Real Life Expectancy Cost has three main factors determining the appropriate electrical and electronic panel cooling cost. These are energy usage, maintenance cost, and life expectancy.
Correct Sizing
The total heat load in your enclosure includes heat from your electrical equipment and heat transferred from the environment. To specify the correct enclosure air conditioner size, use online heat load calculators or get direct assistance from suppliers and manufacturers. Incorrectly sizing the system, whether too low or too high, directly increases energy or utility costs.
A standard air conditioner uses energy mainly through the compressor, which operates at about a 50% duty cycle in normal applications. A smaller air conditioner requires the compressor to function for more time while a larger air conditioner consumes more energy even if it is in operation only for a shorter time. Vortex tube-operated control panel coolers use more compressed air if over-sized, but on-off control can mitigate this.
Temperature differential from ambient to desired internal temperature
The difference between your enclosure’s desired internal temperature and the ambient temperature directly affects the air conditioner’s energy usage. Solar heat gain adds heat to an outdoor enclosure exposed to the sun, significantly increasing the air conditioner’s heat load. For example, a 10 kW variable frequency drive dissipates over 300 W, while a 30 °F temperature differential adds over 200 W of heat load. Using your air conditioner outdoors significantly increases its energy usage compared to an indoor unit of the same capacity.
Standard air conditioners are less efficient in elevated ambient environments. Vortex tube-operated air conditioners maintain good cooling efficiency over a wide range of high ambient temperatures but lose efficiency if the compressed air supply is too warm or hot.
Life Expectancy Cost Cooling efficiency factor
Traditional enclosure air conditioners are available in different grades depending on their efficiency of cooling and defined by a cooling efficiency factor which is the ratio of useful cooling capacity to the power consumed by the air conditioner to produce the cooling effect. Purchasing an enclosure cooling system that has a higher cooling efficiency factor could save on energy costs.
Vortex tube-operated units are relatively efficient across any ambient environment range when properly designed. Ensure they come from respected suppliers and have necessary electrical approvals, such as ULC or other valid certifications, to guarantee quality materials. Their cooling efficiency depends on the supplied compressed air temperature, not the ambient air temperature.
Environmental conditions and location
The level of humidity and particulate matter in the environment can adversely impact the performance of standard air conditioners. The function of the cooling system is to provide the enclosure with dust-free, dry, cool air. For this reason, the enclosure air conditioner is designed to operate with a sealed enclosure so that the inside air is constantly recirculated through the air conditioner.
If your electrical enclosure is in an environment with high particulate levels, the air conditioner’s performance decreases as the condenser inlet filter clogs. Regular maintenance is necessary for optimal performance and low energy costs. In harsh conditions, vortex tube-operated units become economical. The increased compressed air cost is offset by eliminating the time and filter replacement costs that can rapidly increase.
Standard air conditioners need adequate ventilation around the condenser inlet and exhaust to maintain performance. Keep the enclosure and air conditioner at least three inches from other surfaces to avoid performance degradation and increased energy costs. Vortex tube-operated units are advantageous in tight areas since they don’t require such space for ventilation.
If the control panel and the cabinet enclosure cooler are subjected to high vibration, standard air conditioners will maintain their cooling capacity over a dramatically reduced time period requiring refrigerant replacement. This is another are where vibration resistance vortex tube-operated coolers can be much less costly over time. In general, vortex tube-operated units, even in harsh environments as just described can easily last 5 years or more with minimal maintenance and attention.
Life Expectancy Cost Age and maintenance related degradation
The pubished energy costs for any traditional enclosure air conditioner system is typically for a new air conditioner when all the individual components operate at optimum efficiency. Over time, the performance of the components deteriorate along with cooling efficiency. Regular maintenance can boost the performance and lifespan of the system.
Replacing or cleaning and reusing filters are important and requite more attention the more harsh the environment. Keeping the condenser and evaporator coils dirt free is important to lowering the energy consumption costs of a standard air conditioner. But the older the air conditioning system is, it will consume more energy than a newer, comparable system.
For vortex tube-operated air conditioner, the key to maintaining efficiency is using proper filtered compressed air. As long as the air remains clean, the unit will stay clean and efficient throughout its life. Standard air conditioners last 1 to 5 years with proper maintenance, depending on the environment, and can last even longer with consistent care.
Vortex tube-operated units often have a five-year guarantee if the compressed air stays clean, requiring minimal maintenance while maintaining cooling efficiency. If kept clean, a unit can easily last over ten years.
Important Design Features
Standard air conditioner designs, like thermal expansion valves and efficient condensate management systems, improve unit efficiency. Install vortex tube-operated units with a thermostat and solenoid valve or advanced systems to turn off when not needed. This approach dramatically reduces energy costs.
In summary, real-life expectancy cost depends on more than initial costs. It also considers system efficiency, energy costs, and estimated lifetime maintenance, especially in the operating environment.
