Tag: compressed air cabinet cooler

Should You Switch? Freon A/C vs. EXAIR Cabinet Coolers for Industrial Enclosures

Published on by Neal RakerLeave a comment

Electrical panels are the brains of your production line. When they overheat, components trip, machines stop, and downtime costs start ticking away.

To keep these sensitive PLCs and VFDs cool, plants typically rely on traditional Freon-based air conditioners. But is a bulky, mechanical A/C unit actually the best choice for your specific environment?

Let’s look past the initial price tag and run through a quick diagnostic checklist to determine if you should make the switch to an EXAIR Cabinet Cooler.

The 4-Question Diagnostic Checklist

Answer the following questions about your factory floor to see which technology fits best:

1. What does the air look like around your enclosures?

  • A) Clean and controlled ambient environment. Standard temperature, low dust, no airborne oil mist.
  • B) Harsh and dirty. Flour dust, metal shavings, lint, slurry, or heavy ambient oil mist. Uncontrolled shop temperatures.

2. How much physical vibration or shock does the panel experience?

  • A) Minimal. The panel is isolated on a concrete floor or far away from heavy machinery.
  • B) Significant. The panel is mounted directly to a stamping press, vibrating conveyor, or heavy CNC machine. Lots of vibration and/or shock loading.

3. How often does your team perform preventative maintenance on electronics?

  • A) Regularly. We have dedicated HVAC technicians or maintenance shifts with time to clean filters and coils weekly.
  • B) Rarely. We are short-staffed; maintenance is reactive, and filters only get changed when something breaks.

4. What is your primary financial bottleneck?

  • A) Monthly utility bills. We monitor direct electrical consumption aggressively.
  • B) Unscheduled downtime and CapEx budget. A single hour of unexpected line stoppage costs us thousands, and upfront equipment budgets are tight.

Should You Switch?

If you answered mostly A’s: Stick with Freon A/C

If your factory floor mirrors a clean room, experiences zero vibration, and you have the staff to clean filters constantly, a traditional Freon A/C unit makes sense. It is highly efficient at pulling direct electricity to drive a closed refrigeration cycle, making it cost-effective from a pure utility perspective in mild environments.

If you answered mostly B’s: You Should Switch to EXAIR

If your environment is tough, dirty, or vibrating, a Freon system is a ticking time bomb. You should switch to a Cabinet Cooler immediately for three core reasons:

  • Zero Moving Parts: Traditional A/C units rely on compressors, fans, and evaporators that fail under constant industrial vibration. EXAIR Cabinet Coolers utilize a vortex tube to turn compressed air into cold air with zero moving parts. Nothing to wear out, nothing to break.
  • The “Dirty Filter” Trap: In dusty or oily plants, Freon condenser coils clog fast. When they clog, the unit stops cooling, the panel trips, and your line goes down. EXAIR systems maintain a slight positive pressure inside the cabinet, constantly purging dirty ambient air out of the panel, keeping it clean while cooling it.
  • Drastic Maintenance Reduction: Instead of paying for certified HVAC technicians, reclaiming refrigerant, and degreasing coils, the only maintenance an EXAIR system requires is replacing a simple compressed air filter element a couple of times a year.

The True Cost Breakdown (1,700 BTU/hr. System)

Many plant managers hesitate to switch because compressed air is an expensive utility. However, when you look at the Total Cost of Ownership (TCO) over the lifetime of the hardware, the math shifts dramatically:

Cost ElementFreon Air ConditionerEXAIR Cabinet Cooler System
Initial Purchase Cost~$2,500.00 (Lasts ~3-5 years)~$750.00 (Lasts 15-20 years)
Amortized Hardware/Year$500.00 / yr$37.50 / yr
Annual Maintenance & Parts~$320.00 / yr (Coil cleaning/filters)~$0.00 (Standard filter changes)
Annual Utility/Energy Cost~$56.00 / yr (Direct electricity)~$338.00 / yr (With thermostat control)
Total Annualized TCO$924.00 / year$379.50 / year

Pro-Tip for Maximum Efficiency: To keep your compressed air costs low, never run a Cabinet Cooler continuously. Always use an EXAIR Thermostat and Solenoid Valve kit. This ensures the cooler only consumes air when the internal panel temperature ticks past a safe threshold (like 95°F), cutting air consumption by up to 70%.

Ready to stop dealing with failed panel A/C units?

Don’t wait for the heat of summer to trip your critical control panels. You can absolutely be proactive about mitigating heat. Review EXAIR’s Cabinet Cooler Calculator to size the exact BTU/hr. unit your panel needs. You can also speak directly with an application engineer to make the switch. Give us a call today or schedule a meeting with one of our Application Engineers who can walk you through the sizing and selection process in just a few minutes.

Neal Raker, Application Engineering / International Sales Manager
nealraker@exair.com

The Cost Of Cooling Electrical Panels

Published on by Russ BowmanLeave a comment

Heat, dirt, and moisture are natural enemies of electrical and electronic gear. Dirt and moisture are relatively easy to eliminate as dangers: just seal up the enclosure so they can’t get in. Heat, though, is a real “apex predator.” Whether the enclosure is sealed or not, the components inside will generate heat if they’re energized. And no matter what, the enclosure will get as hot as its surroundings in time, as long as the Second Law of Thermodynamics is in effect (spoiler alert: it’s immutable.)

So how do you keep the components in those panels cool? If the environment is clean enough and the temperature and humidity aren’t too high, fans can circulate cooling air from the environment through the panel. These are readily commercially available starting under $100.00, and generally won’t cost any more than about $50.00 a year in operating costs (electricity). If the environment is climate controlled and relatively free of contaminants, you can’t beat them. If you’re on a desktop computer, and it hasn’t burned out, there’s your proof.

Many, if not most, industrial panels, though, are in areas where fan cooling just won’t cut it. Not only will those aforementioned natural enemies like dirt & moisture be allowed in, they’ll be DRAGGED in. Luckily, modern technology presents us with a number of options, depending on the particulars of the environment. The following are some details on “the usual suspects”, and a table with total cost of ownership:

Panel air conditioners work on the refrigerant cycle and are capable of the highest cooling capacities of the methods detailed here. They’re also the most expensive, with a typical annual cost of over $1,100.00.

Aside from the high cost, they can be maintenance intensive and prone to failure, especially in dirty or oily environments. Their cooling capacity is also adversely affected by higher ambient temperatures.

Air-to-air heat exchangers transfer heat continuously through a sealed, hollow tube by vaporizing and condensing a refrigerant-type fluid. Instead of using compressors with electric motors and other mechanical components with lots of moving parts, they rely on capillary action to effect the phase changes. They can’t cool below ambient temperature, but they are the least expensive of these, coming in at around $370.00 in annual cost.

*Hot air (inside the panel) causes refrigerant in heat pipe to flash to a gas.
*Cold air (from the environment) causes the refrigerant to condense to a liquid.

Liquid-to-air heat exchangers work an awful lot like a car radiator: they circulate liquid (usually a water/glycol mix, like anti-freeze) through a heat exchanger/heat sink inside the panel and then through a heat exchanger outside the panel. Like the fan and refrigerant-based coolers, their cooling performance drops as the ambient temperature rises, except for the ones that use chilled water. In facilities that already have chilled water, that might not be a big deal, but if you need one that comes with the chiller, they can get pretty expensive. And, you still have the maintenance & durability issues that come with any refrigerant-operated cooler. Liquid-to-air systems can run as low as ~$425.00 a year in total cost, for the ones that don’t need chilled water.

Thermoelectric coolers use the Peltier effect: when voltage is applied to two electrodes connected to a semiconductor, heat is transferred from one side to the other. Their compact design with no moving parts makes them popular for high-performance gaming computers (like the one my son spends WAY too much time on), small coolers (wine experts like them because they don’t cause any vibration which can affect the wine’s quality), and certain lab, medical, and laser cooling equipment. They have a limited cooling capacity, and because electric current generates heat, that gets added to the overall heat dissipation. The annual cost for these is around $950.00.

EXAIR Cabinet Cooler Systems can be installed in minutes, have no moving parts to wear, no electric motors to burn out, aren’t affected by environmental contaminants or humidity. In fact, of all the methods available for panel cooling, they have the widest range of where they can be used:

They do require an adequate supply of compressed air, which makes up the bulk of their total cost of ownership, which is around $410.00 a year.

I’ve mentioned cost of ownership several times, so I had better get to what that means: it’s the cost of the equipment itself and installation (spread across the effective life of the equipment), plus the annual maintenance & operating costs. Here’s a table with a comparison of the panel cooling options above:

If you have electrical or electronic panels that need heat protection RIGHT NOW, we can help. ALL of our systems are in stock and available for same-day shipment. We can even help out with determining which one is right for your needs with the information from our Sizing Guide, or you can do it yourself with our online calculator. If you want some help with it, give me a call.

Russ Bowman, CCASS

Application Engineer
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ATEX Cabinet Coolers for Dependable Heat Protection in Explosive Areas.

Published on by jasonkirbyLeave a comment

EXAIR Cabinet Cooler Systems have been delivering dependable heat protection for electrical and electronic panels for many years. These systems feature no moving parts or electrical components that can fail, ensuring a long lifespan as long as they are supplied with clean, moisture-free compressed air. This design allows them to function nearly indefinitely without the need for maintenance.

EXAIR’s ATEX Cabinet Cooler® Systems provide an effective and cost-efficient solution for maintaining optimal temperatures in electrical enclosures located in hazardous ATEX classified environments. Now offered in robust aluminum construction, these coolers are specifically designed for use in Zones 2 and 22. They have undergone UL testing, are CE compliant, and adhere to rigorous ATEX standards for purged and pressurized enclosures.

ATEX Cabinet Coolers, with cooling capacities reaching up to 5,600 BTU/Hr., are specifically designed to prevent overheating in electrical cabinets located in explosive environments. These systems are suitable for a variety of applications, including industrial control panels, specialized electrical enclosures, and sensitive electronics in hazardous areas, ensuring that your equipment remains cool, safe, and fully operational. The ATEX Cabinet Cooler is easy to install, fitting through a standard electrical knockout while maintaining NEMA 4 integrity in challenging conditions. Additionally, optional thermostat controls help minimize compressed air consumption, and cold air distribution kits promote uniform cooling throughout the cabinet.

EXAIR offers a comprehensive lineup of Cabinet Cooler Systems for NEMA 12, 4, 4X, hazardous location and ATEX applications. Built with no moving parts, every system is CE compliant, UL-listed, and designed for long-term reliability in the most challenging conditions. From control panels and motor centers to laser housings and surveillance equipment, EXAIR Cabinet Coolers protect your investments and keep your operations running smoothly. Prices start at $1,615.

If you have questions about the ATEX Cabinet Coolers, or anything regarding EXAIR and our products, please do not hesitate to reach out.

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk

Protecting Electrical Enclosures Safely and Reliably with Cabinet Cooler Systems

Published on by Russ BowmanLeave a comment

As summer temperatures increase, so does the volume of calls we get about Cabinet Cooler Systems. A typical call goes something like this:

“One of our control panels has a drive in it that’s overheating. If it goes down, so does the whole line. How soon can I get a Cabinet Cooler System?”

All of our Cabinet Cooler Systems — including the UL Classified HazLoc and ATEX models — are in stock and available for same day shipment.

“Great! How do I get one?”

With just a few key pieces of information, I can quickly and accurately calculate the heat load of your panel, and specify the right Cabinet Cooler System. You can input that information into our Sizing Guide online, or you can call me. It only takes a minute to do the calculations, and we do it over the phone all the time. Here’s what we need to know:

  • Panel dimensions: Grab your favorite tape measure & write down the height, width, and depth of the panel. We’ll calculate the heat transfer surface area from that.
  • Current internal & external air temperatures: Take a thermometer to where the panel is. Write down what it reads when you get there — that’ll be the ‘external’. Then, put it inside the panel, and write down what it reads after a few minutes — that’ll be the ‘internal.’ We use those to calculate the internal heat load — how much heat is being generated by the components inside the panel.
    • Optional: if you have accurate heat dissipation data for the housed components, we can use that instead of the temperatures. This is how we do it if the panel isn’t currently in operation.
    • Important note: if we ARE using temperatures, it’s important to measure the AIR temperatures, as opposed to using a heat gun to ‘shoot’ the surface temperature of a component. The formulas we use are based on tried-and-true HVAC formulas, and we’ve been proving their accuracy for decades.
  • Maximum external air temperature: How hot does it get on the hottest day of summer? We’ll use that to calculate the external heat load — how much heat the panel absorbs from the environment.
  • Desired internal air temperature: Many electrical/electronic component manufacturers specify a maximum operating temperature of 104°F (40°F), so the ‘industry standard’ in panel cooling is to maintain an internal air temperature of 95°F (35°C), so that’s where we pre-set our Thermostats. If you know for a fact that the components inside your panel need a cooler environment to operate in, the Thermostats can be reset. Keep in mind, we may need to provide a Cabinet Cooler System with a higher cooling capacity in those cases. Or, if you know for a fact that your equipment can handle a higher operating temperature, the Thermostats can be adjusted…and you can save on your compressed air usage.

If there are fans circulating outside air through the panel, we’ll need to know about them too. They’re providing a finite (sometimes substantial) amount of cooling, and they’ll have to be removed, and their holes covered, for proper operation of the Cabinet Cooler System. If not, that’s like running your air conditioner with a fan in the window.

The other considerations are all about where the panel is, and what it’s exposed to:

  • NEMA ratings are all about keeping the environment out of the panel:
    • NEMA 12: Oil tight, dust tight, indoor duty
    • NEMA 4: All that, and splash resistant, indoor/outdoor duty
    • NEMA 4X: All that, and stainless steel construction for corrosion resistance.
  • If it’s a UL or ATEX Classified area, we have systems for that:
    • HazLoc systems are UL Class I Div 1, Class II Div 1, and Class III rated.
    • ATEX systems are rated for use in ATEX Zones 2 & 22.

If you have an electrical or electronic panel that needs reliable, durable heat protection, you might need an EXAIR Cabinet Cooler System. To find out more, give me a call.

Russ Bowman, CCASS

Application Engineer
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