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Reducing Electrical Enclosure Size
 

Reducing Electrical Enclosure Size

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Reducing Enclosure Size using Modular Technology and Bus Systems (Rittal) Drive for Technology presentation 2010

Reducing Enclosure Size using Modular Technology and Bus Systems (Rittal) Drive for Technology presentation 2010

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    Reducing Electrical Enclosure Size Reducing Electrical Enclosure Size Presentation Transcript

    • Panel Savings using Modular Technology and Bus Systems Bob Downing – Rittal Corporation g Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 1
    • Rittal Overview • World’s Largest Manufacturer of World s Enclosures and Climate Control - >$2.1 Billion - > 80 Countries (250 Stocking Locations Worldwide) - > Manufacture 1 million free standing enclosures, 2.3 million wall mount enclosures, and 200 000 air conditioners per year ll t l d 200,000 i diti • Industry Leader in Innovation - 250 to 500 New Products per Year - Pioneered many Innovations Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 2
    • Rittal Innovations • Foamed-in-place robotically-applied gasketing • Easily removable doors/interchangeable doors • Modular free-standing industrial enclosures • Unibody enclosure design • E-coat dip-bath primer process • Full usable width bus bar • Articulated arm systems y • R-134a refrigerant for a/c systems; RiNano; Condensate Evap. • Industrial PC enclosures • Zinc mounting p g panels • IT Enclosures (Kiosk Systems) • Industrial Workstations • IP69K Enclosures (high pressure/high temp. hose down) Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 3
    • What is a Modular Enclosure? • A Frame-based design for free-standing cabinets, allowing for additional sections (doors) to be added side to side, front to rear or on top (“baying”, “suiting” or “joining”). • M i t i NEMA integrity (protection rating) Maintains i t it ( t ti ti ) • Offers multiple equipment mounting options (depth dj t bl (d th adjustable panel; partial panels; l ti l l chassis bars; 19” racks; door mounting) Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 4
    • Modular vs. Traditional design Modular Frame-based Traditional designs – welded designs Strength from roll formed & welded (OGB) frame f All surfaces are - vs - load bearing- bearing strength from gauge of steel Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 5
    • Enclosure Functions What are the (3) basic functions of an enclosure (why would you buy one)? Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 6
    • Enclosure Functions Function OGB Modular Place to put White panel, Zinc panel, depth your stuff fixed to rear wall adjustable; partial ( q p (equipment)) p panels ( (F-R, S-S); 19” , ); swing frames; chassis bars; DIN rail; mount on 360° (incl. Door) 360 Protection/security N3R,12, 4, 4X N3R*,12, 4*, 4X* (also IP) Aesthetics Old look (WWII) High-Tech (hidden (piano hinge; clamps) hinges, no clamps) *Rittal only Rittal Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 7
    • Benefits of Enclosure Functions Enclosures E l Over and beyond a very basic welded-box, modular enclosures provide:  Much greater range of dimensions in H x W x D  Comprehensive, quick-install accessories  Multiple mounting options within the same platform  Ease of wiring due to removable skins & doors  Unique configurations with standard inventory Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 8
    • Panel Size Most panel designers only consider p g y the mounting panel when laying out their design. Thus, enclosure size is dictated by panel size. A Modular, frame-based system can offer up to 30% more panel space in an equivalent size enclosure vs. a welded box due to the latter’s large flange support areas (Main panel areas. only- not counting other options). Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 9
    • Panel Comparison (Free Standing) (Sq. Inches) Free Standing OGB: TS8: 90x36x24= 78x32 (2496) 86x39x24= 83x35 (2935) or 79x39x24= 75x35 (2625) 60x24x18= 48x20 (960) 63x24x20= 59x20 (1180) or 55x24x20= 51x20 (1020) 72x60x16= 68x56 (3808) ( ) 71x63x16= 67x59 ( (3953) ) 84x40x18= 72x33.7(2426) 79x39x20= 75x35 (2625) Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 10
    • Assembly Advantages Door Removal ~ 30 sec. (usually sec not done on piano hinge box due to time & difficulty) – avoids having to dodge/deal with doors In the way of installers. or Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 11
    • Equipment Mounting Options Many more options are available with Modular Enclosures: • Partial panels in x-y-z • Chassis bar for direct or DIN Rail mounting (components or wireway) • Load capacity to 500 lbs. Per oad capac ty bs e chassis bar Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 12
    • Equipment Mounting Options Many more options are available with Modular Enclosures: Door mounting for devices & Wireway via standard accessories (no drilling or welding) Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 13
    • 7. Aesthetics…Aesthetics What kind of impression do you want to make? Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 14
    • Common Misperceptions – p p Modular Systems • M d l systems are not as strong (thinner Modular t t t (thi gauge steel) as the traditional style (OGB) – The TS8 holds 3000 lbs., the same as a fully equipped F150 truck • Modular systems are more expensive – They are overall more cost competitive than OGB • Modular systems require a lot of assembly work (“erector set”) – Only the assembly of the side walls is needed to provide a complete enclosure • Must order a bunch of part numbers – Only 2 part numbers are needed to provide a complete enclosure, the same as OGB Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 15
    • Technological Improvements • Most designers have switched to current (2000’s) control technology in PLC’s, Starters, Drives, etc. • Yet they package these products in 1940’s-1950’s enclosure designs (end product looks like old technology) • Most are unaware of improvements in enclosure designs unless they study the global market – Most enclosure manufacturers don’t have the technology (esp local fab shops) (esp. – Those that do (other than Rittal) don’t lead with it; they lead with OGB y Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 16
    • Technological Improvements • M d l i d t i l systems offer: Modular industrial t ff – Multiple mounting options for components – More flexibility in system designs; lower “Use” costs (thus lower Total cost) – More flexibility in incorporating job changes – Less need for customization (can use pre- ( engineered parts) – Greatly improved aesthetics Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 17
    • True Cost Analysis (Modular Free-Standing vs. OGB) Purchase P i P h Price + U C t = Use Costs True C t T Cost -Enclosure & accessories -Time & Space-oriented tasks: Door removal & replacement, Panel removal & replacement, grounding efforts, ease of access & movement in shop, time on shop floor (throughput), product mounting options, weight/freight factors, ease of cutouts, flexibility y of job changes, range of accessories, ease of installation of accessories, ease of working/wiring inside. Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 18
    • Use Cost: Door removal (free standing) (f ) • OGB: 30-45 minutes on/off, so most leave door on. Cutouts done on door while enclosure is on its back. • Shavings go in enclosure, require cleaning • C Cannot be working i enclosure at same ti tb ki in l t time • TS8: Door removal 30 sec ; cutouts at bench sec.; • No cleaning in enclosure; can also work in enclosure while door is being cut • No dodging, moving or working around doors. • Similar for Wall Mount doors vs. OGB Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 19
    • Use Cost: Panel Insertion (free standing) • OGB: Use crane or fork lift to put enclosure on it’s back, then drop panel in over studs, then raise enclosure back up (Takes up additional space – up. sometimes in aisle). Panel in fixed location. • Approximately 10 min. / enclosure • Usually staged due to limited crane availability • 10 enclosures = 100 minutes total • TS8: 1-2 minutes / enclosure; 10-20 minutes total for 10 enclosures 80/90 min. savings enclosures- • No added space required (for laying down) • Panel depth adjustable in 1” increments Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 20
    • Use Cost: Grounding (Earthing) • White panel: Drive ground screw; test for ground; if no ground scrape to bare metal; ground, then test again for ground; touch up. • Potentially 4 labor steps per panel • 50 panels / 200 labor steps /100+ minutes possible (vs zinc panels – no added time) (vs. Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 21
    • Use Cost: Freight (f standing) (free t di ) • OGB 2 door: 300 lbs. (136 kg.) heavier than 2-door: TS8 2-door (Single door to 185 lbs. heavier) • 10 Enclosures = 3000 lbs. (1360 kg.) savings on freight / shipping g g Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 22
    • Weight Comparisons (Freight; ease of handling) WEIGHT COMPARISONS (lbs.)- FREE STANDING CABINETS OGB TS8 SINGLE DOOR Size Enclosure Panel Total Size Enclosure * Sidewalls (Pr) Total %TS to OGB Savings/Cab. 72x25x18 250 45 295 71x24x20 206 24 230 0.78 65 72x31x24 290 57 347 71x32x24 265 26 291 0.84 56 90x24x20 313 56 369 87x24x24 249 35 284 0.77 85 90x36x24 440 88 528 87x32x24 307 35 342 0.65 186 DOUBLE DOOR 72x48x18 575 119 694 71x47x20 382 24 406 0.59 288 72x48x24 600 119 719 71x47x24 396 26 422 0.59 297 90x48x20 650 144 794 87x47x24 458 35 493 0.62 301 FMD (1 DOOR) 84x40x18 642* - 642 79x40x20 346 28 374 0.58 268 Note: (*)= Weight includes mounting panel. If Plinth is necessary, weights would be 8 to 12 lbs.(47x24= 12 lbs.) for complete Plinth. Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 23
    • Use Cost: Adding Cutouts • OGB: Cutouts done while enclosure is standing or on its b k it back • Shavings go in box, requires cleaning • Cutouts done wrong must be welded over • Cannot work in enclosure at same time • Cutting 10 or 12 ga. Steel – hard on tools • TS8: Cutting can be done at work bench – no internal cleaning. Errors easily fixed. • Cutting 16 or 14 ga. Steel- easier on tools • Can work in enclosure while cutouts are done on bench Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 24
    • Consider this… Cutouts / Modifications When the installer cuts into the panel, will metal filings fall on my electrical equipment? How easy is it to do the cutouts? How do I ensure that the equipment is protected during installation? Do I have enough room inside the enclosure for wire bending (per NEC), wire bundles, termination points, tie-off points and spares? Is there enough room around my enclosure for the installer to work? Vs Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 25
    • 8. Cable Cutouts / Modifications, cont.and Management M t How are panel builders and field installers g g to work p going with the enclosure? This impacts how components are installed and how the enclosure is modified, not only inside but outside the enclosure enclosure. Which method saves time and money, is safer and ensures greater quality? or Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 26
    • Use Cost: Job Changes (free standing) (f ) • OGB: If panel is full and job requires additional equipment installed, a new and larger enclosure is usually required; removal g y q and reinstallation of product follows. • TS8: Optional panels, chassis bars, 19” rack possible for new equipment mounting • Worst case: Add new section (baying) for new equipment. No rework of product. Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 27
    • Modular System vs. OGB ISSUE MODULAR OGB ADVANTAGE Strength From closed frame From heavy walls Lighter system; easier ( (Rittal; open for comp.) ; p p) to handle; lower freight ; g Panel insert Slide out on feet Put on back; lift in Easier in/out; less use (in vertical position) in/out with crane cost; easier on paint Panel size Full Ht /Width Ht./Width Partial coverage ~15% more space Door removal Captive hinges; on/ Piano hinge; 45min- Easy to work on; allows off in 20 seconds 1hr. On/off access (esp. multidoor) Sidewalls Sid ll Removable R bl Fi d Fixed Easy access to inside; E t i id ease of cutouts Roof, Rear wall Removable Fixed “ “ “ Suiting Easily joined N/A Accommodate job changes/add’l. equip. Weight (2-Dr.) 300 lbs. Less Heavy steel Less freight; easier to move Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 28
    • Modular System vs. OGB ISSUE MODULAR OGB ADVANTAGE Mounting on Panels, door bars, None More mounting Inside of doors DIN rail surface; flexibility Mounting panel Zinc plated; C-fold Painted steel, Stronger; immediate Design (Rittal) L-fold ground/no scraping Internal mounting Bars; panels; DIN None More mounting Options rail; swing frames surface; flexibility Gasketing Foamed in place Strip tape Better seal; memory (Rittal) ( ) retention Adding cutouts At workbench, on In place, on 12/ Easier to cut; less wear 16/14 ga. Steel 10 ga. Steel on tools; no shavings Paint Finish E-Coat/Powder Coat Powder Coat Longer lasting, (Rittal) scratch-resistant Accessories Very wide range Limited Flexibility/less custom Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 29
    • Total Cost – MOD vs. OGB Summary Issue MOD OGB Global Support Panel Size Doors On/Off Cutouts Panel In/Out Panel Adjustment Grounding Weight/Freight Add'l. Mounting space Wiring access Wi i Job change flexibility Range of accessories Aesthetics Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 30
    • Modular Enclosures –Trending Factors • Globalization – Mergers/Acquisitions (US/EU/Asian) – Modular already standard / multiple countries – Certifications (UL, CE, TUV, DIN, IEC, etc.) – No local Fab/ OGB support • Standardization - Ability to move equipment globally & match up - No local Fab/ OGB meets all standards • Smaller Footprint - Plant Floor / Real Estate Savings / Lower Cost • Flexibility - Design Changes/ Time to Market/ Plant Floor Appearance Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 31
    • Users and Specifiers of Modular Enclosures OEM Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 32
    • Sample Application: Heavy Industry Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 33
    • Sample Application: Process Control Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 34
    • Sample Application: Drives and Controls Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 35
    • Small Bus Systems •May be used in Modular or non-Modular enclosures •Offer numerous advantages over traditional wiring and mounting methods •Cost savings can exceed 25% for a system Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 36
    • Definition of a Busbar System Solid copper bars that act as a conductor of electricity. •Interlocking bars for various lengths/configurations •Standardized power connections or taps •Standardized connection and mounting of electrical components. •May be enclosed or exposed in some cases Modular approach to traditional power distribution Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 37
    • Benefits of using a busbar system Reduction in enclosure or mounting panel size •Elimination of distribution blocks •Elimination of large parallel cable runs with large bend radii •Elimination of line-side wire duct •Use of smaller internationally accepted components Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 38
    • Benefits of using a busbar system Reduction in assembly time •Reduction in number of component mounting holes that must be drilled and tapped in mpl •Elimination of line-side wiring (stripping, labeling and routing) •Bus-mounted adaptors allow for quick power taps and mounting of components (pre-assebly). (pre-assebly) •Simplified future expansion options •Elimination of having to cut, bend or drill custom busbar Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 39
    • What is an ideal busbar application? Multiple power distribution blocks Large parallel wire runs Lots of grounding Motor starters (as few as 4) Lots of three-phase fusing Multiple circuit breakers High amperage distribution •Drives •Switchgear Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 40
    • Multiple power distribution blocks High cost Not always touch safe Labor intensive Wire bend space Panel space Wire size constraints Limited or no future expansion Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 41
    • Multiple power distribution blocks Mounting holes – locate, drill and tap Wiring – cut, strip, route, i.d., terminate (line/load) Wire duct – mounting, bending space 4-5” Wire Duct Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 42
    • Multiple power distribution blocks – Using busbar as a distribution block Install busbar system – 4 screws for complete system Main attaches to bus with single, flexible busbar feed Numerous tap options along bus for any wire size Future Expansion Touch safe Ri-STARTER Ri-STARTER 3x 63A 250A 800A 1600A Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 43
    • Large parallel wire runs Cable routing and labeling Wire duct Lugs Multiple terminations Wire bend space Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 44
    • Large parallel wire runs – Using busbar and flexible busbar in place of large parallel cables Busbar system replaces parallel cables and blocks Flexible busbar for feeding large loads without the needs for lugs Wire bending space reduced with less terminations 360A 1600A System Main CB 400A 250A CB’s CB’s Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 45
    • Lots of Grounding Mount load center bus or terminal blocks Attach individual panel grounds Daisychain panel grounds and house ground Panel Panel Panel Grounds Grounds Grounds House Ground Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 46
    • Lots of Grounding – Using a 1-pole busbar system Continuous ground conductor Easy clamping of wires with conductor connection clamps No drilling or bolting... even when splicing 00 - 350 MCM No-Drill 20 - 12 AWG Splice kits (if needed) 1 - 00 AWG Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 47
    • Motor Starters Locate and mount DIN rail (Worse for panel mounted devices) Cut, route, strip, i.d., terminate L1/L2/L3 Line-side wire duct 2-4 2 4” Wire Duct Distribution Block! Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 48
    • Motor Starters – Using a busbar system Single power feed for complete system Line-side adaptor wires stripped and ready for device Easy expansion and touch safe Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 49
    • Ways to reduce your system cost •Reduction of... •Engineering and design time •Due to pre-engineered busbar systems •Due to pre-engineered enclosures •Quantity of enclosures or enclosure size •Due to elimination of distribution blocks •Due to elimination of line-side wiring & wiring duct •Due to elimination of separate DIN rail •Due to elimination of large parallel cable runs •Due to elimination of multiple grounding systems Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 50
    • Ways to reduce your system cost Reduction of... •Integration time •Due to reduction in drilled tapped mouting holes •Due to elimination of line side wiring •Due to quick mounting and connection of components •Due to quick interconnection or power drops •Due to pre-engineered switchgear connection kits •Required testing and certification Required •SCCR pre-determined (holder spacing) •Global certifications – UL, cUL, CE, etc... Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 51
    • Ways to reduce your system cost Reduction of... •Maintainence and repair time •Easier to trouble shoot, no tracing line-side wires •Quick change bus-mounted components •Availability of replacment parts worldwide Total System Savings: 25-35% depending p g on labor rates Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 52
    • Application Photos – MCCB’s, Flexible Busbar Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 53
    • Application Photos – Miniature CBs, Contactors Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 54
    • Application Photos – MCCBs, MSP Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 55
    • Application Photos – MCCBs, Fusing and Flexible Busbar Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 56
    • Summary Modular Advantages Bus System Advantages •Larger panels •Labor savings (less drilling, ii ) wiring) •Flexibility in mounting •Space savings (no line side •Easier wiring access wireway, smaller bend radius) •Job change flexibility •Eliminate components (DIN •Baying S-S, F-R rail, wireway, lugs, distribution •Lower Use/Assembly blocks) costs •Easier grounding solutions •Panel insertion/removal •Panel depth adjustability •Job change flexibility g y •Cutouts •Future expansion easy •Door removal •Freight, •Freight etc. etc Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 57