When deploying enclosures in an environment with extreme temperatures, thermal management is critical. It is necessary for maintaining the optimum performance of electronics and for keeping a computer system protected from elevated levels of heat. Since a NEMA 4X enclosure requires a watertight seal, a unique set of challenges must be overcome when installing a NEMA 4X computer or printer enclosure. NEMA 4X enclosures are unable to utilize an open cooling system, meaning the cabinet requires a closed loop system that uses forced convection. With a closed loop system, no seal is broken. The enclosure market has several closed loop solutions that will keep your enclosure cool to protect your vital electronics.

Three common types of cooling for NEMA 4X computer enclosures:

Heat Exchanger
A heat exchanger can be used to transfer heat from the inside of the cabinet to the outside to ensure internal electronic components are operating at safe levels. It is important to note that a heat exchanger is an ideal cooling solution ONLY when the electronics can operate safely above the external ambient temperature. Heat exchangers are advantageous when humidity is not a major concern, and a low heat load is generated by the electronics installed inside of the enclosure.

Vortex Cooler
Vortex cooling units produce cool air by using clean/dry compressed air through a tube or hose. These units do not have refrigerants or moving parts, so they are especially valuable in demanding, harsh environments – such as hazardous areas. A vortex cooling unit is operated by a thermostat, which is powered from the inside of the enclosure. The installation location can vary on an enclosure: top, sides, or rear.

Air Conditioners
A NEMA 4X rated air conditioner can be installed in an environment where the electronics – inside of the enclosure – need to be cooled at or below the ambient external temperature. An air conditioner is beneficial in high humidity areas. To properly cool electronics, air conditioners use refrigerants and forced air. It goes without saying, but an A/C requires frequent filter maintenance to run at its maximum capacity. The filter should be changed and/or cleaned at least once a month or more often in dirty or dusty areas.

Prior to deploying a NEMA 4X computer or printer enclosure, perform research and conduct a thorough examination of the installation environment. Compile a list of ALL electronics which will be installed inside of the enclosure. The list should include the average heat load and operating temperatures. This information is helpful in determining the NEMA 4X cooling system that will best fit the desired application.

Looking for a recommendation on the best cooling solution for your enclosure? Click Here

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In many harsh, manufacturing settings, printers, computers, monitors, and electrical equipment are housed in industrial computer enclosures that are designed to protect against severe, exterior environments (humidity, water, dirt, dust). However, even in a NEMA rated enclosure, liquid can enter the enclosure under a variety of circumstances. Obviously, the goal is to keep harmful elements, like moisture or condensation, out of the enclosure!

Condensation is defined as water which collects on a cold surface when humid air makes contact. In other words, temperature fluctuations between the inside and outside of the computer enclosure can cause condensation, which can make its way into the enclosure. Any moisture can damage electronics, shorten their lifetime, and affect the performance of the internal components. When it comes to condensation, corrosion or rust are also serious concerns, which will render critical electronic mechanisms useless.

Moisture can also penetrate the inside of an enclosure through various paths – door left open, a vent, defective door latch/hinge, filtered fan system, brittle gasket, or a poorly sealed cable entry point. Plus, during a regular washdown, it is possible for the high pressure spray and cleaning solution to penetrate around the sealed enclosure doors and gaskets. If the water is not detected, mold or fungi can form in small areas and become an enormous problem. In fact, according to FEMA, mold can grown quickly, “mildew and mold will develop within 24-48 hours of water exposure. Even worse, it will continue to grow until steps are taken to eliminate the source of moisture, and effectively deal with the mold problem… Molds digest organic material, eventually destroying the material they grow on, and then spread to destroy adjacent organic material.”

Naturally, it is advisable to install a “closed-loop” cooling solution for humid, moisture prone environments. Closed loop cooling systems are specifically designed to mount to an enclosure and remove heat, without letting outside air (or water) into the sealed enclosure. To ensure electronics are running at optimum levels, the closed loop system will bring the temperatures below the ambient outside temperature.

Examples of closed loop cooling systems include air conditioners, vortex coolers and heat exchangers (heat exchangers will not cool below the ambient temperature). These systems usually employ a thermostat and/or humidity control for monitoring. Closed loop systems are generally “non-condensating.” The only time condensation may occur is if there is a quick and dramatic temperature fluctuation to the system (i.e. switching thermostat from 80°F to 65°F). In fact, air conditioners and vortex coolers can often work to remove moisture from the inside of the computer enclosure.

When searching for the best enclosures for a humid environment, make sure that it is built to protect against water entering the cabinet. Obviously, water has a way of getting into the tiniest spaces if not properly safeguarded! In humid environments, moisture may enter the enclosure when the door is minimally open for quick routine maintenance.

Properly sealed enclosures in a humid environment (gasket is a plus) will prolong the life of imperative electronics. As always, downtime can be costly, so it is always prudent to keep all electronics up and running for as long as possible.

Looking for a recommendation on the best cooling solution for your enclosure? Click Here

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When storing electronics in a computer, monitor, printer, or rack enclosure, proper cooling is necessary to increase the overall life of the electronics. It comes as no surprise that heat can damage electronics. As a rule of thumb, the life expectancy of electronics is cut in half for every 18°F in which they operate above room temperature. System integrators should be aware that operating electronics in high or elevated temperatures can void manufacturer warranties. Thus, the correct thermal management is critical for a computer enclosure deployment in a manufacturing setting.

Many factors influence the temperature – in which electronics are exposed – on the inside of a computer enclosure. In the blog, ‘Could High Humidity be Hurting Your Electronics?,’ the author notes that “electronics are more delicate than you may think, and are susceptible to damage in high-humidity environments. It is important to keep relative humidity between 40-60% to keep electronics running efficiently.” Therefore, it is imperative to consider not only the electronics’ heat output, but also the environmental factors that may cause high ambient air temperatures.

The following are some examples of potential sources of heat:

• Power Supplies
• Controllers, Drives, or Servers
• Computers and Monitors
• Rack Electronics
• Printers (Barcode, Label, or Desktop)
• Solar Gain Heat
• Furnaces or Ovens
• Foundry Equipment

Electronics, which are more robust than average off-the-shelf products, will most likely have a higher heat output. Because we live in a world where faster is better and processing capacity is extremely important, more powerful systems are being designed at a rapid pace. Powerful electronics will generate more heat and, as a result, will require some form of cooling, like a filtered fan system, heat exchanger, vortex cooling unit, or air conditioner.

What are Common Consequences of Damaging Heat?

Heat building up – on the inside of an industrial enclosure – can adversely affect controls and sensitive electronics.

Below are a few examples of the adverse reactions of too much heat.

• De-Rated Drive Performance
• Electronics Failure
• Productivity Loss/Down time
• High Component Replacement Costs
• Late Shipments
• Lost Revenue
• Customer Dissatisfaction

When searching for the right enclosure solution, speak with an enclosure expert to configure the best cooling solution based on a user’s specific application. When discussing the installation of electronics on the inside of an enclosure, thermal management should always be on the list of must-haves. High heat will damage electronics when stored inside of an enclosure.

Simply put, any type of thermal management will help a computer system run more smoothly.

Download the cooling requirement worksheet for the first step in creating the perfect environment for your electronics.

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When deploying computer, rack, monitor, or printer enclosures in a factory or industrial setting, thermal management (air conditioners, filtered fan systems, heat exchangers, etc.) should be considered to exponentially prolong the life of the chosen electronics.

Once thermal management is installed on (or in) the enclosure, it is important to check and maintain the system often. Regular maintenance will prevent costly breakdowns and downtime. It is necessary on even the most reliable computer enclosure system. Neglecting to maintain proper care will cause systems to be inoperable at their intended capacity and may lead to faulty parts that require costly replacement. In some instances, manufacturers will completely deny warranty claims, if it is discovered that the thermal management systems were neglected.

Depending on environmental conditions, planned maintenance will do wonders to extend the lifetime of enclosure equipment. Simply put, it reduces the probability of failure to electronics and increases a machine’s overall reliability. Developing a structured thermal management maintenance plan will increase operational dependability and longevity.

Routine Maintenance Includes:

• Check filter(s), clean or replace filters as needed
• Re-adjust thermostat(s) depending on fluctuating ambient temperatures
• Check essential functions on all the cooling device’s controls
• Recommended cleaning practices per the manufacturer
• Create a maintenance plan that all users/operators will follow

Consistent maintenance ensures that a fan, heat exchanger, or air conditioner is running at the optimum efficiency, thus lowering energy costs and benefiting the planet. Thermal management maintenance will result in overall longer run times, even under the most extreme temperatures and environmental conditions. Be sure to establish a plan of action, from the beginning, when deploying a computer, rack, monitor, or printer enclosure in a manufacturing environment.

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Why Proper Thermal Management Helps:

1. Prolongs the Life of Electronics

The average lifetime of a computer is approximately 3-5 years. According to AZ Central (USA Today Network), the lifespan is “gauged by a variety of factors including environmental conditions, usage patterns, and computing needs. Many computers will last far longer than this, and possibly a decade or more if properly maintained.” In general, computers and electronics will not survive – on their own – in a hot, dusty manufacturing facility, if not protected inside of a pc enclosure. Furthermore, electronics – installed within the sealed computer enclosure– may also need thermal management to survive. When electronics are used daily, it is good business to maximize their life cycle. If a printer is overheated, then the media may not print properly and if a computer is overheated, it may shut down completely. By keeping electronics running at optimal temperatures, production will never need to slow down.

2. Reduces Costly Downtime

If electronics are housed in an computer enclosure, which is in a hot industrial environment, high ambient temperatures will slowly damage a computer or other electronic devices. If the inside of an enclosure is cool and humidity is removed, the equipment will not overheat and will continue to operate at a peak performance. If the computer or printer is needed for everyday tasks, then it must be WORKING(!)… plain and simple. According to the article, The Cost of IT Downtime, Michael Copeland writes, “Because there are so many differences in how businesses operate, downtime, at the low end, can be as much as $140,000 per hour, $300,000 per hour on average, and as much as $540,000 per hour at the higher end… Downtime is extremely expensive, and in ways that can make or break the success of your organization.” Time is money!

3. Cuts Down on Replacements

Utilizing the same computer enclosure equipment for many years will offer a strong return on investment for businesses. To put it into perspective, the average computer can cost upwards of $800 to $1,200 (if not more), a replacement thermal transfer printer can run from $400 to thousands of dollars, and even standard LCD monitors are a few hundred dollars. Obviously, to save man-hours and money, a company does not want to constantly be swapping out its essential equipment. Plus, replacement products will take a long time to configure, and oftentimes replacements are in short supply – just adding to downtime and lost profits. The learning curve for brand-new equipment is also costly, as it takes time for employees to learn the latest computer system, printer, or other peripheral.

To determine the correct thermal management for an computer enclosure, it is always useful to perform the proper research, so that the electronics being housed are appropriately protected. Companies will often offer a website form to fill out, so that a buyer can purchase the appropriate equipment.

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This formula can also be useful for picking the right thermal management:
(watts x 3.413) + (1.25 x area in square feet x ∆T temperature difference in degrees F) = BTU/hr.

Watts = The total heat load inside the enclosure (the sum of all heat-producing equipment)

Area = Total exposed surface area of the enclosure expressed in square feet

∆T = The difference in temperature between the maximum expected degrees Fahrenheit temperature outside the enclosure and the maximum degrees Fahrenheit temperature allowed inside of the enclosure

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