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Energy Efficient Cooling
Energy Efficient Cooling / C Westwood / 04/03/2015
Energy Efficient Cooling / C Westwood / 04/03/2015
What’s in it for you?
The aim of this seminar is to give you a better understanding of the:
need for enclosure cooling
the cost of ignoring overheating
tell-tale signs that an existing enclosure is too hot
methods used to establish the enclosure internal temperature
value of planning
suitability of cooling solutions for particular environments
relative energy efficiency of different cooling products
Impact of incorrect installation
Importance of service and maintenance
Energy Efficient Cooling / C Westwood / 04/03/2015
Why do we need enclosure cooling?
What is an enclosure?
An enclosure is a closed housing with access for creating
a protective environment for installed equipment at a
specified location
An enclosure is a closed housing with access for creating
a protective environment for installed equipment at a
specified location
High
temperatures
Low
temperatures Condensate
Dust, dirt &
Corrosive
substances
Energy Efficient Cooling / C Westwood / 04/03/2015
Why do we need enclosure cooling? Reasons for electrical equipment failure
Source: US Air Force Avionics Integrity Program (AVIP)/FLOMERICS Limited
80% of electrical equipment failures may be addressed using an
appropriate climate control solution
Temperature 55%
Vibration 20%
Moisture 19%
Dust 6%
Energy Efficient Cooling / C Westwood / 04/03/2015
Why do we need enclosure cooling?
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6 7 8 9 10
En
clo
su
re in
tern
al te
mp
era
ture
(°C
)
Service life (years)
Energy Efficient Cooling / C Westwood / 04/03/2015
Why do we need enclosure cooling? Effect of temperature on component service life
Source: Arrhenius equation
Energy Efficient Cooling / C Westwood / 04/03/2015
The cost of ignoring overheating
A vicious cycle: Components generate heat –
high temperatures reduce service life of components
The risk of breakdown increases dramatically
without climate control
Breakdown costs per hour for various manufacturing sectors
Components generate heat
High temperatures impact severely
on the service life of components
Cooling news of the day March 2015 Free Information
COOL NEWS
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6 7 8 9 10
Am
bie
nt
tem
pe
ratu
re (
°C)
Service life (years)
£ 0
£ 200,000
£ 400,000
£ 600,000
£ 800,000
£ 1,000,000
£ 1,200,000
£ 1,400,000
£ 1,600,000
£ 1,800,000
£ 2,000,000
Automotive Food & Beverage
£ 2,000,000
£ 60,000
Energy Efficient Cooling / C Westwood / 04/03/2015
Listen to what the plant is telling you
Energy Efficient Cooling / C Westwood / 04/03/2015
Now prove it…
Energy Efficient Cooling / C Westwood / 04/03/2015
Planning your cooling requirements
Energy Efficient Cooling / C Westwood / 04/03/2015
Different cooling methods for different environments
Cooling with ambient air
Cooling units
Air/water heat exchangers
Energy Efficient Cooling / C Westwood / 04/03/2015
Fan-and-filter unit Increasingly efficient
Question:
How much cooling could a single
fan-and-filter unit provide, when
maintaining an enclosure internal
temperature of 40 °C in an
ambient temperature of 20 °C?
4.4 kW
Energy Efficient Cooling / C Westwood / 04/03/2015
Fan-and-filter unit Think positive
Energy Efficient Cooling / C Westwood / 04/03/2015
Fan-and-filter unit Feeling the pressure
0
50
100
150
200
250
300
0 100 200 300 400 500 600 700
Syste
m p
ressu
re (
Pa
)
Air throughput (m3/h)
Old fan-and-filter unit
Outlet filter
New fan-and-filter unit
Energy Efficient Cooling / C Westwood / 04/03/2015
Air/air heat exchanger What do they offer?
Energy efficient cooling solution that restricts the ingress of dirt
and dust into the enclosure
Maximum specific cooling
capacity from a single unit
Fan-and-filter unit: 219 W/K
Air/air heat exchanger: 90 W/K
Energy Efficient Cooling / C Westwood / 04/03/2015
Cooling unit What do they offer?
Capable of cooling the temperature inside the enclosure to a level
below that of the ambient
Internal
External
Evaporator
Condenser
Expansion
valve
Compressor
Refrigerant
R134a
Question:
How much cooling is provided by a
fan-and-filter unit maintaining an
enclosure internal temperature of
35 °C in an ambient temperature of
35 °C?
None
Energy Efficient Cooling / C Westwood / 04/03/2015
Cooling unit Increasingly efficient
Consumes upto
45 % less energy
Energy Efficient Cooling / C Westwood / 04/03/2015
Cooling unit What’s next?
Compressor control
Air/air heat exchanger
Fan control
Energy Efficient Cooling / C Westwood / 04/03/2015
Air/water heat exchanger What do they offer?
XX
Energy Efficient Cooling / C Westwood / 04/03/2015
Air/water heat exchanger Energy savings example
Chilled
water
flow
Warm
water
return
Energy savings of 40 %
Energy Efficient Cooling / C Westwood / 04/03/2015
Avoid typical installation mistakes
Energy Efficient Cooling / C Westwood / 04/03/2015
Is no maintenance a false economy?
Energy Efficient Cooling / C Westwood / 04/03/2015
Efficient cooling checklist
4. Control accessories installed
2. Heat loss in enclosure < cooling equipment output
5. Leave the temperature setpoint at the factory setting,
35 °C
3. Installation as per the manufacturer’s instructions
6. Enclosure sealed (ingress protection category IP54)
7. Service cooling units and filters on a regular basis
1. Heat loss calculations undertaken and climate control
products selected using software
Thank you.
Energy Efficient Cooling / C Westwood / 04/03/2015
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