1. Panel Savings using Modular
Technology and Bus Systems
Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 1
2. 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
3. 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 3
4. 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 4
5. 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 5
6. Enclosure Functions
What are the (3) basic functions of an
enclosure (why would you buy one)?
Panel Savings with New Enclosure Technology 6
7. 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 7
8. 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 8
9. 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 9
11. 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 11
12. 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 12
13. 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 13
14. 7. Aesthetics…Aesthetics
What kind of impression do you want to make?
Panel Savings with New Enclosure Technology 14
15. 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 15
16. 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 16
17. Technological Improvements
• M d l industrial systems offer:
Modular i d t i l 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 17
18. 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 18
19. 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 19
20. 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 20
21. 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 21
22. 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 22
23. 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 23
24. 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 24
25. 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 25
26. 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 26
27. 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 27
28. 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 28
29. 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 29
30. 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 30
31. 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 31
32. Users and Specifiers of Modular Enclosures
OEM
Panel Savings with New Enclosure Technology 32
36. 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 36
37. 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
38. 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
39. 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 39
40. 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 40
41. 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 41
42. 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
43. 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 43
44. Large parallel wire runs
Cable routing and labeling
Wire duct
Lugs
Multiple terminations
Wire bend space
Panel Savings with New Enclosure Technology 44
45. 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 45
46. 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 46
47. 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 47
48. 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 48
49. 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 49
50. 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 50
51. 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 51
52. 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 52
53. Application Photos – MCCB’s, Flexible Busbar
Panel Savings with New Enclosure Technology 53
54. Application Photos – Miniature CBs, Contactors
Panel Savings with New Enclosure Technology 54