Tag: heat load

How Can I Stay Calm When My Control Panel’s Overheating?

Published on by Russ BowmanLeave a comment

We’re in the dog days of summer (in the Northern Hemisphere) for sure…or, as we call it, “Cabinet Cooler Season.” If you’re having heat-related problems with a control panel, there are plenty of cooling options out there, but you’ll be hard-pressed to find one that’s as durable, reliable, available, and easy to install as an EXAIR Cabinet Cooler System. All we have to do is find the right one for your enclosure, and we have a couple of different ways to do that:

Cabinet Cooler Systems Sizing Guide: We’ve had this on our website, and in our catalog, for years now. We can also email you one, if you want to print it out & fill in the blanks. Then, you can either email it back, or you can call us with the data. It only takes a minute to do the calculations, and we do it over the phone all the time.

Cabinet Cooler System Calculator: This one’s for the do-it-yourself-ers, and it uses the exact same formulas that an Application Engineer will use if you submit a Sizing Guide. There are still some situations where you might need to contact us — if your enclosure is in an explosive environment, an area with a hazardous classification, or if the heat load is outside the parameters of our stock Cabinet Cooler Systems, the Calculator is going to politely decline to make a selection and refer you to an Application Engineer. Of course, if you have ANY questions about the application or the Cabinet Cooler products, don’t hesitate to call, even if the Calculator doesn’t make you.

Here’s what we’re going to ask for, and why:

  • Enclosure dimensions. To calculate the heat transfer surface area
  • Current Internal Air Temperature. This is the starting point for figuring out the internal heat load…how much heat the components inside the box is generating. This needs to be the air temperature – don’t use a heat gun, or you’re going to give me the surface temperature of something that may or may not be close to what I need. Just put a thermometer in there for a few minutes.
  • Current External Air Temperature. We’re going to compare this to the internal air temperature…the difference between the two is proportional to the heat load. Also, if there’s anything cooling the enclosure right now (like circulating fans; more on those in a minute), this reading is key to figuring out how much heat they’re removing.
  • Maximum External Air Temperature. How hot does it get in the area on, say, the hottest day of summer? We’ll need this to calculate the external heat load…how much heat the enclosure picks up from its surroundings.
  • Maximum Internal Temperature Desired. Most electrical and electronic component manufacturers publish a maximum operating temperature of 104F (40C) – it’s kind of an “industry standard.” Based on this, a lot of us in the enclosure cooling business set our products’ thermostats to 95F (35C) – if we’re maintaining the air temperature a decent amount cooler than the components are allowed to get, history and practice has shown that we’re going to provide more than adequate protection. If your enclosure houses something with more sensitive temperature limitations, though, we can work with that too…that’s the only time you’re going to want to put something other than 95F (35C) in this field.
  • Cabinet Rating. This is all about the environment…we offer three levels of protection, per NEMA standards:
  • Other: If the enclosure is mounted to the side of a machine, or a wall in the plant, you really don’t need to put anything there. If it’s outside and exposed to direct sunlight, tell us what the surface finish (i.e., polished metal, painted grey, etc.) is so that we can account for solar loading too. If anything else is unusual or peculiar about the application, let us know that too.
  • My Cabinet Is… Not Vented, Vented, Wall Mounted, Free Standing, Fan(s). We’ll use what you tell us here to verify the heat transfer surface (a wall-mounted cabinet’s back surface isn’t a radiative surface, for example.) Also, I mentioned fan cooling before, so without further ado…
  • Fan diameter or SCFM. If there are fans circulating air into (and/or out of) the enclosure, they’re providing a finite amount of cooling right now. Proper installation of a Cabinet Cooler System is going to require their removal. Running a Cabinet Cooler System on a vented enclosure is just like running your air conditioner with the windows open. So, if we know the size (or the SCFM…sometimes there’s a label on those fans, and we LOVE those folks who do that) then we can use that, and the temperatures you gave us above, to take the fan cooling into account.

Once we (or the Calculator) have that data, we’ll calculate the heat load & specify the right system. Easy as that.

Before I go…here’s a nice little video, walking you through the Cabinet Cooler Sizing Guide. Yes, I just made you read the book before watching the movie…feel free to tell me which one you liked better.

Cabinet Cooler Systems are in stock and available for same day shipment with an order received by 2pm EDT. If you have a panel that needs cooling, we can fix that right now…give me a call.

Russ Bowman, CCASS

Application Engineer
Visit us on the Web
Follow me on Twitter
Like us on Facebook

How to Select the Right Cooling System with EXAIR’s Electrical Enclosure Heat Load Guide

Published on by jasonkirbyLeave a comment

Selecting the right cooling system for an industrial electrical enclosure requires accurate data rather than guesswork. Under-sizing a cooling unit leads to persistent overheating and component failure, while over-sizing wastes valuable compressed air energy. The EXAIR Cabinet Cooler Sizing Guide provides a structured framework to determine the exact cooling capacity required for your control panels. By accounting for the unique environmental and operational variables of your facility, this guide helps you choose a system that delivers optimal thermal protection.

The heat load calculation begins by mapping the enclosure’s physical dimensions and temperature differentials. Users must measure the cabinet’s width, height, and depth to calculate the total exposed surface area. Next, you must record the current internal and external air temperatures, alongside the maximum expected ambient temperature during the hottest months. Comparing these figures against your desired internal temperature—typically 95°F (35°C) for standard industrial electronics—establishes the temperature differential (ΔT) required to calculate external heat transfer.

A precise calculation requires evaluating four primary sources of heat: internal, external, fan, and solar loads. Internal heat represents the energy dissipated by active electronics such as variable frequency drives (VFDs) and transformers, often expressed in BTU/hr. External heat reflects the ambient thermal energy radiating through the cabinet walls from the surrounding factory floor. For outdoor installations, the guide accounts for solar heat gain based on the panel’s color and sun exposure, and evaluates any existing cabinet fans that must be sealed during installation.

Once all variables are gathered, the data can be submitted through the interactive EXAIR Cabinet Cooler System Calculator for instant configuration. This digital tool instantly processes your specifications to recommend a precise model number from EXAIR’s extensive catalog, which features cooling capacities ranging from 275 to 5,600 BTU/hr. Utilizing this guide ensures that your selected system matches your exact NEMA requirements and voltage preferences, providing a reliable engineering solution that protects your electronics and eliminates downtime

If you have questions about the Cabinet Cooler Systems Heat Load Guide, 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

Cabinet Cooler Accessories: Adding to Efficiency and Effectiveness

Published on by jasonkirbyLeave a comment

Accessories can add much needed enhancements to assist in making your application as efficient and effective as possible. The same is true when it comes to our Cabinet Cooler Systems. Among the most essential accessories for our products are compressed air filters and regulators, which we highly recommend using with all our offerings, as well as with other brands. The Filter Separator effectively eliminates water, dirt, and rust from your compressed air system, while its 5-micron filter element prevents contaminants from clogging or damaging your equipment. For even more precise filtration, an Oil Removal Filter should be installed downstream of the Filter Separator; this filter utilizes a 0.03-micron element to remove oil and solid particulates. Additionally, our Pressure Regulators allow you to set the desired operating pressure, and we advise maintaining the minimum pressure necessary for optimal performance. This not only conserves air consumption but also fine-tunes the efficiency of EXAIR products in various applications.

From left to right; a few value added accessories for your Vortex Tube: Hot Muffler, Cold Muffler, Automatic Drain Filter Separator, Oil Removal Filter, and Solenoid Valve/Thermostat Kit.

A Cold Air Distribution Kit is an additional accessory available with our Cabinet Cooler Systems that enhances their efficiency. This kit features a length of flexible vinyl tubing designed to channel cold air for optimal circulation or to target specific hot spots. It also includes tubing connectors and adhesive-backed clips to secure the tubing in place.

Solenoid valves and thermostats are effective tools for conserving compressed air. Cabinet Cooler Systems equipped with thermostat control utilize a solenoid valve and thermostat to regulate the flow of compressed air, activating it only when cooling is necessary. The thermostat is preset to 95°F (35°C) and typically maintains a temperature within ±2°F (1°C) inside the cabinet. Solenoid valves are available in various voltage options, including 120V at 60Hz, 110V at 50Hz, 240V at 50/60Hz, and 24VDC. All solenoids are CSA Certified and either UL listed or recognized.

EXAIR’s Side Mount Kits facilitate the installation of cooling systems on the sides of electrical enclosures, particularly beneficial in scenarios where vertical or top mounting is impractical. It is important to note that NEMA 4 and 4X Cabinet Cooler Systems must be installed in a vertical orientation. These kits preserve the NEMA ratings for both large and small enclosures classified as Type 12, 4, and 4X, and they fit into standard electrical knockouts measuring 1-1/2 NPS. The Side Mount Kits designed for NEMA 12 Cabinet Cooler Systems are constructed from aluminum, while those intended for NEMA 4 and 4X systems are made from either Type 303 or Type 316 stainless steel.

If you have questions about the Cabinet Cooler Systems accessories, 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

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 
Like us on Facebook
Twitter: @EXAIR_JS