EXAIR Cabinet Cooler Eases Maintenance Schedule, Replaces A/C System for Beverage Manufacturer

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During a recent visit with our distributor in Lima, Peru I had the pleasure of visiting a beverage manufacturing facility to discuss EXAIR’s Cabinet Coolers. They have several panels throughout the facility with A/C units installed. A lack of adherence to scheduled maintenance was causing the filters to clog and restrict the cooling power of the A/C unit. Due to staffing issues, their maintenance department was very thin and regular maintenance items were getting missed.

When the filters would clog, the panels would overheat and stop production. Their solution was to open the panel up and blow fans on them, forcing even more dust into the enclosure. In their search for an alternative solution, they came across EXAIR’s Cabinet Cooler Systems and reached out to our distributor. The A/C unit that was installed on the panel had a capacity of 800W (2,728 Btu/hr). EXAIR offers a 2,800 Btu/hr system from stock that matched up perfectly for them.

They installed a Model 4340-24VDC Nema 12 Cabinet Cooler System with 24VDC thermostat control and removed the A/C system. With no moving parts and no refrigerants, there’s absolutely no maintenance required. Just set it and forget it! The Cabinet Cooler has kept the electronics inside at 95°F, preventing any potential for heat related shut downs. Since all Cabinet Coolers must be installed onto a sealed enclosure, there is no need for filters on the enclosure to prevent dirty ambient air from entering. They’re now working to replace each of the A/C units in the facility with an EXAIR Cabinet Cooler.

EXAIR manufactures Cabinet Coolers for any industrial environment. Cabinet Coolers maintain Nema 4, Nema 4X, and Nema 12 integrity on the enclosure and are also UL Listed and CE Compliant. For applications that may be in a classified area, the Hazardous Location Cabinet Cooler has been approved by UL for use in Class 1 Div 1 – Groups A, B, C, and D; Class II Div 1 – Groups E, F, and G; and in Class III areas. Cooling capacities as high as 5,600 Btu/hr can be achieved with one of our Dual Cabinet Cooler Systems.

Stop wasting precious time maintaining you’re A/C systems, or dealing with heat related shutdowns and get a Cabinet Cooler on order today. Fill out the sizing guide online, and one of our Application Engineers will be in touch to provide you with the most suitable model for your application. Act fast, the current Cabinet Cooler promotion expires at the end of August!

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

EXAIR Cabinet Cooler Systems: Thermostats and Accessories

For most industrial enclosure cooling applications, a temperature of 95°F (35°C) is sufficient to be below the rated maximum operating temperature of the electrical components inside the cabinet. So, it is important to turn the cabinet cooler system on to keep the components cool, but at the same time we all know compressed air can be expensive if you over use it. A thermostat allows you to turn the cooler off when the enclosure is at or below the desired temperature, saving compressed air over continuous operation.

Cabinet Cooler

Here at EXAIR we are all about Engineered Solutions that will not only save you money but help your company “Go Green” by drastically lowering your energy costs. And when it comes to Cabinet Coolers, we have several options to control and manage the compressed air supply.

The most popular option is our Thermostat Control. EXAIR thermostats feature a bimetallic contact strip to open and close the electrical circuit in response to air temperatures.  These thermostats quickly respond to changes in air temperature and are specifically suited for their intended use.  Preset for 95°F (35°C), a suitable temperature for most electronic devices, these thermostats are fully adjustable for specific application needs. When thermostat closes it then turns the solenoid valve off turning the compressed air supply off. These thermostats are available in 12VAC, 240VAC and 24VDC.

Thermostat and ETC

In the event a more sophisticated thermostat control is needed, Electronic Temperature Control units can be implemented.  These standalone units utilize a thermocouple to determine internal cabinet temperatures which display onto a digital readout.  Push-button controls on the digital readout board allow for easy modification of the internal cabinet temperature set-point.  When the desired internal temperature is reached, the Cabinet Cooler system will turn off automatically.

One accessory that will give the flexibility to install EXAIRS cabinet cooler system is our Side Mount Kit. Sometimes there isn’t room above an electrical panel to fit the Cabinet Cooler, even though it takes just 5″ to 7.25″ of space above. In these cases, the Side Mount Kit is available to handle any of the Cabinet Cooler sizes and NEMA ratings. The NEMA 4 and 4X Cabinet Coolers must be mounted vertically for the unit to properly resist the ingress of liquids and maintain the integrity of the cabinet NEMA rating.

EXAIR NEMA 12 Cabinet Cooler System w/ Side Mount Kit
NEMA 12 Cooler with Side Mount Kit

The Side Mount Kits install into a standard electrical knockout (1-1/2 NPS) for easy installation.

If you’re in need of a suitable cooling solution for an industrial enclosure, consider an EXAIR Cabinet Cooler systems.  They’re smaller than traditional AC units, faster to install, and require little-to-no-maintenance.  Feel free to contact an EXAIR Application Engineer with any questions, or fill out our online Cabinet Cooler Sizing Guide to have an Application Engineer contact you.

Jordan Shouse
Application Engineer
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Hazardous Location Cabinet Coolers

Last year was a big year for EXAIR’s Cabinet Cooling product line, in November  we launched our first Hazardous Location Cabinet CoolersEXAIR has always been a leading supplier in compressed air-based Cabinet Coolers, now we have expanded on that to work in the most high-risk conditions.

When a Hazardous Location Cabinet Cooler is used in conjunction with a purge system, they will keep electrical equipment at the desired operating temperature to protect and lengthen the lifetime of pricey controls and power supplies.

hazloc_illLsr-800w
Hazardous Location Cabinet Cooler

 

Electrical equipment can cause explosions in certain atmospheres. Equipment used in areas where explosive concentrations of dusts or vapors may exist must be equipped with special wiring and other electrical components for safety purposes. Hazardous (classified) locations such as these might exist in aircraft hangars, gasoline stations, paint-finishing locations or grain bins. EXAIR’s Hazardous Location Cabinet Coolers have been approved and tested by UL for use in the following areas:

classified_cULus_360x283
UL Approved and Tested

Class I Div 1&2 – Groups A, B, C, and D

  • Class I Areas refer to the presence of flammable gases or vapors in quantities sufficient to produce explosive or ignitable mixtures. Class I Div 1 will have ignitable concentrations of flammable gases present during the course of normal operations. This is level of approval is one that differentiates the EXAIR Hazardous Location Cabinet Coolers from much of the competition. Class 1 Div 2 areas will have flammable gasses or vapors present only in the event of an accident or during unusual operating conditions.

Class II Div 1&2 – Groups E, F, and G

  • Class II areas are locations in which combustible dust may exist. The end user shall avoid installation of the device in a Class II environment where dust may be readily disturbed from the exhausts of the Hazardous Location Cabinet Cooler. Any dust formed in the vicinity of the cooler must be cleaned regularly.

Class III

  • Class III areas are locations that will have ignitable fibers or flyings present. This is common within the textile industry.

The Cabinet Cooler also carries a temperature rating of T3C, meaning it cannot be installed near any materials that could auto-ignite at temperatures in excess of 320°F.

The Hazardous Location Cabinet Cooler is available in (8) different cooling capacities ranging from 1,000 Btu/hr – 5,600 Btu/hr. The Cabinet Cooler is the best solution for protecting your sensitive electronics from heat, dirt, and moisture. With Nema 4/4X systems available, the Hazardous Location Cabinet Coolers will keep the cabinet cool without compromising the integrity of the enclosure.

If you’ve got an electrical cabinet installed within a hazardous location, fill out the Cabinet Cooler Sizing Guide and allow an EXAIR Application Engineer to determine the most suitable model for you.

Jordan Shouse
Application Engineer
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6 Primary Benefits of Cabinet Coolers (Vortex Tube Enclosure Coolers)

First off, I want to dispel any notion that there might be something that’s NOT great about EXAIR Cabinet Cooler Systems.  Are there other methods to provide effective cooling to an electrical panel?  Of course there are, and frankly, if one particular method was clearly superior in any & every situation, the makers of that one would have put all the others out of business by now.  But for now, let’s consider:

1. Simplicity: Cabinet Cooler Systems need compressed air to work.  That’s it.  Supply them with clean, moisture free air, and they’ll run darn near indefinitely, maintenance free. What could be easier?

2. Control:  Continuous Operation systems have their place (more on that in a minute,) but in most cases, Thermostat Control is preferred, for a couple of reasons:

  • Most electrical and electronic components have a rated maximum operating temperature of 104°F (40°C).  Maintaining the air temperature at a reasonable level less than that is all you need…any lower, and you’re just wasting energy, no matter what method of cooling you use.  Our Thermostats are preset at 95°F (35°C) to ensure heat protection, while limiting operating costs.
  • There is such as thing as “too cold.” Particularly sensitive instrumentation & controls may exhibit varied behavior at different temperatures.
  • Our bimetallic probe-type thermostats are ideal for controlling air temperature.  They have much faster response time than other mechanical styles, meaning the system won’t keep running once it’s cool enough, and it starts running as soon as it starts getting too hot.  They’re also easy to reset, if the preset of 95°F (35°C) is not suitable for particular specific needs.
  • If constant monitoring, or frequent changes in control temperature are desired, the ETC Electronic Temperature Control offers these benefits, via a quick response thermocouple and pushbutton operation.

3. Environmental concerns: No matter where a panel is located in your plant, and what it might be exposed to, EXAIR Cabinet Cooler Systems will keep the environment out of that panel:

  • NEMA 12 Cabinet Cooler Systems are oil tight, dust tight, and rated for indoor duty.
  • NEMA 4 systems provide the same protection as NEMA 12, and are additionally splash resistant, and are rated for indoor/outdoor duty.
  • NEMA 4x systems offer NEMA 4 protection, and are made of stainless steel for corrosion resistance.
  • HazLoc Cabinet Coolers are UL Classified & CE Compliant.

    HazLoc Cabinet Cooler Systems also maintain NEMA 4 or 4X integrity, and are for use with classified enclosure purge & pressurization systems in hazardous locations:

    • Class I Div 1, Groups A, B, C and D
    • Class II Div 1, Grouds E, F and G
    • Class III

4. Dependable protection: In most cases, the less moving parts something has, the more reliable it is.  With NO moving parts, EXAIR Cabinet Cooler Systems absolutely prove this out:

  • Unlike refrigerant-based systems, there are no filters to clean, no coils to foul or corrode, and no electric motors to burn out.
  • No potential contaminants from outside air ever enter the enclosure…all the cold air comes from your compressed air supply, through an Automatic Drain Filter Separator fitted with a 5 micron particulate element and a centrifugal separator for moisture removal.

5. Selection:  Cooling capacities range from 275 Btu/hr to 5,600 Btu/hr, and they’re all in stock, ready for immediate shipment.

6. Special considerations:  “Customized” usually means high prices and long lead times. Not so for a number of EXAIR Cabinet Cooler System options:

  • This NEMA 4 Dual Cabinet Cooler System protects a critical equipment panel on a hot roll steel line.

    High Temperature systems are available from stock, for installation in areas where the ambient temperature can exceed 125°F (52°C,) all the way up to 200°F (93°C.)

  • Continuous Operation Systems aren’t the only way to constantly keep environmental contaminants out…Non-Hazardous Purge (NHP) systems combine the efficiency of Thermostat Control by always passing a small amount of air flow, to provide a slight positive pressure, even when the temperature is lower than the Thermostat set point.  This way, the Cabinet Cooler System only operates to maintain appropriate cooling, but the panel is still protected all the time.
  • When additional protection from harsh and corrosive environments is needed, or when specified by strict facility requirements (I’m looking at you, Food, Pharma, and Nuclear Plants,) our NEMA 4X Cabinet Cooler Systems can be provided in Type 316 Stainless Steel construction, from stock.

6.5 Simplicity, part 2:  Not only are they simple to operate…

  • They install, in minutes, through a standard knockout in the top of your enclosure.

    Side Mount Kits maintain NEMA 4/4X Splash Resistance.
  • If there’s no room on top, or if it’s just more practical, you can put them on the side of the panel using a Side Mount Kit.
  • Don’t know which one to pick, or need help determining your heat load?  Then use our Cabinet Cooler System Sizing Guide.  There’s one in the catalog that you can fill out and fax or email to us, or you can find it on our website under the “Features” tab on any Cabinet Cooler product page…just fill in the blanks and click “Submit.”  Or, you can always simply call in the data to an Application Engineer.  We can calculate your heat load in just a minute or so, and we do it over the phone all the time.

If you’d like to find out more about heat protection for your electrical or electronic panels, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Cabinet Cooling with Thermostat Control and ETC

An EXAIR Cabinet Cooler® System with either the Thermostat Control or the Electronic Temperature Control (ETC) option includes a temperature measuring device that is used to control the operation of the Cabinet Cooler System to maintain the set-point temperature.Thermostat and ETC

For most industrial enclosure cooling applications, a temperature of 95°F (35°C) is sufficient to be below the rated maximum operating temperature of the electrical components inside the cabinet. EXAIR Thermostats are preset to 95°F (35°C) and are adjustable. Maintaining the cabinet at 95°F (35°C) will keep the electronics cool and provide long life and reduced failures due to excessive heat. But if 95°F (35°C) is good, why not cool the cabinet to 70°F (21.1°C)?

When cooling an enclosure to a lower temperature, two things come into play that need to be considered. First, the amount of external heat load (the heat load caused by the environment) is increased. Using the table below, we can see the effect of cooling a cabinet to the lower temperature. For a 48″ x 36″ x 18″ cabinet, the surface area is 45 ft² (4.18 m²). If the ambient temperature is 105°F (40.55°C), we can find from the table the factors of 3.3 BTU/hr/ft² and 13.8 BTU/hr/ft² for the Temperature Differentials of 10°F (5.55°C) and 35°F (19.45°C). The factor is multiplied by the cabinet surface area to get the external heat load. The heat load values calculate to be 148.5 BTU/hr and 621 BTU/hr, a difference of 472.5 BTU/hr (119.1 kcal/hr)

External Heat Load

The extra external heat load of 472.5 BTU/hr (119.1 kcal/hr) will require the Cabinet Cooler System to run more often and for a longer duration to effectively remove the additional heat. This will increase, unnecessarily, the operating costs of the cooling operation.

The other factor that must be considered when cooling an enclosure to a lower temperature is that the Cabinet Cooler cooling capacity rating is effected. I won’t go into the detail in this blog, but note that a 1,000 BTU/hr Cabinet Cooler (rated for 95°F (35°C cooling) working to cool a cabinet down to 70°F (21.1°C) instead of 95°, has a reduced cooling capacity of 695 BTU/hr (174 kcal/hr).  The reduction is due to the cold air being able to absorb less heat as the air rises in temperature to 70°F instead of 95°F.

In summary – operating a Cabinet Cooler System at 95°F (35°C) provides a level cooling that will keep sensitive electronics cool and trouble-free, while using the least amount of compressed air possible.  Cooling to below this level will result in higher operation costs.

If you have questions about Cabinet Cooler Systems or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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UL Classified Certification for HazLoc Cabinet Coolers

Although history only records back so far, I am certain (based on my experiences with sharp and heavy objects) that humans have been injuring themselves with tools, and the stuff they make with them, since the beginning of time.  In fact, recorded history DOES bear this out…the famous Code of Hammurabi (circa 1750 B.C.) set specific amounts of compensation for specific injuries, as did laws from all over the ancient world, from the empires of Rome to China.  Since then, we’ve come a long way in regulating safety not only for the worker in the workplace, but in public places, homes, and workplaces where manufactured products are used.

UL LLC (or Underwriters Laboratories, as they were known throughout the 20th Century) is a safety consulting & certification company founded in 1894 by an electrical engineer named William Henry Merrill.  A year earlier, an insurance company hired Merrill to perform a risk assessment and investigation of new potential clients…George Westinghouse and Nikola Tesla, the proprietors of the Palace of Electricity at the 1893 Chicago World’s Fair.  It was this experience that made him realize the potential for such an agency to test and set standards for product safety at the dawn of a new age of technology development.  And 120 years on, the benefits in safety & protection have been proven many times over.

If a product or device carries one of these markings, it’s been evaluated for safety by top professionals in the field.

One of the more critical accreditations that a manufacturer can receive for a product is the UL Classified Mark.  This differs from other markings (like the ones shown above for Certified, Listed, or Recognized) in that Classification means that samples of the product were tested & evaluated with respect to certain properties of the product.

EXAIR’s new Hazardous Location Cabinet Cooler Systems bear the UL Classified Mark.  This means they meet the stringent UL requirements for installation on purged electrical enclosures in specific classified areas:

  • Class I Div 1, Groups A, B, C and D
  • Class II Div 1, Groups E, F and G
  • Class III
EXAIR Hazardous Location Cabinet Cooler Systems maintain NEMA 4/4X Integrity and are CE Compliant.

When choosing products for use in classified areas, it’s critical to ensure safety through compliance, and the HazLoc Cabinet Cooler Systems allow you to do that, with simplicity and reliability.  If you’d like to discuss an enclosure cooling application, in or out of a classified area, give me a call.

Russ Bowman
Application Engineer
EXAIR Corporation
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Explanation of Hazardous Locations – Class II Div. 1, Groups E, F and G

Per the National Electrical Code (NEC) there are (3) classifications for areas that are defined as hazardous.  They are Class I (gases & vapors), Class II (flammable dusts) & Class III (fibers), the focus of today’s Blog is on Class II locations.

Class II locations are those that are hazardous because of the presence of combustible dust. Note that the dust must be present in sufficient quantities for a fire or explosion hazard to exist. The fact that there is some combustible dust present does not mean a Class II hazardous location exists. Dust is defined as a combustible material that must exist as a finely divided solid of 420 microns (0.420 mm) or less. This will allow the dust to pass through a No. 40 sieve.  Just as in Class I, Division 1 and 2, the subdivision of Class II into Divisions 1 and 2 identifies the likelihood that there is an explosion hazard.

Division 1 locations are defined as an area where the amount of combustible dust is either suspended in the air or accumulated on surfaces in a sufficient concentration to allow for ignition.  The ignition could be caused by a failure or malfunction of the equipment in the classified area.  Group E & F dust (see chart below) are considered conductive and could penetrate into electrical equipment such as electric motors, control panels, electrical panels, etc.. and cause an electrical failure.

Chart1

Group E dusts are metal dusts, such as aluminum and magnesium. In addition to being highly abrasive, and likely to cause overheating of motor bearings if it gets into them. Group E dusts are also electrically conductive and if they are allowed to enter an enclosure can cause an electrical failure.

Chart2

Group F dusts are carbonaceous, the primary dust in this group is coal dust. Coal dust has a lower ignition temperatures than those in Group E.  While Group F dust has a higher thermal insulating value than the layer of Group E.  Therefore Group F requires more control of the temperature on the surfaces that the dust settles on. Group E dusts are semi-conductive, however if the voltages are 600 volts or less it is not generally considered a factor.

Chart3

Group G dusts include plastic dusts, most chemical dusts and food-grain dusts. They are not electrically conductive. Generally these dusts have the highest thermal insulating characteristics and the lowest ignition temperatures. Therefore the equipment used in Group G areas must have the lowest surface temperatures to prevent ignition of a layer.

Chart4

Lastly, equipment rated for use in Classified Environments have a rating called the Temperature Code or “T-Code”.  This is the temperature or temperature range that the rated device will operate normally and/or in a failed or failing state.  Consider something as common as a light fixture, electric motors, etc.. as they could become hot enough to cause ignition depending on the type of dust in the area.  So be sure to check the “T-Codes” for every piece of equipment that will be used within a Classified Environments.

Chart5

When you are looking for expert advice on Hazardous Location Cabinet Coolers or safe, quiet and efficient point of use compressed air products give us a call.   We would enjoy hearing from you.

Steve Harrison
Application Engineer
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