What is condensation reason for substation switchgear?

Probably you are wondering how to prevent condensation in electrical enclosures. Well, we have an answer for you – install an electrical enclosure dehumidifier.

But, what is condensation in electrical enclosures? what causes it? how does it harm and how to prevent it? We’ll cover these questions in today’s guide.

What is condensation in electrical enclosures?

Condensation in electrical enclosures occurs when moisture in the air condenses on cold surfaces within the electrical enclosure.

This often happens in humid or cold environments. When electrical equipment of electrical enclosures operates, it generates heat, creating a temperature difference between the inside and outside of the electrical enclosure.

This temperature difference can cause moisture in the air to condense on the cooler surfaces, leading to condensation in electrical panel.

What causes condensation in electrical enclosures?

Temperature differential between inside and outside electrical enclosures

The common condensation reason in electrical enclosures is the temperature difference between the enclosure’s internal and external surfaces. Condensation can form if the internal surfaces are significantly warmer or cooler than the external air. For example, electrical components like VFDs, servo drives, indicator lights, PLCs, and transformers generate heat during operation. When these components cool down, the temperature difference between the warm components and the cooler enclosure surface can cause moisture in the air to condense on the cooler electrical panels.

Environmental Temperature Differential

Electrical enclosures in humid environments, such as rainy climates or washdown areas, are more prone to condensation. A significant difference between outdoor and indoor humidity and temperature increases the risk of condensation in electrical box.

Rapid temperature changes

Sudden temperature changes can lead to condensation in electrical enclosures. For example, moving an enclosure from a warm indoor to a cold outdoor area, and frequently opening and closing electrical enclosures in humid environments can introduce warm, humid air, leading to condensation in electrical panel.

Lack of Ventilation

The air inside the electrical cabinet is not circulating, moisture cannot be discharged, and it is easy to condense on the surface of the electrical enclosures.

Equipment aging in electrical enclosures

The aged and deformed sealing strip compromises the enclosure’s seal, allowing moist air to enter and increase internal humidity, which can lead to condensation in electrical box.

Other condensation reason in electrical enclosures

Some other condensation reasons include installation problems, poor insulation, or dehumidifier capacity, locations, and numbers, etc.

What are the hazards of condensation in electrical cabinets?

Condensation in electrical enclosures is a common and serious problem in power systems. It not only affects the normal operation of electrical components and causes damage to electrical enclosures themselves but may even lead to safety accidents. Here are the hazards of condensation in electrical cabinets in the following:

Short circuits
Corrosion
Deterioration of insulation performance
Premature breakdown
Contamination by mold and other organisms
Water drainage from enclosures

How to prevent condensation in electrical enclosures?

Install Enclosure Heater, Enclosure Fan and Enclosure thermostat

The traditional solution involves installing enclosure fans and heaters with thermostats. When the ambient temperature is too high or too low, the thermostat activates the enclosure fans or the enclosure heaters to regulate the enclosure’s temperature. For cooling applications, enclosure fans reduce the enclosure’s temperature, helping to control humidity. For heating applications, enclosure heaters increase the enclosure’s temperature, aiding in humidity control.

Install Enclosure Temperature and Humidity Controller

Blue Jay’s enclosure temperature and humidity controller allows you to effectively control the temperature and humidity level inside the electrical enclosure.

Blue Jay Smart Temperature and Humidity Controller

Dial pad setting temperature/humidity threshold
Sensor length max 10meter & High sensor sensitivity
Stable relay control & accurate and reliable control
48*48mm Panel Mount, Din Rail Mount option

Installing Electrical Cabinet Dehumidifier

Adding an electrical enclosure dehumidifier is a higher-accurate and energy-saving solution for preventing condensation in electrical enclosures. When the humidity exceeds a preset value, the enclosure dehumidifier will automatically absorb moisture from the air, condense the moisture, and then expel dry air out of the electrical enclosure. The electrical enclosure dehumidifiers are often used to reduce humidity and control condensate within the electrical enclosure.

DH6-200 Sheet Metal Dehumidifier for Cabinet

Dehumidifying capacity: 600ml/day
Materials: sheet metal with anti-rust spray
Optional RS485, heater(100-300V) & alarm functions

Using low thermal conductivity and ventilation electrical enclosures

Additionally, using low thermal conductivity and ventilated enclosures can help prevent condensation in electrical enclosures. The Insulating material enclosure can stabilize the internal temperature of the electrical enclosure. Using gaskets and seals in the electrical enclosures can prevent external moisture from entering. Corrosion inhibitor sprays or gels on electrical enclosures or components, and desiccant packets can absorb moisture to prevent condensation in electrical box. However, condensation in electrical enclosures cannot be substantially prevented by these methods.

Conclusion

The most efficient solution is to use electrical dehumidifiers. You also can use enclosure temperature and humidity controllers, or combine fans and heaters with thermostats. More questions about how to prevent condensation in electrical enclosures with dehumidifiers. We would love to hear from you. Just contact us online for a free quote.