Reducing Electrical Enclosure Size

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


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)

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)


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


Enclosure Functions

What are the (3) basic functions of an
enclosure (why would you buy one)?


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


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 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 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)

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


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


Equipment Mounting Options

Many more options are available
with Modular Enclosures:

Door mounting for devices &
Wireway via standard accessories
(no drilling or welding)


7. Aesthetics…Aesthetics

What kind of impression do you want to make?


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

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

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

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.


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

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

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.


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


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.


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

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


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


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.


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


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


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

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


Users and Specifiers of Modular Enclosures
OEM


Sample Application: Heavy Industry


Sample Application: Process Control


Sample Application: Drives and Controls


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


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


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


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


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


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


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


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

Large parallel wire runs

Cable routing and labeling
Wire duct
Lugs
Multiple terminations
Wire bend space


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


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


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

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


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


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



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...



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


Application Photos – MCCB’s, Flexible Busbar


Application Photos – Miniature CBs, Contactors


Application Photos – MCCBs, MSP


Application Photos – MCCBs, Fusing and Flexible Busbar


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


Reducing Electrical Enclosure Size

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