TOP 29 ENCLOSURE COOLING QUESTIONS ASKED BY PROSPECTIVE THERMAL EDGE CUSTOMERS 2015 Thermal Edge, Inc. 888.580.0202
About the Authors LISA BAKER Lisa Baker is the Inside Sales Manager. When you need help determining the best cooling solution for your application, she can size your application and quote a recommended cooling solution. With eight years experience in solving customer cooling needs, Lisa can recommend solutions for difficult environments such as hazardous location or corrosive applications, vibration issues, or public/remote applications needing secure enclosures. For replacing existing units, she can cross reference part numbers and size for mounting plates. She will provide formal quotes, literature, drawings - everything you need to make a fact based decision for important enclosure cooling solutions. NOEL FERNANDEZ Noel Fernandez is a Technical Support Manager with Thermal Edge Inc. He provides resources to customers, ensuring any questions they have about Thermal Edge products are answered accurately. Mr. Fernandez has more than 8 years experience in HVAC mechanical operational performance with advanced knowledge of the practices and procedures for HVAC troubleshooting, returns, and warranty claims. 2
Introduction The early 1960s witnessed the advent of the first air conditioners and heat exchangers for electrical equipment in enclosures. However, the importance of enclosure cooling solutions has not been fully understood until recently. Modern electrical devices not only are more powerful and efficient, but also dissipate more of the heat that can raise the enclosure temperature by a significant amount. Equipment manufacturers specify maximum allowable temperatures for their products above which performance, reliability, and lifespan are deteriorated. The emphasis on the use of enclosure cooling solutions for electrical equipment has encouraged customers to come forward with questions about choosing the best fit for their applications. Here are some of the top questions that Thermal Edge is asked about enclosure air conditioners by prospective customers: 3
Pre-Sales Questions 1 2 3 HOW MUCH DOES AN ENCLOSURE AIR CONDITIONER COST? The cost of an enclosure air conditioner varies based on its cooling capacity, NEMA type, voltage specifications, and the design profile. It can range from $1,500 for a 120V, 1,000 BTUH air conditioner designed for a NEMA 12 enclosure, to $8,000 for a 480V, 20,000 BTUH model designed for a NEMA 4X enclosure. Options and accessories for specific applications can be added to the enclosure air conditioner at extra cost. WHERE CAN I PURCHASE THERMAL EDGE ENCLOSURE AIR CONDITIONERS? Thermal Edge sells enclosure air conditioners and other enclosure cooling solutions directly to customers as well as through several national and independent distributors across the US. The Thermal Edge website can provide more information on how to contact a technical sales representative to size your enclosure air conditioner for the project s application. HOW DO THE UNIT FEATURES AND FUNCTIONALITY COMPARE WITH COMPETITORS PRODUCTS? Thermal Edge air conditioners have been designed with energy efficiency and smaller footprint in mind, therefore, are smaller and consume from 30 to 50 percent less energy than other units of comparable cooling capacity. Thermal Edge units also include a condensate evaporation system, a digital controller, and a thermal expansion valve as part of standard designs, whereas most competitors offer these as paid options. 4 5 WHAT ARE THE DIMENSIONS AND WEIGHT OF AN ENCLOSURE AIR CONDITIONER? The size of an enclosure air conditioner depends on its cooling capacity. The smallest air conditioner with 1,000 BTUH capacity fits in a 17 x 7 x 7 space; on the other end of the spectrum, Thermal Edge offers a 20,000 BTUH unit that fits in a space of 65.7 x 23 x 15. The former weighs 30 pounds; the latter 320. HOW SHOULD THE AIR CONDITIONER BE SIZED? Sizing an air conditioner requires the calculation of heat loads in the enclosure due to equipment, solar heat gain, heat due to ambient temperature, and heat from other equipment in the vicinity. The design should take into consideration the size of the enclosure, the ambient temperature, enclosure material, color and insulation, and air flow conditions in the location of the enclosure. The BTUH calculator from Thermal Edge can simplify the process of sizing the air conditioner for your application. Thermal Edge offers air conditioners in the range of 1,000 to 20,000 BTUH, designed for use with various applications. 4
Application-Specific Questions 6 7 8 WILL THE AIR CONDITIONER CORRODE WHEN INSTALLED IN A POTENTIALLY HARMFUL ENVIRONMENT? Thermal Edge air conditioners are provided with different corrosion protection options for use in potentially harmful locations. The AXX and BXX packages are available for use with NEMA types 12, 4 and 4X and offer protection for the condenser and evaporator coils against acids, solvents, salt, and chemicals. The CXX option is a more comprehensive corrosion protection package that covers all the coils and the brazed fittings. Selection of stainless steel (NEMA type 4X) models is strongly advised. DOES THERMAL EDGE PRODUCE AIR CONDITIONERS FOR USE IN HAZARDOUS LOCATIONS? This is all going to change when we get ATEX and IECeX certification later this year! Thermal Edge makes enclosure air conditioners specifically for hazardous duty. They are designed for exposure to Class 1, Division 2, and Groups B, C, and D. The design conforms to the standard requirements of ANSI/NFPA 70, NEC and CAN/CSA-C22.1, and CEC, and exceeds the specifications of Zone 2 T5 rating. These systems are available with cooling capacities from 2,000 to 20,000 BTUH. WHAT ARE THE OPTIONS FOR AN ENCLOSURE THAT IS SUBJECT TO FREQUENT WASHDOWN (WASH-DOWN) OR SPRAYING? In washdown (wash-down) and spraying situations with high-pressure hoses and water or chemical solutions, Thermal Edge provides enclosure air conditioners with a seam-welded housings for use with a NEMA 4 or 4X enclosure. The design of the housings minimizes accumulation of dust and mold; sloped housing roofs prevent liquid accumulations as well. Enclosure air conditioners used in food processing plants can include filter hoods for their standard filters that offer additional protection against washdown (wash-down). Rugged stainless steel filters are also options designed to work in 9 10 food processing plants where frequent washdowns ) wash-down) and spraying happen; these filters have extended capacity and are superior to aluminum filters in their ability to withstand chlorine. WOULD THE AC STILL BE ABLE TO FUNCTION OPTIMALLY IF THE ENVIRONMENT HAS A HIGH LEVEL OF POLLUTANTS (DUST AND PARTICULATE MATTER)? Many of Thermal Edge s products are being used in environments that are subject to dust from coal, wood, flour, and other contaminants. The products are equipped with optional 2-inch deep pleated 250-micron filters that protect the condenser coil and fan from potentially damaging particulate matter with 94 percent efficiency. The 2-inch-filters have 400 percent more capacity than standard filters so they do not have to be serviced as often. WHAT KIND OF REFRIGERANT IS USED IN THE AC? IS IT TOXIC? WHAT ARE THE IMPLICATIONS IF IT LEAKS, ESPECIALLY IN A FOOD PROCESSING PLANT? Different models of enclosure air conditioners use different refrigerants; the CS and NE series use R134a and R422d, and the HC series uses R438a. Environmental Protection Agency reports state that the toxicity for all three refrigerants is very low. There have been no recorded effects of exposure to these chemicals in trace amounts to humans and animals. Because refrigerant vapors are lighter than air, there is little chance that they mix with food. Material safety data sheets (MSDS) are available with procedures for handling or working with the refrigerants in a safe manner, and include information such as physical data (melting point, boiling point, flash point, etc.), toxicity, health effects, first aid, reactivity, storage, disposal, protective equipment, and spill-handling procedures. 5
Application-Specific Questions (cont.) 11 12 HOW CAN THERMAL EDGE PRODUCTS DEAL WITH TEMPERATURE EXTREMES? The Ambient package options for Thermal Edge air conditioners protect the compressor and optimize the system for operation at temperature extremes (below 50 F and above 125 F). The Low Ambient Temperature package applies heat within the compressor and protects it from damage due to stalling or starting from a non-optimal lowtemperature state. The condenser fan switches off to build up the heat inside the unit, thus allowing rapid warm-up to optimal conditions. The High Ambient Temperature package optimizes the system to perform efficiently at high ambient conditions. The standard maximum ambient temperature for operation is 125 or 131 F, but most models can be customized to operate at 140 F. HOW CAN A UNIT BE PROTECTED AGAINST VANDALISM? Outdoor applications are prone to theft and vandalism. Thermal Edge has a range of enclosure air conditioner options designed for secure applications. The remote controller option relocates the digital controller from the front of the air conditioner to inside the enclosure. The controller is attached to an eight foot cable and has a universal mounting bracket for easy installation. Security filter frames are available with or without protective louvers that require removal of four screws to access the filters, instead of the standard sliding filter frames. 13 14 WHAT STEPS CAN BE TAKEN TO PROTECT AIR CONDITIONERS AGAINST VIBRATION? Thermal Edge provides easy solutions to protect their air conditioners in applications subject to vibrations. The Vibration package replaces vulnerable refrigerant lines with flexible shockabsorbing lines; rubber bushings are installed to reduce stress from vibration on copper joints. High-quality silver solder is used in brazed joints. HOW DOES THERMAL EDGE ADDRESS CRITICAL APPLICATIONS IN WHICH FAILURE IS NOT AN OPTION? The Redundant System option is available for applications that are critical to a business. Two self-contained air conditioners share the cooling load for the application and alternate operation so that efficient cooling is provided. In the event of failure of one air conditioner, the cooling load will be borne by the remaining unit. In the event extra cooling is needed, both air conditioners will operate. 6
Installation Questions 15 16 17 HOW DOES THE AIR CONDITIONER MOUNT ON THE ENCLOSURE? HOW EASY OR DIFFICULT IS THE MOUNTING PROCESS? The air conditioner package contains a template that can be used to cut the required holes in the enclosure. After the mounting position of the AC is determined and the holes are cut, an insulation gasket must be installed on the air conditioner. The air conditioner can then be hung on the enclosure cutout by the easy-hang tabs. Fasteners are provided with the package to attach the AC to the enclosure. The process is straightforward and can be accomplished with basic tools. CAN THERMAL EDGE AIR CONDITIONERS REPLACE OTHER AIR CONDITIONERS WITHOUT MAKING DESIGN CHANGES TO THE ENCLOSURE? The Universal Mounting Plate accessory allows mounting of Thermal Edge products to the enclosure to replace any existing enclosure air conditioner. The plate is precut for mounting specific models on NEMA 12, 4 or 4X enclosures and can be used as a template to adjust the existing cutouts on the enclosure. WHAT ARE THE STANDARD COMPONENTS THAT ARE PROVIDED WITH THE UNIT FOR INSTALLATION? Enclosure air conditioners are provided with templates that are used to make cutouts in the enclosure for their mounting and installation. Gaskets are provided to ensure an airtight, closed loop seal around the periphery of the cutout. The unit can be hung from easy-hang tabs on the air conditioner while the air conditioner is attached to the enclosure with the hardware supplied. 18 19 WHAT DO THE DIGITAL CONTROLLER ALARM CODES MEAN, AND HOW CAN THE SETTINGS BE CHANGED? The digital controller has several alarm codes to monitor the status of the air conditioner. P1 and P2 indicate enclosure probe and condenser probe failure. HA and LA are the maximum temperature and minimum temperature alarms. HA2 and LA2 are high and low temperature alarms for the condenser. CA indicates low refrigerant pressure in the evaporator coil. The settings for all these alarms can be changed from the programming interface of the digital controller. See the user manuals on the Thermal Edge web site. WHAT IS THE OPTIMAL TEMPERATURE SETTING FOR THE AIR CONDITIONER? The optimal temperature setting for an enclosure depends purely on the nature of the electrical equipment inside it. Variable Frequency Drives are designed for operation below 104 F; conventional energy storage devices such as Li-Ion batteries require an operating temperature of about 86 F. 7
Temperature Control Questions 20 HOW EASILY CAN THE AIR CONDITIONER BE WIRED TO THE POWER SUPPLY? IS IT ONE-PHASE OR THREE-PHASE? Thermal Edge standard air conditioners are supplied for 120V, 230V, and 480V single-phase 60 Hz power. Each unit is provided with an easy-connection power terminal block. See the user manuals on the Thermal Edge web site. Standard Features Questions 21 22 DOES THE AIR CONDITIONER DRIP WATER? No. The condensate management system is so efficient in Thermal Edge air conditioners that drain pipes are unnecessary as long as the enclosure remains closed. The Thermal Edge system also increases the air conditioner efficiency by using the hot refrigerant tubing from the compressor to boil off the water. WHAT ARE THE FILTERS MADE OUT OF? ARE THEY CORROSION-RESISTANT? The standard filters on Thermal Edge air conditioners are made out of aluminum and offer good resistance to corrosion. Options such as filter shrouds can protect the filters against direct ingress of water and chemicals from wash-down or spraying. Stainless steel filters, available as options instead of standard filters, offer better resistance to corrosion against chlorine, bleaching agents, and other heavy chemicals. Furthermore, they require less maintenance with their extended filter capacity. 23 24 HOW OFTEN MUST THE FILTERS BE REPLACED? DO THE FILTERS COME WITH OPTIONS? Clean filters are an essential prerequisite to efficient air conditioner operation and performance. Dirty and clogged filters can interfere with normal operation and even damage the system. The frequency with which filters must be washed or replaced depends on the environment where the enclosure is located. The lifespan of these filters depends on the methods used for washing and cleaning. For dusty and polluted environments, Thermal Edge offers two inch pleated filters, with 400 percent greater capacity than flat filters that increase the time between filter maintenance. WHAT ARE THE IMPLICATIONS OF HIGH ENVIRONMENTAL HUMIDITY AND DISPERSED OIL ON THE ENCLOSURE AIR CONDITIONER? Closed-loop cooling systems are capable of handling high humidity and dispersed oil in the air by virtue of their design. The efficient condensate evaporation system in Thermal Edge air conditioners removes all the moisture in the enclosure, thus eliminating risk of exposure of the electrical equipment to condensation. 8
Standard Features Questions (cont.) 25 26 HOW RELIABLE ARE THERMAL EDGE AIR CONDITIONERS? Enclosure air conditioners are industrial appliances consisting of electromechanical components that must be cleaned, maintained, and serviced periodically for reliable operation. Thermal Edge products have been designed with quality, energy efficiency, and footprint in mind. The safety features and fail-safe design make the products extremely reliable in all applications. HOW LONG DOES AN AC LAST IN FOOD PROCESSING AND WASTEWATER TREATMENT FACILITIES? Thermal Edge designs its products for use with many applications, including food processing and wastewater treatment facilities. NEMA type 4X units made from 304 stainless steel with electrostatic epoxy-coated condenser coils. Additional options include high-capacity filters, filter hoods, and integrated heaters. The lifespan of ACs in these applications varies based on the environment, frequency of use, and extent of service and maintenance. 27 IS THERE A WAY TO GET ALARM OPTIONS FOR THE AIR CONDITIONERS? There are different alarm options for Thermal Edge air conditioners. The Dry Contact option provides for an easily programmable, early hightemperature alarm warning that can be seen or heard at a distance. The Remote Control and Monitor options make it easy for all programming to be done remotely and the alarms to be transmitted through Ethernet/IP, or Modbus RTU or TCP/IP Ethernet networks. 9
After-Sales Questions WHAT IS THERMAL EDGE S WARRANTY? 28 29 Thermal Edge offers products with defect-free workmanship, materials, and components. The warranty period is one year from the date of shipment, provided the operating conditions of the air conditioner are within the limits specified on the nameplate (ambient temperature, voltage and frequency specifications, cooling load) and compliance to installation and maintenance instructions. Extended warranties are also available. DOES THERMAL EDGE OFFER PRE-SALE SUPPORT FOR THEIR CUSTOMERS? First-time buyers may find the sizing of an enclosure air conditioner for their applications tricky. For this reason, Thermal Edge offers its customers a BTUH calculator that gathers information about their applications and helps them size a suitable air conditioner. Furthermore, Thermal Edge gives customers the option to speak with an experienced technical sales team that can find the best solution for their requirements. Multiple guides are available in the Resources section of the website that simplify the process of choosing an enclosure AC manufacturer and buying an efficient product. Do you have any additional questions about Thermal Edge products and your cooling needs? If you need help selecting the right temperature control solution for your application, talk to the professionals at Thermal Edge. Our experts will work with you from beginning to end to ensure that you have the most cost-effective solution for your application. We also work with engineers who design electrical enclosures to help determine the right temperature control solution early in the design process. Get in touch with us today to review case studies that are similar to your application, review product literature, or schedule a consultation. Get a Quote For an Enclosure Cooling System Get a Quote Now > 10