans listed in Pelonis Technologies' catalogue and see which one is right for you. If you’re still unsure on which fan is right for you, make sure to download our eBook, How to Select a Cooling Fan. Additionally, we can customize your choice to meet even the most demanding restrictions. If you have any questions or wish to learn more about HVAC system fans, contact our team today.

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Cooling Fan Applications in the Medical Industry

Posted by Sam Pelonis | Mar 2, 2017 9:31:36 AM | 0 Comments

The Importance of Selecting the Right Cooling System


In the medical equipment industry, proper component functionality and performance is of utmost importance, as failures can cause dangerous malfunctions and delays that put patients at risk. When selecting a cooling system for your medical equipment application, it’s important to consider your project’s specific temperature and application needs. This will help to ensure longevity and reliability in your medical equipment.

cooling equipment medical (1).jpgAC Blowers in the Medical Industry

AC blowers — machines that provide air flow to facilitate various machine processes through the use of rotating blades — are often used in medical equipment to provide reliable, efficient air movement. For instance, AC blowers are utilized in medical and surgical beds to pump airflow up through mattresses, providing air circulation that prevents patients from experiencing pressure sores, skin shearing, hot flashes, and night sweats.

AC blowers can also have a great impact on the performance of thermal imaging systems, as many medical devices lose efficacy after critical temperature is reached, causing delays and added costs.

The Problem

Because medical device performance can suffer after reaching critical temperature, equipment such as MRIs, computed tomography (CT) devices, ultrasounds, and radiography (X-ray) machines are susceptible to subpar or slowed functioning. All of these devices rely on enclosure cooling to keep temperatures at optimal levels, as even slight fluctuations can affect performance. The FDA, however, helps maintain near-perfect (≥95%) repeatability and reproducibility of results in such equipment.

Because imaging technology designers generally have a narrow temperature range to work with, usually 50 ºF (10 ºC) between cabinet interior and exterior ambient temperature, cooling systems must be of the highest quality — dependable, quiet, and high performing, while also meeting the hygienic requirements of the medical industry.

The Solution

Typically used for sealed enclosures or devices, heat exchangers circulate hot air inside a device over an extended surface area, like internal fins, and circulate cooler external air over external fins. This keeps the interior temperature consistently warmer than the outside temperature.  If devices or enclosures are not sealed, however, small, silent, high-performing fans for medical equipment manufacturing can be used, which are less expensive and just as effective for non-sealed applications. Because most medical devices require sealing to maintain sanitation, heat exchangers are an ideal option to keep equipment functioning optimally and thereby reduce downtime and additional maintenance costs.

When incorporating a heat exchanger into medical equipment that requires a fan, be sure the power supply can accommodate the additional required power.

Cooling Solutions from Pelonis: The B1793 Blower

As a leading manufacturer of heating and cooling technologies, Pelonis is proud to offer a wide array of cooling options, including axial AC and brushless DC fans, as well as high-technology motors and OEM manufacturing solutions. Our B1793 TITAN AC blower, in particular, is ideal for use in the medical equipment industry.

With a patented engineered aluminum enclosure that acts as a heat sink, the B1793 is extremely heat resistant. This allows for cooler surface temperatures and reduced internal component wear. It also features an isolated open collector tachometer, which monitors running speed and locked rotor protection, ensuring automatic restart if the motor is released from a locked state. The B1793 blower also includes PWM operation that enables it to operate at various speed settings and it is a compact unit, allowing for easy installation and use in smaller medical devices.

To discuss how our cooling solutions can serve your application, or to learn more about fans, blowers, and heat exchanger components for the medical field, contact one of our in-house experts today, or download our AC blower catalog.

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Applications & Benefits of Frameless Fans

Posted by Sam Pelonis | Aug 22, 2016 11:59:07 AM | 1 Comment

Pelonis Technologies, Inc. (PTI) is already well-known throughout the manufacturing sector for providing fans of the highest quality available. With our custom design expertise and advanced technology, we have a product line that includes AC, DC, and micro fans, along with a complete array of complementary items and accessories.

Our reputation was earned, in part, to our commitment to constant advancement and improvement. We are proud to announce our latest advancement, an addition to our current selection of industrial fans — our brand new line of frameless fans. Frameless fans from Pelonis are uniquely engineered and designed to provide the most efficient cooling for applications with extremely limited space constraints.

With the proliferation of personal electronics and a host of other technical applications, the demand is high for small, lightweight cooling products. Our frameless fans are quiet, consume minimal energy, and effectively reduce heat to safe levels.

Benefits and Applications of Frameless Fans

Frameless fans are designed to be mounted directly onto smaller scale products, such as circuit boards, or into enclosures with minimal space. Without a surrounding frame, these fans combine optimal cooling performance and remarkable space efficiency. They provide a number of benefits, including:

  • Cost effectiveness — Frameless fans produce less friction, lowering noise levels and increasing their overall lifespan. They also use less power, which saves battery power in portable applications.
  • More aesthetically pleasing — With the reduced noise and mechanical friction, frameless fans are more pleasing to work with than their counterparts. They are also styled in the design of ceiling fans for a nice aesthetic touch.
  • Highly versatile — Frameless fans can work at different operating temperatures. Standard models work anywhere between -10°C and 70°C, and custom models with ranges extend to as wide as -35°C to 90°C are available.
  • Design flexibility — There are many different design options available for our frameless fans. These include dust, moisture, and salt fog protection, as well as dual ball or proprietary bearings for improving reliability, performance, and longevity. Additional options include Tachometer and Pulse Width Modulation speed control.

The unique design features of frameless fans make them ideal for a wide range of electronic Frameless_Fans_Cover.jpgapplications, some of which include:

  • Circuit boards, computer servers, and CPU, IC, and embedded sink designs
  • Laptops, tablets, e-readers, mobile phones, and other personal devices
  • Portable hard drives
  • Refrigerators and coolers
  • Portable medical, air quality monitoring, and other health and safety devices
  • Video boards
  • Defense and aerospace applications
  • Ventilation and defrosting applications
  • Other electronic equipment

Learn More

Frameless fans represent premium quality and design for custom cooling in limited spaces, uniquely engineered to fulfill the cooling requirements of virtually any application. To learn more about our new line of frameless fans, download our free Product Catalog or contact us today.

Download Now

 

 

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