Tag: electronics cooler

Freon-based Air Conditioning Units or Cabinet Coolers for Electrical Panels

Published on by John BallLeave a comment
Whatever you do, DON’T do THIS to your panel.

These hot summer months can bring some elevated temperatures within electric control panels.  With freon-based coolers, higher ambient conditions make them less efficient; and opening the electrical panel to have a fan blow inside creates a dangerous electrical hazard.  For every 10oC rise above the operational temperature, the life of an electrical component is cut in half.  To reduce loss in productivity and premature equipment failures, it is important to keep your electrical mechanisms cool.  The EXAIR Cabinet Coolers are designed to do just that.

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

We receive many questions when it comes to panel cooling as the Vortex technology is relatively new in this area.  The main question is the comparison between the Cabinet Cooler System and the Freon-based A/C panel units.  In short, the Cabinet Coolers have no moving parts to wear, do not use Freon, and require no maintenance.  But they do require clean compressed air to operate.  The Freon-based A/C units do not use compressed air, and only need electricity to operate.  In this blog, I will cover a term to consider: Total Cost of Ownership.

What do I mean by Total Cost of Ownership?  I mean that you not only take into account energy use, but also other, very real issues of owning the system.  There are some significant financial impacts on the bottom line when one considers the need for using electrical Freon panel coolers.

Initial Unit Cost – The initial cost to acquire a vortex-style Cabinet Cooler is between 1/3 and ¼ the cost to acquire a Freon-based air conditioner system. And if we consider that a typical life span for a Freon-based cooling solution is 5 years, then the yearly cost is $500.00/year.  An EXAIR Cabinet Cooler system, by comparison, will have a 20-year life span as there are no moving parts to wear out. That makes for a yearly cost of $36.45 / year. Quite a large difference between the two. Also note that over the 20-year life of an EXAIR Cabinet Cooler, the Freon unit will have to be replaced four times. We’re not taking that into account for our calculations, but assuming the cost remains the same over that time.

Installation – Because it is so easy to install an EXAIR Cabinet Cooler system, the estimated time to install is only 1 hour. One small hole to mount the unit on the top of the panel and another hole to route the thermostat to the solenoid.  With some small amount of plumbing for the compressed air and cold air distribution kit, the extent of the installation is complete. Compare that to the estimated 3-hour minimum time in order to install a Freon-based solution. With this unit, it will come with very large cut-outs on the panel to allow for the airflow to process through.

Maintenance – In this comparison, we are stating that there are no maintenance or downtime requirements for EXAIR Cabinet Cooler systems. This is another area where the EXAIR Cabinet Coolers really pull ahead of the Freon-based solutions. Yes, there is some small amount of annual filter maintenance for the compressed air supply, but a quick washing and re-installation of the sintered bronze element, and you are back in business in a very short time.  The Freon-based solution, by comparison, will require a minimum of 4 hours per year (one time per quarter) for charging Freon (due to any leaks), cleaning and replacing filters, washing the condenser, and performing compressor checks. At an estimated $80.00/hour, that is $320.00 per year for labor plus any parts. 

Operations – Here we can compare the energy use.  If we use a simple estimate for the cost of compressed air at $0.25/1000 Standard Cubic Feet, then over the course of a year of operation, a vortex-style cooling solution will run about $338.00 / year to operate. For a comparable Freon-based cooling system, it will be about $56.38 / year to operate.  But with a Freon-based system, it will need to be oversized for ambient conditions over 95oF (35oC), which will make this more comparable. 

Electrical shutdowns are expensive and annoying, and if you do not maintain the Freon-based systems regularly, the shutdowns can occur often.  In showing the Total Cost of Ownership, it shows that the EXAIR Cabinet Coolers are a great purchase.  With no moving parts, Freon, or costly preventative maintenance required, they can operate for decades by keeping your electronics cool.  For our U.S. customers, we are offering a promotion.  You will receive a1104SS Super Air Nozzle, a $197.00 value, for free as a promotional item from now until the end of August 2026 with a qualified purchase.  How can you not give them a try?  If you have any questions about Cabinet Coolers or the Sizing Guide, you can contact an Application Engineer at EXAIR.  We will be happy to help you.  Remember whenever you make a purchase, you should always look at the Total Cost of Ownership to get the entire story. 

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

See the Difference: EXAIR Cabinet Cooler Performance on Thermal Camera

Published on by Jordan T ShouseLeave a comment

Heat inside electrical enclosures can lead to component failure, downtime, and inconsistent machine performance. In our latest video, we used a thermal camera to show how quickly an EXAIR Cabinet Cooler reduces temperatures inside a control panel.

Thermal imaging makes the results easy to see in real time. Hot spots across the enclosure begin cooling almost immediately once the Cabinet Cooler is activated, helping stabilize temperatures around critical electrical components.

The video highlights:

  • Rapid panel cooling
  • Reduction of hot spots
  • Consistent airflow across components
  • Cooling without pulling contaminated plant air into the enclosure

Unlike traditional fan cooling, the EXAIR Cabinet Cooler uses compressed air to cool the enclosure while maintaining positive pressure to help keep dust and debris out.

For facilities dealing with overheating VFDs, PLCs, or electrical panels, thermal imaging provides a clear look at how effective enclosure cooling can improve reliability and reduce downtime.

If you think a Cabinet Cooler will help your process, please reach out! I’m happy to help you get the right one selected and in service.

Jordan Shouse
Application Engineer
E: JordanShouse@exair.com
O: (513) 671‑3322
F: (513) 671‑3363
A: 11510 Goldcoast Dr Cincinnati OH 45249
www.exair.com

Find time on my calendar by scheduling a meeting here.

Hazardous Location Cabinet Coolers

Published on by jasonkirbyLeave a comment

HazLoc Cabinet Cooler Systems are engineered and certified for use in purged electrical enclosures within classified environments. These systems meet the requirements for Class I Division I, Groups A, B, C, and D, as well as Class II Division I Groups E, F, and G, and Class III areas. EXAIR’s HazLoc Cabinet Cooler Systems have passed extensive testing by UL, confirming their adherence to the stringent UL standards relevant to these specific environments.

Cabinet Cooler Systems provide a cost-effective and reliable method for cooling purged electric control panels across diverse settings. By employing Vortex Tube technology, these systems can produce cooling capacities of up to 5,600 BTU/Hr without the need for moving parts, making them a low-maintenance choice for cooling purged cabinets in hazardous locations.

EXAIR’s HazLoc Cabinet Cooler Systems stand out in the market due to their UL classification for Division I environments. These systems are designed for optimal efficiency with thermostatic controls and include UL-listed solenoids that are appropriate for hazardous locations. Engineered for easy installation on purged enclosures, EXAIR Cabinet Cooler Systems require minimal maintenance and are built to operate reliably under the most demanding industrial conditions.

EXAIR provides Hazardous Location Cabinet Cooler Systems in eight different cooling capacities, ranging from 1,000 BTU/Hr to 5,600 BTU/Hr. This extensive selection allows you to choose a system that best meets your cooling needs while reducing compressed air consumption. These systems effectively protect your electronic equipment from heat, dirt, and moisture, ensuring seamless operation of your processes. They serve as a cost-efficient alternative to bulky, high-maintenance coolant-based air conditioning systems and are designed for easy installation.

Components can fail, sensors may yield erroneous readings, controls might drift, and displays can become unreliable. EXAIR HazLoc Cabinet Coolers effectively mitigate these challenges, ensuring sustained productivity while avoiding expensive shutdowns and the replacement of components. Should you have any inquiries about HazLoc Cabinet Cooler Systems or any other EXAIR products, please feel free to contact us.

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

Beat the Heat: Why EXAIR Cabinet Coolers are the Ultimate Industrial Fix – (Cabinet Cooler Promo)

Published on by Al WooffittLeave a comment

As the mercury rises, industrial facilities face a familiar foe: heat-related downtime. When sensitive electronics and control panels overheat, production grinds to a halt—often at the most inconvenient times. While fans or traditional air conditioners might seem like the go-to solutions, they often bring their own headaches, like clogged filters or mechanical failures.

Enter EXAIR Cabinet Cooler Systems, a low-cost and highly reliable alternative that uses nothing but compressed air to keep your critical components running cool and clean. And now through the end of August, with the purchase of these systems, you will receive a free AC Sensor — Model 7929.

How They Work: The Power of the Vortex

At the heart of every EXAIR Cabinet Cooler is a Vortex Tube. This clever piece of engineering converts a standard supply of compressed air into two streams: one hot and one cold.

  • Cold Air Injection: The cold air is discharged directly into the cabinet through a distribution kit, creating a pressurized environment.
  • Contaminant Exclusion: Because the cabinet is slightly pressurized, outside air—along with its dust, dirt, and oil—can never get in.
  • Heat Exhaust: The warm air inside the cabinet is displaced and vented out through the cooler body, leaving your electronics in a clean, temperature-controlled environment.

Maintenance-Free Reliability

One of the biggest advantages of EXAIR’s design is what it doesn’t have. There are no moving parts to wear out, no filters to clog, and no refrigerants (like Freon) to leak.

  • Simple Installation: These units can be installed in minutes through a standard electrical knockout.
  • Long Lifespan: With a clean, dry supply of compressed air, these coolers can run for decades—some have even been tested to work perfectly after 20 years of service.

Smart Cooling with Thermostat Control

While the coolers are incredibly effective, using compressed air continuously can be expensive. To maximize efficiency, most systems include a Thermostat Control.

  • Automated Operation: The thermostat (factory set at 95°F) acts as an on/off switch, activating the cooler only when the temperature reaches critical levels.
  • Digital Precision: For even tighter control, Electronic Temperature Controls (ETC) are available to maintain a constant temperature with a digital LED display.

A Solution for Every Environment

No two facilities are the same, which is why EXAIR offers several ratings to match your specific needs:

  • NEMA 12 (IP54): For dust-tight, oil-tight indoor industrial environments.
  • NEMA 4 (IP66): For splash-resistant indoor or outdoor use.
  • NEMA 4X: Corrosion-resistant 303 or 316 stainless steel for food service or aggressive chemical settings.
  • Hazardous Locations (HazLoc/ATEX): Specifically designed and certified for explosive environments containing gases or dust.
  • High Temperature Models: Capable of providing relief in ambient temperatures reaching up to 200°F (93°C).
Both the HazLoc (left) and ATEX Cabinet Cooler Systems are available from stock in NEMA 4 and NEMA 4X ratings.

Stop the Shutdowns

Don’t wait for a 100°F day to realize your cooling is insufficient. You can use the Cabinet Cooler System Calculator on EXAIR’s website to find the exact cooling capacity you need, with models ranging from 275 to 5,600 Btu/hr.

Al Wooffitt
Application Engineer

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