EXAIR Cabinet Cooler Systems Vs. Refrigerant-Based Panel Cooling Options

If you’ve got an electrical enclosure that needs heat protection, you’ve got a good number of options at your disposal. Frankly, if any one of them were the “be-all and end-all” solution, the rest of us would be looking for something else to do. Fact is, there are certain situations where one particular method makes more sense than the others, and other situations where one method just won’t work but several others will.

In industrial and commercial settings, these situations will often present conditions where there is indeed an ideal solution. Today, we’ll explore the ones where the choice comes down to a compressed air-operated EXAIR Cabinet Cooler System or refrigerant-based panel cooling.  Let’s consider:

Environment – Now, we’re all going to make sure we protect our gear from the elements, as much as is humanly possible. Your company’s computer server is likely a lot closer to the climate controlled office spaces than the welding or grinding stations. But what happens when sensitive electronics need to be in close proximity to the machinery they’re controlling? And that machinery isn’t in climate controlled office spaces?

EXAIR NEMA 4 Cabinet Cooler System on an enclosure in a hot steel mill.

Even if an A/C type panel cooler would fit on this box, it would be problematic:

  • See all that dust on the ducts? And the belt? And the rails? And the…well, everywhere? Yeah; would be in the filters, condenser coils, the compressor motor bearings and eventually, inside the panel.
  • They make condensate. The big thing about air conditioners is that they lower the humidity…and that water has to go somewhere. Even if a small drain line is easy enough to run, what happens when it gets clogged (that dust is going to find its way here too, by the way)?
  • They’re sensitive to vibration. Every fastener, every brazed joint, every electrical connection, risks cyclical failure if they’re shaken about.

EXAIR Cabinet Cooler Systems are impervious to all of these conditions:

  • The only air they use comes straight from your compressed air supply. We even provide Automatic Drain Filter Separators to make sure this is clean & dry.
  • There are no moving parts. Vibration is not a problem.
  • We offer different levels environmental considerations to meet most any challenge:
    *NEMA 12 (dust tight, oil tight) are ideal for general industrial environments.
    *NEMA 4 (splash resistant) keep liquids out too, and are indoor/outdoor rated.
    *NEMA 4X (corrosion resistant) also keep liquids out, and are stainless steel construction. They’re also available in 316SS construction for the most exacting, harshest, and critical environments such as food service, pharmaceutical, or highly corrosive atmospheres.
    *High Temperature Cabinet Cooler Systems are specified for installation in areas where ambient temperatures exceed 120°F (52°C.)

Location – Sometimes, there’s just not room to mount an air conditioner. The compressor, and, especially, the condenser coils have to take up a finite amount of space, by design.

When there’s no room to use a bulky air conditioner, a compact EXAIR Cabinet Cooler System is ideal.

EXAIR Cabinet Cooler Systems have a small footprint…a NEMA 12 550 Btu/hr system, for example, installs through a ½ NPS knockout, is under 6” tall, and just over 1” in diameter.

Reliability – We talk to callers all the time about the frustration of:

  • Having to replace a burned out Variable Frequency Drive because their panel cooler failed.
  • Constantly resetting controls that have tripped due to an overheat condition because they missed, or don’t have time for, their panel cooler’s maintenance.
  • Down time and lost production while waiting for replacement parts…or a whole new panel cooler.

Even in less aggressive environments, filters and coils can slowly accumulate dirty buildup, which reduces the unit’s cooling power.  Then, a heat wave hits early in the season, and your machine trips out (if you’re lucky) or burns out (if you’re not) -either way, that part or process you were in the middle of is scrap, and you’re back to step one.

EXAIR Cabinet Cooler Systems are not affected by this – in fact, a system with thermostat control may just sit there dormant through the winter, and “spring” (pun intended) into action when that first heat wave rolls through.  And it’ll be just as powerful as that last hot day, the previous autumn.

Availability – Let’s say you installed some new equipment recently, and its first exposure to the heat of summer created one of the frustrating situations above.  An air conditioner-type panel cooler will require:

  • “Invasive surgery” on your enclosure. Most of these require a sizeable rectangular hole for installation.
  • These systems can pull 5 amps or more, which might mean a dedicated circuit breaker & wiring.
  • Many are built-to-order, so you might have to wait, depending on their assembly schedule.  And they might be busy, because if the heat just started causing you problems, you’re probably not the only one.
  • Once it’s received, installed, and wired up, you may still have to wait for the compressor’s oil (special oil for use with refrigerant) to settle before you start it up the first time.

EXAIR Cabinet Cooler Systems are stock products.  We ship same day, across the country, with orders received by 3pm EST.  They install in minutes, and most of the preparation can be done today, so you’re ready to install when it comes in tomorrow – which isn’t a big deal…most Cabinet Cooler Systems weigh only 5lbs or less, so expedited shipping isn’t near as painful to your wallet as a big box full of electric motor, copper coil, and refrigerant.

Environment (friendly, that is) – No matter how well they’re built, a refrigerant system is going to leak sooner or later.  And every whiff through an aging seal, or sudden loss through a failed tube, will contribute to the ozone depletion that today’s strict controls and high attention to CFC’s are trying to prevent.

Our Cabinet Cooler Systems are solely compressed air operated…the only thing they exhaust is the air from inside the enclosure.

Durability – Refrigerant leaks. Electric motors wear out.  Coils corrode.  Filters clog.  A GOOD warranty on an air conditioning type panel cooler is two years.  And it won’t cover environmental effects.

All EXAIR Compressed Air Products have a Five Year Built To Last Warranty.  But if you supply your Cabinet Cooler System with clean, dry air, it’s going to run darn near indefinitely, maintenance free.

Don’t trust your critical electronics to anything less than the assurance provided by an EXAIR Cabinet Cooler System. If you’d like to find out which one(s) are right for your needs, give me a call.

Russ Bowman
Application Engineer
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Video Blog: Cabinet Cooler Thermostat Installation

Many EXAIR Cabinet Cooler Systems are available with thermostat control, Model 9017 thermostat is used to monitor temperature in the panel as part of a typical thermostat controlled system.  Below is a video on how to physically mount model 9017 thermostat into your panel as part of the overall installation process for NEMA 12 or NEMA 4/4X Cabinet Cooler Systems. Wiring the thermostat will be covered in a separate video.

 

John Ball, Application Engineer
johnball@exair.com

http://www.twitter.com/EXAIR_JB

Cabinet Cooler Systems Save The Day, Every Day

Summertime temperatures get hot. Protect your electronics with an EXAIR Cabinet Cooler System.

As you may have seen in our most recent E-NEWS Special Bulletin, or experienced in real life (depending on where you’re located,) most of the eastern United States is seeing a pretty significant heat wave for early summer…or, as we call it at EXAIR, “Cabinet Cooler Season.”  And this year is kicking it off with a bang, for sure.

On Tuesday, when the E-NEWS email went out, I was on the phone, processing an order for a Model 4340 NEMA 12, 2,800 Btu/hr, Thermostat Controlled Cabinet Cooler System, to ship overnight to a user who wanted to protect the new drive they were replacing because theirs overheated.  They were up and running before noon on Wednesday.

On Wednesday, four local customers placed “will call” orders for Cabinet Cooler Systems.  I had the pleasure of talking with one of them, who was installing one for the very first time.  As he was looking over the Installation & Operation Guide before he left our building, he just wanted to make sure that hooking it up was as simple as it sounded…and it is.  We pulled the parts from the box and went over exactly how each step is performed, and he left feeling confident that he’d have it installed pretty quickly.  Just in case, I also got his email address and sent him a link to our NEMA 4 Cabinet Cooler System Installation Video Blog:

I don’t know what the rest of the summer holds in store, but I know this: if you have concerns about protecting sensitive, critical, and/or expensive electrical & electronic enclosures, EXAIR Cabinet Cooler Systems are the solution you’re looking for.  Easy to install.  Maintenance free operation.  Durable, UL Listed, and CE Compliant.  If you’d like to discuss your application and get one for yourself, call me; let’s talk.

***Order an EXAIR Cabinet Cooler System before July 31, 2017, and get a FREE AC Sensor!***

Russ Bowman
Application Engineer
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EXAIR Won’t Keep You Waiting For Anything

Have you ever sent an email, or left a voice mail message for someone without knowing they were out of the office? It can be pretty frustrating to not hear back from someone, especially if your needs are urgent.

At EXAIR, we make sure this doesn’t happen:

*For starters, we don’t have an automated attendant…if you call EXAIR during normal business hours, you’re going to talk to a real live human being.

*What’s more, that real live human being is going to be one of our Customer Service Representatives, and they can answer any questions you might have about price and availability of any of our Engineered Compressed Air Products.

*If you need detailed technical information, they’ll transfer you to an Application Engineer…and they are always keenly aware of who’s available & who’s not.  You won’t get anyone’s voice mail unless you specifically ask for it, and if one of us is on vacation (and won’t be able to return your call for a number of days,) you’ll know that before you’re transferred to leave that message.

*Not only that, but we’ve got a system in place to monitor each other’s emails.  Which brings me to the success story that inspired this blog:

It’s vacation season, and another of us took off for some well deserved R&R with the family.  According to The System, I get to check those incoming emails while this co-worker is out.  And he (like the rest of us) gets a LOT of emails.  Some are new requests for application/performance data, and some are continuing conversations of the details of (sometimes) complex applications.  Like the project he was working on with a customer who wanted to use Air Knives to blow off a continuous strip of material exiting a wash/rinse vessel.  After a discussion of the details of the application, they had decided to try (2) Model 110003 3″ Aluminum Super Air Knives, one mounted on either side, to “strip the strip.”  And it worked perfectly.  They just wanted to run the details of this first installation by us before doing the other seven.  Part of my process was to go back through the chain of emails…while this looked pretty straight forward, the devil is indeed in the details, and I hate that guy.  But, try as I might (sorry; I’m an engineer,) I could not find fault, or room to improve, with the setup they designed…it was most pleasantly devil-free.

Compact, efficient and quiet, the EXAIR 3″ Super Air Knife is an ideal blow off solution for a variety of applications.

Anyway, with my agreement that their installation was indeed optimal (it’s exactly what I would have done too, for the record,) they placed an order for the (14) Super Air Knives to outfit the other (7) wash/rinse operations.

If we were keeping score, it would be coworker-2, Russ-14.  But we’re not.  Lest my record suffer when I “break for the Lake” in June.  By then, it’ll be Cabinet Cooler Season, and I almost hate to miss a week of that.  Almost.

Man, I don’t even take long pants with me to the Lake.

If you have questions about compressed air products or applications, we’ve got answers.  Live and in real time, every day.  Call us; let’s talk.

Russ Bowman
Application Engineer
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Non Hazardous Purge Cabinet Cooler System Keeps Enclosure Dust Free

A mining company has processing machinery operating in a poorly ventilated, dusty environment (actually, it’s a mine…as you might have guessed.) This machine’s control panel was supplied with filtered vents and fans to cool the electronic components inside. The filters clog regularly, and even though they checked them frequently, it’s not always frequently enough to prevent the drive from overheating.

Based on a referral they got from another one of their facilities, they called to get more information on a Cabinet Cooler System. For total dust exclusion, our Non-Hazardous Purge systems are ideal…they’re thermostatically controlled, so compressed air consumption is responsible and efficient, but they also provide a small, continuous flow, even when the thermostat set point temperature is attained, and the solenoid valve is shut. This keeps a low positive purge volume of clean, dry air in the enclosure.

EXAIR Non Hazardous Purge Cabinet Cooler Systems provide reliable and efficient cooling in the most aggressive environments.

The caller already had the data from our Cabinet Cooler Sizing Guide, so specification was quick & easy. A Model NHP4340 NEMA 12 Non-Hazardous Purge Cabinet Cooler System – 2,800 Btu/hr – w/Thermostat Control was ordered and installed the next day. We keep them in stock for situations just like this.

If you have heat issues with electrical & electronic equipment enclosures, give me a call.

Russ Bowman
Application Engineer
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Beat the Heat with EXAIR Cabinet Coolers!

As we begin to approach the heat of summer in the northern hemisphere, we begin to break out the flip-flops, swimsuits, and warm weather attire. If you’re not a fan of the warmer temperatures, this may not be your favorite time of year. For me, I can’t wait to spend some time outdoors and enjoy all of the activities that summer has to offer. Whether you like the heat or not one thing is certain, the electrical enclosures within your facility most certainly do not.

CC_Actionshot

EXAIR’s Cabinet Cooler Systems were designed specifically to rectify these issues within your facility. Utilizing Vortex Tube technology, the Cabinet Cooler produces cold air from an ordinary supply of compressed air. This cold air keeps the enclosure free of debris and moisture and is easily installed in minutes through a standard electrical knockout. Here is a short video that shows just how simple it really is. The Cabinet Cooler Systems are available with Nema 12 (IP54) ratings and are also available in Aluminum, 303 Stainless Steel, and 316 Stainless Steel construction for Nema 4 (IP66) rated enclosures. For systems that are not able to be mounted on top of the cabinet, we also have Side Mount Kits available in Aluminum, 303 Stainless, and 316 Stainless.

These systems are available with cooling capacities of anywhere from 275-5,600 Btu/hr. To make things much easier for you, we offer a Cabinet Cooler Sizing Guide that will allow us to recommend the most suitable model for your cabinet. With a few quick measurements, we’ll be able to determine the exact heat load that we’ll need to dissipate and offer you a quick and easy solution. If you’re experiencing heat related issues somewhere within your facility or remember the troubles that they caused you last year, contact an Application Engineer today and we’ll see to it that this summer your cabinets remain cool!

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

When things get heated, a Cabinet Cooler can cool things down.

Heated Desiccant Dryer

Many of us have walked into a compressor room.  They are typically a small room that is very warm as it contains an air compressor, a dryer, and other items that create heat.   To help remove the heat, a fan is placed near the ceiling to remove as much heat as possible.  But, when the days get warmer, it makes it more difficult to keep things cool inside the compressor room.  Recently I was working with a pharmaceutical company about the issues with the operation of his dryer.

For this customer, he was using a heated-type regenerative dryer in their facility to get a -40 deg. F dew point.  It was important in their process to have very dry compressed air because it was coming in contact with powders.  As the outside temperatures began to warm up, they started to see alarms and failures with their dryer system.  With a dryer shutdown, they had a potential of water going downstream into their process.  They contacted EXAIR for a solution.

He explained the situation in a bit more detail about his desiccant type dryer.  It had two towers next to each other.  One tower would dry the compressed air while the other tower would be heated to remove any water that was adsorbed by the desiccant.  The control panel was mounted in between the desiccant towers, and it operated the switching valves and heating cycle of the dryer.  When a tower was being regenerated by heat, the ambient temperature around the control panel was getting near 140 deg. F.  With this added heat, the electronics inside would malfunction and shut down the function of the dryer.  They did have a control fan near the ceiling to try and remove the heat from the room, but it was not very effective.  They needed an alternative way to keep the dryer running.  With the location of the control panel between the two towers, there was very little room to work.  He needed something very compact, easy to mount, and effective in maintaining a cool internal temperature.

EXAIR High Temp Cabinet Coolers

In calculating the high ambient heat and the size of the control panel, I recommended the HT4315 High Temperature Cabinet Cooler System.  It is able to handle the high ambient conditions from 125 – 200 deg. F.  With a dimension of 1.34” diameter and a length of 8”, this compact design had no problem fitting onto the panel between the towers.  Even with this small design, the model HT4315 had plenty of cooling capacity to keep the electronics inside from overheating, eliminating the concern with their dryer system shutting down.

To mount this Cabinet Cooler System, a 1 1/8” knock-out hole in the cabinet and a small wire connection hole for the thermostat are the main steps.  This makes it fast and easy to install onto the panel to start getting the cold air to  the electronics.  With a thermostat control, it will only operate the Cabinet Cooler during high temperature conditions, making the system very effective.  The design of the Cabinet Coolers has no moving parts, no motors, no Freon or condensers to clean.  Once they are installed, they are maintenance and worry-free.

If you wish not to have failures in your compressor room during the hot months, a Cabinet Cooler System can be the correct product for you.  If you need help in sizing, you can fill out the EXAIR Cabinet Cooler Sizing form and send it in to us.  For my customer mentioned above, the integrity of their compressed air system was sustained to keep their production process running smoothly.

 

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Heated Desiccant Dryer by Compressor1.  Creative Commons Attribution-NoDerivs 2.0 Generic.

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