Tag: electronics cooler

EXAIR Cabinet Coolers for Cooling Motor Control Centers

Published on by John BallLeave a comment

Motor Control Centers, or MCCs, are designed to protect motors and equipment in a single enclosure.  They help to start/stop electrical motors as well as protect them from over-voltage.  MCCs are used in many types of industries, like manufacturing plants, the oil and gas industry, water treatment facilities, and power generation companies. They are crucial for controlling pumps, compressors, fans, and other equipment powered by electric motors.  They can improve the efficiency of motors, increase safety, monitor the system for faults, and reduce down-time. 

A customer contacted me about their MCC as they were overheating.  They contained twelve direct starters to control 15KW motors.  The A/C panel cooler that they were using failed due to corrosion in the heat exchangers.  They wanted to try something different and more reliable as it was costly for replacement units.  Also, the shutdowns caused a loss in productivity.  They contacted EXAIR to see if we could help with our Cabinet Cooler Systems. 

EXAIR NEMA Type 4/4X Cabinet Cooler System

Cabinet Coolers are powered by an EXAIR Vortex Tube which only uses clean dry compressed air to generate cold air.  This phenomenon does not have any moving parts, no Freon to leak, or refrigerant compressors to fail.  So, they are very reliable for a long time.  We offer cooling capacities ranging from 275 BTU/hr (80 Watts) up to 5,600 BTU/hr (1,641 Watts) with different NEMA (IP) ratings.  These simple, but effective, cooling devices can be used in the toughest of environments.  They can quickly be installed and start cooling your electrical components in less than an hour. 

For the company above, they needed corrosion resistance to protect against the salty air from the sea.  EXAIR offers Cabinet Coolers in both 303SS and 316SS with NEMA 4X (IP66) protection.  They opted to get the highest corrosion resistance, which was 316SS.  They sent a list of electrical components inside, and I was able to calculate the internal heat load.  EXAIR has other methods to determine heat loads, like with our Cabinet Cooler Sizing Guide and Cabinet Cooler System Calculator.  I gathered some additional information about maximum temperatures, panel sizes, and external heat loads, and I was able to recommend a model 4880SS-316-240 Dual Cabinet Cooler System. 

This system includes a 316SS Cabinet Cooler that produces 5,600 BTU/hr (1,641 Watts) of cooling, NEMA 4X protection, a filter, a cold air distribution kit, a thermostat, and a 240Vac solenoid valve to turn off compressed air when cooling is not required.  Instead of replacing the A/C unit with another unit that would fail, they removed it and started using the EXAIR Cabinet Cooler System.  The ease of installation and temperature consistency made the company and maintenance crew very happy. 

EXAIR offers a variety of protection, materials, and hazardous and non-hazardous units in stock for quick delivery.  For our U.S. customers, we are offering a promotion.  You will receive an AC Sensor, a $76.00 value, for free as a promotional item from now until the end of August 2025 with qualified purchases.  How can you not give them a try?  If you are having trouble with electrical components over-heating, you can contact an Application Engineer at EXAIR.  The company above Motor Control Centers was glad that they did.

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

Cabinet Coolers: How to Determine Heat Loads

Published on by John BallLeave a comment

As the weather starts warming up, electrical panels will start to feel the “heat”.  Freon-based coolers can be less effective in higher ambient conditions; and opening the electrical panels to have a fan blow inside creates a dangerous hazard.  The circuit industry states that for every 10oC rise above the operational temperature, the life of an electrical component is cut in half.  To reduce premature equipment failures and loss in production, it is important to keep electrical components cool.  The EXAIR Cabinet Cooler Systems are designed to do just that. 

To find the correct type and size, we need some information about your electrical panel.  EXAIR makes it easy with the Cabinet Cooler Sizing Guide.  This sheet goes over the important details to find heat loads, proper NEMA type, and options for easy installation.  With a filled-out form, we can make sure that the correct model is recommended.  First, we have to start with the surface area of the electrical panel.  From here, we can do some heat load calculations to compare it with the proper cooling capacity. 

To properly reduce the temperature internally, we need to calculate how much heat is being generated.  Heat loads come from four main areas; internal, external, fan, and solar.  From these four, we can add them together to get the total heat load.  So, on the hottest day of the hottest month, the EXAIR Cabinet Cooler System will still keep your electronics cool.  Here are some methods to find the information needed for heat load calculations.

Internal Heat Load:  The internal load is the heat generated from inside the electrical panel.  This heat is produced by the inefficiencies of electrical devices.  There are two main ways that we can figure out the internal heat load.

Step A: The simplest way is by hanging a piece of metal like a washer inside the panel for about 15 minutes.  We can get an average temperature inside.  In the sizing guide, you can mark the temperature next to “Internal temperature now”.  To calculate the heat load, we will also need the external temperature at the same time as you measured the piece of metal.  This temperature difference can determine the internal heat load per surface area of the panel.  See the chart below.

Step B:  if you know the electrical components inside that generate heat, a list can be made with volt/amp ratings, or watts.  This is very useful for new panels.  The major devices would be VFDs (Variable Frequency Drives), power supplies, UPS, transformers, thyristors, etc.  We can calculate the inefficiency of the electrical components which will give us the internal heat load. 

External Heat Load:  To keep the electronics cool on the hottest day, we will need to know the highest external temperature that the panel will see.  This can include the temperature that is near an oven.  This can be marked in the Max External Air Temperature Possible.  We can compare this to the Max Internal Air Temperature Desired.  Most electrical components are designed to operate at 95oF (35oC).   With the same chart as above, you can use the temperature difference to determine the external heat load per surface area of the panel.

Panel Fans:  To control the environment inside the electrical panels, we need to block all openings and vents.  And this will include removing panel fans.  The Cabinet Cooler System will blow dry cold air to push out the hot humid air from the electrical panel back through the Cabinet Cooler.  Since we are removing a “poor” cooling device like the panel fan, we still need to add this to the heat that is being removed.  You can either give the diameter of the fan or the flow of the fan. 

Solar Heat Load:  The solar heat is only needed if the panel is located outside without cover and exposed to sunlight.  For this type of heat load, we will need to know the color of the electrical panel.  Lighter colors will not absorb as much heat as darker colors.

EXAIR makes it easy to help correctly size the Cabinet Cooler.  We have the Cabinet Cooler Sizing Guide which you can submit to the Application Engineers to review.  And we have released the Cabinet Cooler System Calculator.  It will give you a quick recommendation to order online.  For our U.S. and Canadian customers, you will receive an AC Sensor for free, a $76.00 value, as a promotional item from now until the end of August 2025 with qualified purchases.  How can you not give them a try?  If you have any questions about Cabinet Coolers, the Sizing Guide or Calculator, you can contact an Application Engineer at EXAIR.  We will be happy to help you to keep your machines operating.

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

ATEX Cabinet Cooler Systems Approved for Zone 2/22 Areas

Published on by John BallLeave a comment

EXAIR’s ATEX Cabinet Cooler® Systems deliver a powerful and affordable solution for keeping electrical enclosures cool in hazardous ATEX classified areas.  Engineered for use in Zones 2 and 22, these coolers are UL-tested, CE compliant, and meet stringent ATEX standards for purged and pressurized enclosures. 

As an overview, the ATEX Cabinet Coolers will require a purge and vent system on the electrical panel to keep their certification.  The purge system is designed to “flush” clean air inside the panel to remove any vapor or dust to produce a non-hazardous area prior to allowing electrical operations.  The maximum pressure is 8.6 bar, the maximum inlet air temperature is 45oC, and we stock cooling capacities from 1,000 BTU/hr to 5,600 BTU/hr (293 Watts to 1,642 Watts) in aluminum, 303SS, and 316SS materials.

We laser mark the ATEX number on the Cabinet Cooler for easy reference.  The ATEX nomenclature falls under the EN/IEC 60079-2 international standard for explosive zones.  It covers three zones in two hazardous materials: gas/liquid and dust.  The ATEX Cabinet Coolers can be used in Zone 2 for gas/liquid and Zone 22 for dust.  The ATEX terminology is as follows:

Gas – CE EX II 3 G Ex h IIC T3 Gc

Dust – CE EX II 3 D Ex h IIIC 200oC Dc

From these codes, it defines the equipment group and category, the environment, the protection, the group of materials, the temperature class, and the equipment protection level.  Most companies that have dealt with ATEX are familiar with these designations.  Just to give a slight overview, the CE EX is the ATEX protection through the European directive, CE.  The next symbol, II, is the Equipment Group, which refers to all locations except mines.  The fourth part would be the category and zone.  So, II 3 G would be Zone 2 for gas, and II 3 D would be Zone 22 for dust.   The Ex h is the protection principle and is used in the last section for the type of protection.  In conjunction with the Gc and the Dc, it designates a ventilator type of protection for explosive gas and dust. The remaining portion includes the type of gases or dust with temperature range.  The IIC T3 is for all gases that have an ignition temperature between 200oC and 300oC.   The IIIC 200oC is for conductive dust material with a maximum permissible surface temperature of 200oC. 

This would include industries like oil and gas, chemical processing, pharmaceutical, and food processing plants.  Designed for quick and easy installation, the ATEX Cabinet Cooler mounts through a standard electrical knockout and maintains NEMA 4/4X integrity even in demanding environments.  Optional thermostat controls reduce compressed air usage, while cold air distribution kits ensure even cooling throughout the electrical panel.  If you’d like to discuss any of the information above, EXAIR is staffed by Application Engineers who can be contacted by email, chat, and phone calls.    

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

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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