Category: Cabinet Cooler

Rule #1 – Always Look Cool

Published on by Brian FarnoLeave a comment

The past two weeks here in Cincinnati have reminded me just what humidity is all about. While the static charge in my garage at home is at an all-time low, the humidity is enough to make me wish I had gills to breathe. Even rucking before work has become a rather sweaty event. When I am rucking, one of the 4 Rules of Rucking is, #1 Always Look Cool. This is an idiom as in don’t let people see you sweat. If you are stressed, just stay cool, keep a level head and look the part. A good pair of aviators always helps to hide what your eyes can’t.

Then I open my garage fridge, because every Midwesterner has their old kitchen fridge in the garage, right? Grab a nice cold aluminum can out. And before I can put it in a thermal insulating housing, I see the condensation of the humidity forming on the aluminum. This makes me think of some of the electrical panels I encountered during my time in machine shops.

I once approached a vertical machining center whose spindle chiller, with a thermo-couple failure, had been cooling the spindle continuously during the summer months. This spindle looked like the ice-cold aluminum can I had sitting out on my workbench yesterday. Fully covered in condensate from the humidity in the air. Condensate collected on an aluminum can and leaving a ring of water on a workbench is one thing. Water running down a high-speed spindle and causing issues with a dry machining process is another. This also reminded me of a recent call where a new customer wanted help sizing a Cabinet Cooler System to replace an air-to-air heat exchanger that had failed. When walking through the information needed to size the panel, I reached the Internal Temp Desired field, and there was a pause. While I thought maybe they were checking their notes, they came back with 72°F. I wrote down the value on my notepad, then asked, “That’s oddly specific. Is there a piece of equipment that alarms out over 72°F that we are trying to protect?” The response I received was no. So I asked what the need was for this low set point.

I dug further with them, and it turned out that’s what they kept the engineers’ office set for in the summer, so they thought my question was odd and figured, if they are comfortable there and their computer on their desk operates well, then it must be a good temperature. This is not an incorrect statement. The control cabinet for the machine would operate just fine at 72°F; however, all the electronics that were in the panel were rated up to 104°F before they overheat, so it doesn’t quite make sense to extend the cooling capacity needed to reach that 72°F requested set point. Once we talked this over, we settled on the standard of 95°F for the internal set point with the understanding that by using a thermostatically controlled system, they could adjust it down lower if they really wanted to. In the end, we saved them some energy by sizing the Cabinet Cooler System to meet the demands of their industrial electronics, not what makes a person feel comfortable.

This isn’t always the case; occasionally, there is a panel that requires a low maximum temperature in order to keep a critical piece of equipment stable. This is why we ask the questions to validate any concerns with the data we are viewing as Application Engineers. This is also why we have built in a number of warnings/alerts on our Online Cabinet Cooler Sizing Calculator.

If you have a panel that needs to be cooled, the online calculator has fields for all the information we need. If you want to walk through the math behind the calculator and talk through the reasons we ask for the information that we do, you can either call, email, or even live chat with an Application Engineer, and we will gladly walk you through our process and the math to determine which Cabinet Cooler System is right for your needs.

Brian Farno, MBA – CCASS Application Engineer

BrianFarno@EXAIR.com
@EXAIR_BF

Who Wants to Save on Compressed Air?

Published on by Al WooffittLeave a comment

At EXAIR we pride ourselves on helping our customers optimize their compressed air usage. Our intelligent compressed air products are engineered to be quiet and efficient, saving you on compressed air consumption. This is just one of the six steps that we recommend in order to optimize your compressed air system.

The first step we would recommend is to measure your air consumption. If you are going to attempt to reduce air consumption in your facility, it is necessary to know what is using it. If you know the consumption of your compressed air-operated products, you can make note of this. A more comprehensive solution would be to install some of our Digital Flowmeters in branch lines in your facility. The flow data provided by this will help you narrow down the high consumption areas and processes.

The second step we would suggest is to find and fix leaks. Our Ultrasonic Leak Detector is perfect for this. According to the Compressed Air and Gas Institute, leaks should not exceed 5-10% of your system’s air supply (we would obviously want 0%, but realistically this is unachievable). However, it is not uncommon to see leaks account for over 30% of many facilities’ compressed air supply being lost through leakage. That’s a potential for a 25% gain in compressed air supply!

The third step would be to upgrade your blowoff, cooling and drying operations using engineered compressed air products. All of EXAIR’s products, like our Super Air Knives, or Super Air Nozzles, are designed with efficiency in mind. Upgrading to an efficient EXAIR product is going to reduce your consumption, sometimes dramatically so!

The fourth step is to turn off your compressed air when not in use. This may sound obvious, but it is not uncommon for compressed air products to be left running continuously. We offer many solutions here, from a simple ball valve (found in many of our Drum Vac Kits), to a solenoid valve (found in our Cabinet Cooler Systems), to our Electronic Flow Controllers – combining a solenoid valve and photoelectric sensor.

The fifth step would be to use intermediate storage near the point of use. If you are controlling your compressed air usage through the use of valves and controls, then your consumption won’t be constant. This fluctuation in demand can be evened out with the use of secondary storage, like our Model 9500-60 Receiver Tank. This will ensure you have the volume and pressure when and where you need it.

Finally, our sixth step is to control the operating pressure. More specifically, to reduce the pressure to the minimum required to get the job done. Simply installing a pressure regulator at the point of use will lead to big savings.

If you would like to start optimizing your compressed air system, then give me a call!

Al Wooffitt
Application Engineer

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Keep Your Electronics Cool with EXAIR’s Cabinet Coolers: Cabinet Cooler® System Calculator

Published on by Jordan T ShouseLeave a comment

In today’s fast-paced industrial world, maintaining the performance and longevity of electronic equipment is crucial. Overheating electrical enclosures can lead to costly downtime, and premature component failure. Fortunately, EXAIR offers a reliable, efficient, and innovative solution with their Cabinet Cooler Systems. Paired with their intuitive Cabinet Cooler System Calculator, choosing the right cooling solution has never been easier. Let’s dive into what makes EXAIR Cabinet Coolers stand out and how the system calculator simplifies the selection process.

From right to left: Small NEMA 12, Large NEMA 12, Large NEMA 4X

EXAIR Cabinet Coolers are compressed air-powered cooling systems designed to keep electrical enclosures at optimal temperatures, even in the harshest environments. Unlike traditional air conditioners that rely on refrigerants and moving parts, these coolers use vortex tube technology to generate cold air from compressed air. This means no Freon, no maintenance headaches, and no risk of mechanical breakdowns—perfect for industries where reliability is non-negotiable.

Available in a variety of models, EXAIR Cabinet Coolers cater to different needs:

  • NEMA 12: Ideal for dust-tight, oil-tight indoor environments.
  • NEMA 4: Built for splash-resistant, indoor/outdoor use.
  • NEMA 4X: Corrosion-resistant stainless steel for food service or harsh settings.
  • Hazardous Location Models: Certified for explosive environments like Class I, II, or III areas.
  • ATEX:  Electrical enclosures located in ATEX Zones 2 and 22, for hazardous gases and dust.

Cooling capacities range from 275 Btu/hr for small panels to 5,600 Btu/hr for larger enclosures, with options for continuous operation or thermostat-controlled systems to save on air usage. Plus, they’re UL-listed, CE-compliant, and easy to install—typically in under an hour through a standard electrical knockout.

Launched as a do-it-yourself solution, the Cabinet Cooler System Calculator is a free, web-based tool available on EXAIR’s website under the Knowledge Base’s Calculator Library. It’s designed to provide instant feedback on the exact model you need, saving time and ensuring accuracy. Here’s how it works:

  1. Input Basic Information: Enter details like:
    • Enclosure dimensions (height, width, depth).
    • Current internal and external temperatures.
    • Maximum external temperature expected.
    • Desired internal temperature (typically 95°F for most electronics).
    • NEMA rating required.
    • Compressed air supply details (pressure and temperature).
  2. Heat Load Calculation: The calculator computes the internal heat load (from electronics inefficiency) and external heat load (from ambient conditions), factoring in variables like solar heat gain if applicable.
  3. Model Recommendation: Within seconds, it spits out the precise Cabinet Cooler model number—complete with cooling capacity in Btu/hr—and a link to learn more or order online.

Before the calculator, you’d fill out a Cabinet Cooler Sizing Guide and wait up to 24 hours for a recommendation. While that process still works (and EXAIR’s team responds promptly), the calculator delivers results in under 5 minutes. It’s perfect for engineers who want quick answers or companies facing urgent overheating issues. Plus, it’s packed with EXAIR’s decades of expertise, ensuring the recommendation compensates for non-optimal conditions like high air temperatures or low pressure.

In keeping with the understanding that we want to take your pain away quickly, not only can you get a recommendation for the right Cabinet Cooler system quickly, but we also keep all of our cataloged models on the shelf, ready for immediate delivery to your facility as quickly as the next day. Our customers have up until 2:00 p.m. Eastern time to get a recommendation and get an order in with us to be delivered the next day if the situation demands it.

EXAIR Cabinet Coolers are a proven, cost-effective way to protect your electrical enclosures from heat-related chaos. Paired with the Cabinet Cooler System Calculator, you’ve got a powerful duo that makes cooling simple, fast, and precise. No more guessing, no more delays—just cold air where and when you need it.

Ready to cool things down? Head to EXAIR.com, plug your specs into the calculator, and see the difference for yourself. Your electronics—and your bottom line—will thank you.

Jordan Shouse, CCASS

Application Engineer

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Choosing the Right EXAIR Cabinet Cooler System

Published on by Jordan T ShouseLeave a comment

EXAIR Cabinet Coolers are compressed air-powered systems that use vortex tube technology to deliver cold air into sealed enclosures, preventing overheating without refrigerants or moving parts. They’re durable, easy to install, and designed for various environments, making them a cost-effective alternative to traditional air conditioners or heat exchangers. Key benefits include:

  • No moving parts: Virtually maintenance-free with a long lifespan.
  • Compact design: Installs in minutes through a standard electrical knockout.
  • Environmental resistance: Available in NEMA 12, 4, 4X, and Hazardous Location ratings.
  • Energy efficiency: Thermostat-controlled systems minimize compressed air use.

To ensure you select the right model, follow these steps.

First Calculate the Heat Load

The total heat load includes:

  • External heat load: Heat transferred from the ambient environment, based on enclosure surface area and the temperature differential (ΔT) between external and desired internal temperatures.
  • Internal heat load: Heat generated by components inside the enclosure.
  • Solar heat load (if applicable): For outdoor enclosures exposed to sunlight, factor in heat absorption based on the enclosure’s color (darker colors absorb more heat).
  • Existing Cooling Devices: If fans are currently used, note their diameter or airflow (CFM) to account for the heat they remove, as these openings must be sealed when installing a Cabinet Cooler.

EXAIR’s Cabinet Cooler System Calculator simplifies this process. Enter your data online for an instant model recommendation, or submit the Sizing Guide to an EXAIR Application Engineer for assistance. For quick calculations, you can call EXAIR at 1-800-903-9247, and an engineer can estimate the heat load in minutes.

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

Second, select the Appropriate NEMA Rating

EXAIR Cabinet Coolers are designed to maintain the environmental integrity of your enclosure, with models available for different conditions. Choose a NEMA rating based on your application’s environment:

  • NEMA 12 (IP54): For indoor use, protecting against dust and oil. Ideal for general factory settings.
  • NEMA 4 (IP66): For indoor or outdoor use, offering dust, oil, and splash resistance. Suitable for wash-down areas or wet environments.
  • NEMA 4X (IP66): Same as NEMA 4 but made of corrosion-resistant stainless steel (Type 303 or 316). Perfect for food processing, pharmaceutical, or corrosive environments.
  • Hazardous Location (HazLoc): UL Classified for Class I Div 1, Class II Div 1, or Class III areas or ATEX Zones 2 & 22. Used in environments with explosive gases or dust, such as chemical plants or coal facilities. Must be paired with a purge and pressurization system.
  • High Temperature: For ambient temperatures of up to 200°F (93°C), such as near furnaces or in desert climates.

Ensure the Cabinet Cooler’s NEMA rating matches or exceeds your enclosure’s rating to maintain its integrity. For example, a NEMA 4X enclosure requires a NEMA 4X Cabinet Cooler.

From right to left: Small NEMA 12, Large NEMA 12, Large NEMA 4X

Third, choose the Operating System

EXAIR offers two operating modes to suit different cooling needs:

  • Thermostat-Controlled Systems: These are the most energy-efficient option, using a thermostat and solenoid valve to activate cooling only when the internal temperature exceeds the setpoint (preset at 95°F but adjustable). Includes a filter, cold air distribution kit, and solenoid valve (available in 120Vac, 240Vac, or 24Vdc). Ideal for enclosures with fluctuating heat loads or seasonal temperature changes.
  • Continuous Operating Systems: Provide constant cooling and positive pressure to keep out dust and debris. Best for applications requiring uninterrupted cooling or in extremely dirty environments. Includes a filter and cold air distribution kit.

For precise temperature control, consider adding an Electronic Temperature Control (ETC), which offers digital monitoring and easy temperature adjustments, especially useful in sensitive applications like pharmaceutical plants.

Fourth, Consider Additional Options

EXAIR provides accessories and features to tailor the Cabinet Cooler to your needs:

  • Non-Hazardous Purge (NHP): Delivers a 1 SCFM airflow to maintain positive pressure when cooling isn’t needed, keeping dust and debris out of the enclosure.
  • Side Mount Kits: Allow installation on the side of the enclosure if top mounting isn’t feasible due to space constraints for the NEMA 4 and 4X coolers.
  • High-Temperature Models: Designed for ambient temperatures between 125°F and 200°F (52°C–93°C).
  • Material Options: Standard models use aluminum, while NEMA 4X models offer Type 303 or 316 stainless steel for corrosion resistance.
  • Voltage Options: Solenoid valves for thermostat-controlled systems are available in 120Vac, 240Vac, or 24Vdc to match your electrical setup.

Final Tips for Success

  • Act Early: Install a Cabinet Cooler before heat-related failures occur, especially in summer or high-temperature environments.
  • Plan for Installation: Ensure all enclosure openings (e.g., fan vents) are sealed to maintain positive pressure and prevent contamination.
  • Monitor Performance: Use the ETC for real-time temperature monitoring in critical applications.
Inside, outdoors, high temperature, dirt/dust/humidity, corrosive and classified environments are no problem for EXAIR Cabinet Cooler Systems

Choosing the right EXAIR Cabinet Cooler involves calculating your heat load, selecting the appropriate NEMA rating, deciding between thermostat-controlled or continuous operation, and ensuring a reliable compressed air supply. By using EXAIR’s Sizing Guide or Calculator and consulting with myself or any one of our Application Engineers, you can confidently select a system that protects your electronics, minimizes downtime, and saves on maintenance costs.

Ready to cool your enclosures? Visit EXAIR.com to explore Cabinet Cooler options, use the Cabinet Cooler System Calculator, or contact an Application Engineer at 1-800-903-9247. Keep your electronics cool and your operations running smoothly with a EXAIR Cabinet cooler system.

Jordan Shouse, CCASS

Application Engineer

Send me an email
Find us on the Web 
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Twitter: @EXAIR_JS