Thermal Management Design Guide

Incorporating thermal cooling within an enclosure

Air Conditioner
Closed Loop System: Can maintain a Type 3R, 12, 4 or 4X rating and can create an environment cooler than ambient. This is an ideal type of cooling which creates a more reliable system and improves equipment life cycle. A typical internal temperature design point is 85-95F. Hoffman air conditioners are designed for continuous operation in ambient environments up to 125 F or 131 F, depending on the model. For sizing and selecting an air conditioner, refer to page2, or go to hoffmanonline.com to use the Thermal Management Selection Software. When an electrical enclosure wall is penetrated with an opening it must be covered by a rated part. All of the above cooling systems have been designed and certified to be used on electrical enclosures and maintain the product Type Rating identified on the corresponding product specification sheet.

can lengthen system life and increase control line reliability. The accumulation of heat in an enclosure is potentially damaging to electrical and electronic devices. Overheating will shorten the life expectancy of costly electrical components and can lead to catastrophic failure. It is, therefore, important that system designers be aware of the temperature implications of their designs prior to implementation and, where necessary, take steps to reduce heat build-up inside the enclosure.
Extreme temperatures can have the following effects on industrial control equipment: Catastrophic failures can occur Silicone material properties can change Drive performance is de-rated I/C-based devices may experience intermittent fluctuations in output and voltage migration Mean Time Between Failure (MTBF) decreases exponentially The costs when a line goes down due to temperature extremes are: Productivity losses Increased labor costs Increased scrap Opportunity losses Component costs Missed ship dates Decreased customer satisfaction

Most Common Enclosure Type Ratings* Indoor

Type 1 enclosures are intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment or locations where unusual service conditions do not exist. Type 12 enclosures are intended for indoor use primarily to provide a degree of protection against dust, falling dirt and dripping noncorrosive liquids.

Outdoor
Type 3R enclosures are intended for outdoor use primarily to provide a degree of protection against falling rain and sleet; undamaged by the formation of ice on the enclosure. Type 3RX enclosures are intended for outdoor use primarily to provide a degree of protection against corrosion, falling rain and sleet; undamaged by the formation of ice on the enclosure. Type 4 enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water and hose directed water; undamaged by the formation of ice on the enclosure. Type 4X enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against corrosion, windblown dust and rain, splashing water and hose-directed water; undamaged by the formation of ice on the enclosure. * According to National Electrical Manufacturers Association (NEMA Standard 250) and Electrical Equipment Manufacturers Association of Canada (EEMAC)

Types of Cooling
Open Loop: Utilizes the ambient or outside air, filtered or unfiltered, to cool the electronics Closed Loop: Maintains the sealed integrity of the cabinet while utilizing the internal cabinet air to cool the electronics Active Cooling: An external device enhances the cooling process Passive Cooling: Cooling occurs via natural convection and heat dissipation

Filter Fan and Exhaust

Open Loop Systems: Usually only used in relatively clean Type 1 or Type 3R environments where the temperature inside the enclosure will always be greater than outside the enclosure. Equipment inside the enclosure must be evaluated to sustain a worst-case temperature rise above ambient. For sizing and selecting filter fan packages, refer to page46.

Heat Exchanger
Closed Loop System: Maintains a sealed system that will match the Type rating of the heat exchanger. Temperature will always be greater than ambient. Equipment inside the enclosure must be evaluated to sustain a worst-case temperature rise above ambient. For sizing and selecting heat exchangers, refer to page38.

Vortex Cooler
Closed Loop System: Can maintain a Type 12, 4 or 4X rating and can create an environment cooler than ambient. This is an ideal type of cooling for smaller enclosure applications where compressed air is available.
Open Loop Closed Loop

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Thermal Management Design Guide

Finding the Right Thermal Management Solution
To determine the best thermal management products for the application, the user needs to define information about the environment, enclosure and the equipment inside. Project Environment/Thermal Evaluation Data Form Environment
System Location: Indoors, outdoors shaded or outdoors direct sunlight Environment: Corrosive, dust, grit, dirt, oily-cutting fluids, wash down, dripping water, freezing rain or other Open Loop _____ or Closed Loop _____ System

Enclosure Surface Area

The physical size of the enclosure is one component in determining its ability to dissipate heat. For non-vented passive cooling, the larger the surface area of the enclosure, the lower the temperature rises due to the heat generated within it. To determine the surface area of an enclosure in square feet, use the following equation: Surface Area = 2[(A x B) + (A x C) + (B x C)] 144 where the enclosure size is A x B x C in inches. This equation includes all six surfaces of the enclosure. If any surface is not available for transferring heat (for example, an enclosure surface mounted against a wall), it should not be included in the calculation. NOTE: Enclosure volume cannot be used in place of surface area.

Enclosure Temperature Rise (T)

The temperature rise illustrated by the curve in the graph below is the temperature difference between the air inside a non-ventilated and non-cooled enclosure and the air outside the enclosure (or ambient air temperature). This value is a function of input power in Watts per square foot. To predict the temperature inside the enclosure, add the temperature rise indicated in the graph to the ambient temperature where the enclosure is located. The enclosure temperature rise is not dependent on the ambient temperature; rather, it should be added to the worst-case ambient temperature.
Sealed Enclosure Temperature Rise
Temperature Rise Above Ambient (F)
100 80 60 40 20 0 2 4 6 8 10 12 14 16 Input Power (Watts/Square Foot) 55.5 44.4 33.3 22.2 11.1 120 66.6

Enclosure
Size: _____ H x _____ W x _____ D = _____
Determine the area that allows heat transfer and identify any dimensional limits of thermal system. Type Rating: _____ (Typically Type 1, 3R, 12, 4, or 4X) Enclosure finish/color: _________ (external color will effect solar load if in direct sunlight; if internal finish is metallic, the passive cooling of the enclosure is less)

Equipment
Internal Heat Load: _____ (determine the full-load heat produced by the major power-consuming components; then add an additional 25% for passive components and connections) Determine the level of protection the equipment needs based on the environment. Identify the most sensitive components relative to temperature or humidity and determine the upper and lower temperature extremes. Available Power: _____ Volts

Temperature Limits Cooling Extremes

__________ Maximum temperature outside the enclosure __________ Maximum allowable temperature inside the enclosure (8595 F is a typical value used to provide a reliable system and maximize the systems life)

Unfinished Aluminum and Stainless Steel

Painted Steel and Non-metallic

Determine Temperature Rise for an Enclosure Without a Cooling System

The temperature rise inside a sealed cabinet without forced ventilation or other cooling system can be approximated. 1. Calculate the surface area of the enclosure. 2. From the expected heat load and the surface area, determine the heat input power in Watts/sq. ft. 3. Read the expected temperature rise from the chart above. Find where the input power intersects the line for the enclosure material and read the approximate expected temperature rise at the left. Example: What is the temperature rise that can be expected from a 48x36x16in. painted steel enclosure with 300 Watts of heat dissipated within it? Solution: Surface Area = 2[(48 x 36) + (48 x 16) + (36 x 16)] 144 = 42 sq. feet Input Power = 300 42= 7.1 Watts/Square Foot From the Sealed Enclosure Temperature Rise Graph: Temperature Rise = approximately 30 F (16.7 C)

Heating Extremes
__________ Minimum temperature outside the enclosure __________ Minimum allowable temperature inside the enclosure (heaters are frequently required to maintain temperatures above minimum startup and to remove condensation)

Estimating Heat Inside and Operating Temperatures Cooling Effects Based on Enclosure Finish and Materials
The following discussion applies to gasketed, unventilated enclosures. Higher temperature rises can be expected with aluminum and stainless steel finished enclosures due to their surface reflective radiant heat transfer coefficient at lower temperatures. Non-metallic enclosures have similar heat transfer characteristics to those constructed of painted steel.

Enclosure Heat Input

For any temperature rise calculation, the heat generated within the enclosure must be known. Obtain this information from the supplier of the components mounted in the enclosure. The system designer must obtain estimates of heat input from the information available. Since these are only estimates, inclusion of a safety factor might be prudent.

Safety Margins
The graph provides only an approximation of temperature rise. Actual temperature rise will vary due to enclosure layout, internal fan use, air movement in the vicinity of the enclosure and other factors. Safety margins should be used in critical situations. A safety margin of 25 percent is recommended.

Subject to change without notice

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2008 Hoffman Enclosures Inc.

Temperature Rise Above Ambient (C)

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Thermal Management Design Guide

Internal Circulating Fans
The use of circulating fans in an enclosure will improve heat dissipation by as much as 10 percent. Circulating fans are most commonly employed to eliminate hot spots inside an enclosure. The graph below illustrates the temperature rise of two identical enclosures except one has an internal circulating fan. Each enclosure has two temperature sensors, one located near the top and the other near the bottom. The top and bottom black curves reflect the temperature in the enclosure without an internal fan. Adding a circulating fan removed the heat stratification.
Remove Hot Spots with Internal Fan
24 22
Temp Rise Above Ambient Degrees F

Acoustical Noise
Acoustical noise is typically measured by the Sound Pressure Level ( Lp), expressed in decibels and is dependent upon the distance from the source as well as its surroundings. The Sound Pressure Level is defined as: Lp = 10 log ( p2 / po2 ) Where: Lp = Sound pressure level (dB) p = Measured sound pressure (Pascals) po = Sound reference level 20 N/m2 There are many different ways to reduce the noise generated by an air mover. Some of the more common are: Avoid obstructions to air flow Run larger fans at lower speeds Lower the system impedance Minimize inlet losses and obstructions The most significant factor influencing the noise from a given air mover is the speed of rotation. This is given by the following equation: dB2 = dB1 50 log (rpm1 / rpm2 ) Where: dB1 = Sound pressure of the air mover operating at rpm 1 dB2 = Sound pressure of the air mover operating at rpm 2 rpm1 = Operating speed of impeller at condition 1 rpm2 = Operating speed of impeller at condition 2 Therefore, a blower at half speed will be 15 dB quieter than at full speed. Air flow will also be half and, since static pressure is a squared function of speed, it is reduced by a factor of four.

Encl w/ Fan: Temp Sensor TOP Encl w/ Fan: Temp Sensor Bottom Encl No Fan: Temp Sensor TOP Encl No Fan: Temp Sensor Bottom

20 18 16 14 12 10 8 6 4 2 0 6/15/02 6:00 PM 6/16/02 12:00 AM 6/16/02 6:00 AM

Decibel Loudness Comparisons

Decibels (dBA)
10 20 30 40 50 60 70 75 80 90 100 110 115

Loudness Comparisons
Grand Canyon at night Quiet basement Quiet bedroom (at night) Typical living room Background music Average human voice Airplane interior noise EPA recommends protection for 8-hour exposure Kitchen garbage disposal Lawn mower Leaf blower Rock concert OSHA forbids unprotected exposure

Multiple Air Movers for Open Systems

Air movers can be combined in series or parallel, as this may provide the optimum solution. In addition, a degree of redundancy in the event of fan failure can be a benefit. The graph illustrates how airflow performance changes when air movers are placed in series or parallel with one another in a system. This performance curve shows that adding a second 10-in. exhaust package provides an increase in airflow from 215 CFM to 290 CFM. The intersection point of the fan curve and the system curve approximates the CFM performance.

Parallel vs Series Performance

2.5

2 Static Pressure (In. WG) 2 Fans Series 1.5

1 1 Fan 0.5 0 2 Fans Parallel

Sound and Distance

0 100 200 300 Air Flow (CFM) 400 500

When the distance from a Point source doubles, the sound level decreases six decibels.
Sound Level
95 decibels 89 decibels 83 decibels

Distance
50 feet 100 feet 200 feet

Addition and Subtraction of Decibel Levels

Doubling sound energy yields an increase of three decibels. In this example, each source is 50dBA. Note the characteristics of logarithmic addition or subtraction of decibel levels.
Number of Sources
1 2 4 8

Decibel Level
50 dBA 53 dBA 56 dBA 59 dBA

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Thermal Management Design Guide

Solar Consideration
When evaluating the thermal management needs of outdoor electrical enclosures, solar gain must be considered. Variables that affect the enclosures internal temperature rise include the amount of solar exposure, enclosure color and material type, highest sustained atmospheric temperature, heat build-up from internal components and heat reflectance from the surrounding environment. Examples: 1. What amount of heat energy must be removed from a 24 x 20 x 12 (surface area = 14 ft 2) ANSI 61 gray enclosure located outdoors, without any heat dissipated internally, to maintain the enclosure temperature equal to the ambient (temperature rise = 0)? From the following chart, at 0 F temperature rise we find the solar load is approximately 14 Watts/ft.2 14 ft.2 x 14 Watts/ft.2 = 196 Watts This is the heat energy that must be removed to maintain the enclosure temperature at ambient. 2. If the same enclosure has internal equipment dissipating 200 Watts of heat, what is the amount of heat energy that must be removed to maintain the enclosure at a temperature rise of 20 F above the ambient temperature? From the chart, at 20 F temperature rise we find the solar load is approximately 6 Watts/ft.2 14 ft.2 x 6 Watts/ft.2 = 84 Watts All of the internally dissipated heat of 200 Watts must also be removed. 84 Watts + 200 Watts = 284 Watts This is the total amount of heat energy that must be removed to maintain the enclosure at 20 F above the ambient temperature.
Solar Load Based on Color and Allowable Temperature Rise
50

Exposure to Solar Radiation

Over much of the United States, the approximate peak values of solar radiation striking the Earths surface is 97 Watts/ft. 2 and the ambient air temperature can reach 104 F. Altitude, humidity and air pollution have an impact on these values, even more so than the locations latitude. In the high dry climates of the southwest, solar radiation values of 111 Watts/ft. 2 and air temperatures greater than 104 F can be reached. The extreme conditions the enclosure will be exposed to should be identified. If the internal enclosure temperature is greater than the outdoor (ambient) temperature, wind will provide greater heat transfer and thus cool the enclosure. But, because the presence of wind cannot be guaranteed, it is usually not taken into account when establishing a worst-case evaluation.

Effect of Surrounding Location

T (Internal Temp. - Ambient Temp.)

Reflection of solar energy from the foreground and surrounding surfaces can impact the total amount of radiant exposure by as much as 30 percent.

40 30 20 10 0

Effect of Enclosure Color and Finish

The percent of solar energy absorbed by the enclosure depends on surface color, finish and texture. Absorption values of the finish will increase with age. Low temperature radiation (larger wavelengths) presents a different set of values for surface color. Low temperature values effect the enclosures surface ability to absorb internal heat loads and dissipate radiant heat surrounding objects. Solar Absorption s = 1 - reectance Low Temperature Emissivity Absorption = 1- reectance
Surface
Polished Aluminum White Yellow Cream Light Grey, Green Blue Medium Grey, Green Blue Dark Grey, Green Blue Black

10

15

20

25

30

Solar Load (watts/ft2)

Solar Radiation ( s ) absorption

.15 .14 .30 .25 .50 .75 .95 .97

Low Temperature Radiation 25C ()

.06 .97 .95 .95 .87 .95 .95 .96

Black ANSI 61 Gray White

Stainless Steel RAL 7035 Light Gray Aluminum

Units and Conversions

Temperature Airow Pressure Power ____ Degrees F = 1.8* (____ Degrees C)+32 1 CFM = 1.7 M3 /hr. 1 Inches H2O = 248.9 Pascal = 0.0361 psig 1 Watts= 3.413 BTU/Hr. 1 Horsepower= (745.6 Watts)

Standardized Test Evaluation

Telcordia NEBS GR-487 provides a test procedure for evaluating the solar load on electrical/electronic enclosures. The test is run with the internal electronics on in an environmentally controlled room. Three sides of the enclosure are illuminated uniformly with controlled banks of lights to a measured surface radiant value of 70 Watts/ft.2 The temperature rise inside the enclosure above ambient is added to 115F (46C). This temperature total must not exceed the lowest rated component.

Example: Approximate the amount of heat produced by three 5 Hp variable frequency drive (VFD) mounted with a disconnect and bypass contactors in an enclosure given a drive efficiency of 97%, (neglect motor efficiency). 3 VFD x 5 HP x 745.6 Watts/HP x (1-.97) eff. x 1.25 (factor for passive connections and other minor heat-producing components) = 419 Watts

Evaluation of Solar Heat Gain

To evaluate the heat load on an enclosure, you must take into account: Total surface area of the enclosure Color of the enclosure Internal heat load Maximum allowable internal temperature Maximum ambient temperature Solar load

Subject to change without notice

PH 763 422 2211 FX 763 422 2600 www.hoffmanonline.com

2008 Hoffman Enclosures Inc.