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Electrical Enclosure panels
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Panel Savings using Modular Panel Savings using Modular Technology and Bus SystemsTechnology and Bus Systems
Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 1
Rittal OverviewRittal Overview• World’s Largest Manufacturer ofWorld s Largest Manufacturer of
Enclosures and Climate Control- >$2.1 Billion- > 80 Countries (250 Stocking Locations Worldwide)- > Manufacture 1 million free standing enclosures, 2.3 million
ll t l d 200 000 i ditiwall mount enclosures, and 200,000 air conditioners per year
• 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 InnovationsRittal 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 systemsy• R-134a refrigerant for a/c systems; RiNano; Condensate Evap.• Industrial PC enclosures• Zinc mounting panelsg p• IT Enclosures (Kiosk Systems)• Industrial Workstations• IP69K Enclosures (high pressure/high temp. hose down)Panel Savings with New Enclosure Technology 3
IP69K Enclosures (high pressure/high temp. hose down)
What is a Modular Enclosure?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 i t it ( t ti ti )• Maintains NEMA integrity (protection rating)
• Offers multiple equipment mounting options (d th dj t bl l ti l l(depth adjustable panel; partial panels; chassis bars; 19” racks; door mounting)
Panel Savings with New Enclosure Technology 4
Modular vs. Traditional design
Traditional
Modular Frame-based Traditional
welded designs (OGB)
designs –Strength from roll formed & welded f(OGB) frame
- vs -All surfaces are load bearing-load bearingstrength from gauge of steel
Panel Savings with New Enclosure Technology 5
Enclosure FunctionsEnclosure Functions
What are the (3) basic functions of anWhat are the (3) basic functions of an enclosure (why would you buy one)?
Panel Savings with New Enclosure Technology 6
Enclosure FunctionsEnclosure FunctionsFunction OGB ModularPlace to put White panel, Zinc panel, depthyour stuff fixed to rear wall adjustable; partial (equipment) panels (F-R, S-S); 19”( q p ) p ( , );
swing frames; chassisbars; DIN rail; mounton 360° (incl. Door)on 360 (incl. Door)
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
Panel Savings with New Enclosure Technology 7
Rittal only
Benefits of Enclosure FunctionsE lEnclosures
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 8
Panel Size
Most panel designers only considerp g ythe mounting panel when laying out theirdesign. Thus, enclosure size isdictated by panel size.dictated by panel size.
A Modular, frame-based system canoffer up to 30% more panel space inoffer up to 30% more panel space inan equivalent size enclosure vs. awelded box due to the latter’s largeflange support areas (Main panelflange support areas. (Main panelonly- not counting other options).
Panel Savings with New Enclosure Technology 9
Panel Comparison (Free Standing)Panel Comparison (Free Standing)(Sq. Inches)
Free Standing OGB: TS8:Free Standing OGB: TS8:90x36x24= 78x32 (2496) 86x39x24= 83x35 (2935)
or 79x39x24= 75x35 (2625)
60x24x18= 48x20 (960) 63x24x20= 59x20 (1180)or 55x24x20= 51x20 (1020)or 55x24x20= 51x20 (1020)
72x60x16= 68x56 (3808) 71x63x16= 67x59 (3953)( ) ( )
84x40x18= 72x33.7(2426) 79x39x20= 75x35 (2625)
10
Assembly Advantages
Door Removal ~ 30 sec (usuallyDoor Removal ~ 30 sec. (usuallynot done on piano hinge box dueto time & difficulty) – avoidshaving to dodge/deal with doorsIn the way of installers.
oror
Panel Savings with New Enclosure Technology 11
Equipment Mounting Options
Many more options are availablewith Modular Enclosures:with Modular Enclosures:
• Partial panels in x-y-z
• Chassis bar for direct or DINRail mounting (components or wireway)
• Load capacity to 500 lbs. Per oad capac ty to 500 bs echassis bar
Panel Savings with New Enclosure Technology 12
Equipment Mounting Options
Many more options are availableMany more options are availablewith Modular Enclosures:
Door mounting for devices &Wireway via standard accessories(no drilling or welding)
Panel Savings with New Enclosure Technology 13
7. Aesthetics…Aesthetics
What kind of impression do you want to make?
Panel Savings with New Enclosure Technology 14
Common Misperceptions –p pModular Systems
M d l t t t (thi• Modular systems are not as strong (thinner 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• Modular systems require a lot of assembly work (“erector set”)
– Only the assembly of the side walls is needed to provide a complete enclosureenclosure
• 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 15
as OGB
Technological ImprovementsTechnological 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 oldenclosure 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)technology (esp. local fab shops)– Those that do (other than Rittal) don’t lead with it;
they lead with OGBPanel Savings with New Enclosure Technology 16
y
Technological ImprovementsTechnological Improvements
M d l i d t i l t ff• Modular industrial systems offer:– Multiple mounting options for components
More flexibility in system designs; lower– More flexibility in system designs; lower “Use” costs (thus lower Total cost)
– More flexibility in incorporating jobMore flexibility in incorporating job changes
– Less need for customization (can use pre-(engineered parts)
– Greatly improved aesthetics
Panel Savings with New Enclosure Technology 17
True Cost AnalysisTrue Cost Analysis(Modular Free-Standing vs. OGB)
P h P i U C t T C tPurchase Price + Use Costs = True Cost-Enclosure & accessories -Time & Space-oriented
tasks: Door removal &tasks: Door removal &replacement, Panel removal& replacement, grounding efforts,ease of access & movement inease of access & movement inshop, time on shop floor (throughput),product mounting options, weight/freightfactors, ease of cutouts, flexibilityyof job changes, range of accessories,ease of installation of accessories,ease of working/wiring inside.
Panel Savings with New Enclosure Technology 18
Use Cost: Door removal (f )Use Cost: Door removal (free standing)
• 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 cleaningC t b ki i l t ti• Cannot be working in enclosure at same time
• TS8: Door removal 30 sec ; cutouts at bench• TS8: Door removal 30 sec.; cutouts at bench• 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. OGBPanel Savings with New Enclosure Technology 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 spaceenclosure back up. (Takes up additional space –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. savingsfor 10 enclosures 80/90 min. savings
• No added space required (for laying down)• Panel depth adjustable in 1” increments
Panel Savings with New Enclosure Technology 20
Use Cost: Grounding (Earthing)Use Cost: Grounding (Earthing)
• White panel: Drive ground screw; test for ground; if no ground scrape to bare metal;ground; if no ground, scrape to bare metal; then test again for ground; touch up.
• Potentially 4 labor steps per panel• Potentially 4 labor steps per panel• 50 panels / 200 labor steps /100+ minutes
possible (vs zinc panels – no added time)possible (vs. zinc panels no added time)
Panel Savings with New Enclosure Technology 21
Use Cost: Freight (f t di )Use Cost: Freight (free standing)
• OGB 2-door: 300 lbs. (136 kg.) heavier thanOGB 2 door: 300 lbs. (136 kg.) heavier than TS8 2-door (Single door to 185 lbs. heavier)
• 10 Enclosures = 3000 lbs. (1360 kg.) savings on freight / shippingg g
Panel Savings with New Enclosure Technology 22
Weight ComparisonsWeight Comparisons (Freight; ease of handling)
WEIGHT COMPARISONS (lbs.)- FREE STANDING CABINETS
OGB TS8
SINGLE DOORSize 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 DOORDOUBLE 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 23
Use Cost: Adding CutoutsUse Cost: Adding Cutouts• OGB: Cutouts done while enclosure is standing or on
it b kits back • Shavings go in box, requires cleaning• Cutouts done wrong must be welded overCutouts 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.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
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?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 25
8. Cable Cutouts / Modifications, cont.and M tManagement
How are panel builders and field installers going to work p g gwith the enclosure? This impacts how components are installed and how the enclosure is modified, not only inside but outside the enclosureinside but outside the enclosure.
Which method saves time and money, is safer and ensures greater quality?ensures greater quality?
or
Panel Savings with New Enclosure Technology 26
Use Cost: Job Changes (f )Use Cost: Job Changes (free standing)
• OGB: If panel is full and job requires• OGB: If panel is full and job requires additional equipment installed, a new and larger enclosure is usually required; removal g y qand reinstallation of product follows.
• TS8: Optional panels, chassis bars, 19” rack possible for new equipment mounting
• Worst case: Add new section (baying) for new• Worst case: Add new section (baying) for new equipment. No rework of product.
Panel Savings with New Enclosure Technology 27
Modular System vs. OGBISSUE MODULAR OGB ADVANTAGE
Strength From closed frame From heavy walls Lighter system; easier(Rittal; open for comp.) to handle; lower freight( ; p p ) ; 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 Partial coverage ~15% more spacePanel size Full 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)
Sid ll R bl Fi d E t i idSidewalls Removable Fixed Easy access to inside;ease of cutouts
Roof, Rear wall Removable Fixed “ “ “
Suiting Easily joined N/A Accommodate jobchanges/add’l. equip.
Weight (2-Dr.) 300 lbs. Less Heavy steel Less freight; easier to move
Panel Savings with New Enclosure Technology 28
Modular System vs. OGBISSUE MODULAR OGB ADVANTAGE
Mounting on Panels, door bars, None More mountingInside of doors DIN rail surface; flexibilityInside of doors DIN rail surface; flexibility
Mounting panel Zinc plated; C-fold Painted steel, Stronger; immediateDesign (Rittal) L-fold ground/no scraping
Internal mounting Bars; panels; DIN None More mountingOptions 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 wear16/14 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 29
Total Cost – MOD vs. OGB Summary
Issue MOD OGBIssue MOD OGBGlobal SupportPanel SizeDoors On/OffCutoutsPanel In/OutPanel AdjustmentGroundingWeight/FreightAdd'l. Mounting spaceWi iWiring accessJob change flexibilityRange of accessoriesAesthetics
Panel Savings with New Enclosure Technology 30
Aesthetics
Modular Enclosures –Trending Factors
• Globalization– Mergers/Acquisitions (US/EU/Asian)Mergers/Acquisitions (US/EU/Asian)– Modular already standard / multiple countries– Certifications (UL, CE, TUV, DIN, IEC, etc.)– No local Fab/ OGB support– 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- Plant Floor / Real Estate Savings / Lower Cost
• Flexibility- Design Changes/ Time to Market/ Plant Floor Appearance
Panel Savings with New Enclosure Technology 31
OEMUsers and Specifiers of Modular Enclosures
OEM
Panel Savings with New Enclosure Technology 32
Sample Application: Heavy Industry
Panel Savings with New Enclosure Technology 33
Sample Application: Process Control
Panel Savings with New Enclosure Technology 34
Sample Application: Drives and Controls
Panel Savings with New Enclosure Technology 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•Cost savings can exceed 25% for a system
Panel Savings with New Enclosure Technology 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 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 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)mounting of components (pre-assebly).
•Simplified future expansion options
•Elimination of having to cut, bend or drill custom busbar
Panel Savings with New Enclosure Technology 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 breakersMultiple circuit breakers
High amperage distribution
•Drives
•Switchgear
Panel Savings with New Enclosure Technology 40
Multiple power distribution blocks
High cost
Not always touch safe
Labor intensive
Wire bend space
Panel space
Wire size constraintsWire size constraints
Limited or no future expansion
Panel Savings with New Enclosure Technology 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 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
800A 1600A250A3x 63A
Panel Savings with New Enclosure Technology 43
800A 1600A250A3x 63A
Large parallel wire runs
Cable routing and labeling
Wire duct
Lugs
Multiple terminations
Wire bend space
Panel Savings with New Enclosure Technology 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
1600A360A 1600AMain CBSystem
400A CB’s
250ACB’s
Panel Savings with New Enclosure Technology 45
Lots of Grounding
Mount load center bus or terminal blocks
Attach individual panel grounds
Daisychain panel grounds and house ground
PanelGrounds
PanelGrounds
PanelGrounds
House Ground
Panel Savings with New Enclosure Technology 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 20 - 12 AWGNo-DrillSplice kitsSplice kits(if needed)
1 00 AWGPanel Savings with New Enclosure Technology 47
1 - 00 AWG
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
Distribution2 4” Wire DuctBlock!
2-4 Wire Duct
Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER
Panel Savings with New Enclosure Technology 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-STARTERRi-STARTER
Panel Savings with New Enclosure Technology 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 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 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 certificationRequired testing and certification
•SCCR pre-determined (holder spacing)
•Global certifications – UL, cUL, CE, etc...
Panel Savings with New Enclosure Technology 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% dependingp g
on labor rates
Panel Savings with New Enclosure Technology 52
Application Photos – MCCB’s, Flexible Busbar
Panel Savings with New Enclosure Technology 53
Application Photos – Miniature CBs, Contactors
Panel Savings with New Enclosure Technology 54
Application Photos – MCCBs, MSP
Panel Savings with New Enclosure Technology 55
Application Photos – MCCBs, Fusing and Flexible Busbar
Panel Savings with New Enclosure Technology 56
SummaryModular Advantages•Larger panels
Bus System Advantages•Labor savings (less drilling,
i i )•Flexibility in mounting
•Easier wiring access
wiring)
•Space savings (no line side wireway, smaller bend radius)
•Job change flexibility •Baying S-S, F-R
•Lower Use/Assembly
•Eliminate components (DIN rail, wireway, lugs, distribution blocks)•Lower Use/Assembly
costs•Panel insertion/removal
•Panel depth adjustability
blocks)
•Easier grounding solutions
•Job change flexibility•Panel depth adjustability
•Cutouts
•Door removal
•Freight etc
g y
•Future expansion easy
Panel Savings with New Enclosure Technology 57
•Freight, etc.