Electrical control cabinets often overheat even when ambient temperature appears normal.
You walk into the facility. The room feels manageable — 26–30°C (78–86°F). But when you open the enclosure, the internal temperature is far higher. Drives feel hot to the touch. PLCs are warm. Fans are running constantly.
This is not unusual.
It’s a heat load problem — not an air temperature problem.
Why Cabinet Temperatures Rise Unexpectedly
Electrical enclosures trap heat by design. Even moderate internal loads can push temperatures beyond component ratings.
Common causes include:
1. Internal Heat Load From Drives and Power Supplies
Variable frequency drives (VFDs), transformers, and power supplies generate continuous heat. When several components operate simultaneously, internal temperature can rise 10–20°C above ambient.
2. Poor Internal Airflow
Fans circulate air, but they often recirculate hot air inside the enclosure rather than removing heat. Without directed cooling, hotspots form around high-load components.
3. Outdoor Solar Gain
For exterior panels, direct sun exposure can raise enclosure surface temperature significantly. Even if ambient air is moderate, solar radiation adds continuous thermal load.
4. Humid or Tropical Conditions
In high humidity environments, traditional fan/filter units struggle. Moving humid air into the enclosure can create condensation risk without effectively reducing internal temperature.
5. Undersized Cooling or No Cooling at All
Many enclosures rely on passive ventilation that was adequate at installation — but not after additional equipment was added later.
Why Traditional Fan Cooling Often Fails
Fan and filter systems depend on ambient air being cooler than the target internal temperature.
If ambient air is warm — or if humidity is high — airflow alone does not remove enough heat. It may even introduce contaminants or moisture.
This is where cooling method selection becomes critical.
When Vortex Cooling Makes Sense
A vortex tube cooling system uses compressed air to generate cold air without refrigerants or moving parts.
It can be effective when:
- Heat load is localized
- Ambient air is warm or humid
- Contamination risk must be minimized
- Simplicity and reliability are priorities
However, vortex cooling is not always the right solution. Compressed air consumption must be evaluated. Noise levels must be considered. Operating cost impact must be calculated.
Cooling should not create a larger energy problem.
What Should Be Evaluated Before Selecting a Cooling Method
Before choosing any enclosure cooling solution, evaluate:
- Total internal heat load (watts)
- Ambient temperature range
- Humidity conditions
- Available compressed air supply
- Noise considerations (dBA impact)
- Duty cycle (continuous vs intermittent operation)
Without this analysis, cooling systems are often oversized, undersized, or misapplied.
If Your Cabinet Temperature Is Unstable
If your enclosure runs hot, shuts down intermittently, or operates near component limits, the issue is rarely “just ventilation.”
Submit your system details for review.
We evaluate cooling load, compressed air impact, and noise considerations before recommending a solution. When appropriate, we connect you with pre-approved manufacturers or distributors who specialize in the correct application.
Reliable systems start with proper evaluation — not guesswork.