Optimizing Temperature Control: A Guide to the Enclosure Heater with Thermostat

Condensation inside electrical enclosures can cause costly corrosion and dangerous electrical damage or fires. What is the best way to avoid or control condensation? The answer is enclosure heaters with thermostats.

Moisture can build up in poorly insulated enclosures, indoors or outside. An enclosure heater with a thermostat will keep the temperature inside the box at least 9°F (5°C) warmer than the ambient air, avoiding condensation. 

This guide will explore the functionality and importance of enclosure heaters, particularly those equipped with thermostats.

Understanding Enclosure Heaters

Enclosure heaters are specialized heating devices designed to maintain a consistent temperature within enclosed spaces. Other names include cabinet heaters, industrial cabinet heaters, box heaters, and control panel heaters.

These powerful tools are essential for preventing condensation, frost, and freezing in various applications. From small electrical enclosures to large industrial cabinets, enclosure heaters provide the warmth needed to keep your equipment running smoothly.

There are several types of enclosure heaters available on the market, such as convection enclosure heaters, fan-assisted enclosure heaters, silicone rubber enclosure heaters, and hazardous location heaters.

Each type of enclosure heater fits a specific enclosure.

The Role of Thermostats in Enclosure Heaters

Do not underestimate the importance of enclosure heaters. While standard heaters are effective, an enclosure heater with thermostat takes temperature control to the next level. It combines heating capability with precise temperature regulation, ensuring that your enclosure maintains the ideal temperature at all times.

The integrated thermostat in these advanced heaters offers several key advantages, such as energy efficiency, precise temperature control and equipment protection.

Understanding a heater’s technical specifications helps you choose the right one. 

Technical Specifications of Enclosure Heaters with Thermostats

There is a wide range of specs for enclosure heaters. 

• Power Ratings: Enclosure heaters are available in various wattages, ranging from 25W to 200W for small to medium-sized enclosures. Custom solutions can provide higher wattages for larger spaces.
• Voltage Options: Most enclosure heaters operate on standard voltages such as 120V or 240V AC. Some models offer dual voltage capabilities, providing flexibility for use in different power environments and making them suitable for various industrial and residential settings.
• Temperature Range: Thermostat settings typically include options like closing at 4°C (40°F) and opening at 15°C (60°F) or closing at 15°C (60°F) and opening at 27°C (80°F). Custom settings are available for specific applications.
• Construction: Some models of enclosure heaters use heating elements laminated between two layers of fiberglass-reinforced silicone rubber. This design offers excellent heat distribution and resistance to moisture, chemicals, and vibration. 
• Operating Temperature: High-quality enclosure heaters can withstand maximum temperatures of 260°C (500°F). 

Enclosure heaters often feature mounting options such as bonding to an aluminum plate with pre-drilled holes for secure attachment. Standard models typically come with 122 cm (48″) PFA-insulated lead wires for flexible installation. Additionally, these heaters generally offer a dielectric strength greater than 2000 volts, ensuring electrical safety in various applications.

Exploring The Two Common Types of Enclosure 

Here are two popular types of enclosure heaters and their applications:

1. Silicone Rubber Enclosure Heaters

Silicone rubber enclosure heaters conform to various shapes and sizes, making them ideal for complex enclosures. They provide excellent heat distribution and resistance to moisture, chemicals, and vibration. 

Key features of silicone rubber enclosure heaters include:

• Moisture and chemical resistance
• Radiation resistance
• Operating temperature range from -51°C (-60°F) to 232°C (450°F)
• Customizable shapes and sizes
• Optional pressure-sensitive adhesive (PSA) backing for easy installation
  

  2. Hazardous Location Heaters

Hazardous location heaters can operate safely in areas where flammable gases, dust, or vapors may be present. These specialized enclosure heaters are built to stringent safety standards, ensuring reliable heating without the risk of ignition.

Hazardous location heaters feature:

• Explosion-proof housings
• UL/CSA certifications for specific hazardous area classifications
• Temperature-limiting devices to prevent surface temperatures from exceeding ignition points
• Specialized wiring and connection methods to maintain the integrity of the explosion-proof design

While hazardous location heaters are for specific high-risk environments, all enclosure heaters share certain main features. 

Key Features of Effective Enclosure Heaters

Here is a list of the essential characteristics for selecting the right heater for any application. 

1. UL Recognized: UL-recognized enclosure heaters have undergone rigorous testing to ensure safety and reliability. This certification means the heater meets industry standards.
2. Aluminum Mounting Plate: An aluminum mounting plate provides secure mounting, plus it provides excellent heat distribution.
3. Compact Design: Enclosure heaters with a compact design allow for easy integration into small enclosures without compromising on heating performance.
4. DIN Rail Mountable: Many enclosure heaters are DIN rail mountable, offering quick and easy installation in standard electrical enclosures. This feature saves time during setup, and it allows for flexible positioning within the enclosure.
5. Integrated Overheat Protection: Some advanced models include built-in overheat protection mechanisms to prevent damage to the heater and surrounding equipment in case of thermostat failure or other issues.

Now that we’ve explored the key features, let’s examine how these characteristics translate into real-world applications.

Applications of Enclosure Heaters

Following is a list of enclosure heater applications in a wide range of industries:

1. Telecommunications: Protecting sensitive equipment in outdoor cabinets from temperature fluctuations.
2. Manufacturing: Maintaining optimal temperatures in control panels and electrical enclosures to ensure smooth operations.
3. Water Treatment: Preventing freezing in pump houses and chemical storage areas.
4. Renewable Energy: Safeguarding inverters and control systems in solar and wind energy installations.
5. Aerospace: From cockpit instrumentation to satellites, small, efficient heaters are essential for keeping the electronics in an optimal working environment.
6. Winterizing: Heaters are an essential component in winterizing power plants and other industrial areas.

In each of these applications, enclosure heaters maintain optimal surface temperatures and protect electrical components from the adverse effects of cold and moisture.

Custom Solutions Tailored to Your Needs

Custom equipment box heaters and custom enclosure heaters are specialized heating solutions. 

These custom heaters offer unique features such as flexible wattage and voltage options, compact designs, and integrated overheat protection. One example is Kapton® heaters, designed to heat satellites. It is a thin polyimide film with the heating element etched into the foil surface. They include integrated thermal switches, sensors and cut-offs for safety.

Heating manufacturers offer plenty of other custom options for enclosures of any size.

Installation and Maintenance Tips

Proper installation and maintenance will increase the enclosure heater’s lifespan. Here are some tips for optimal performance:

1. Ensure proper airflow: Position your heater to allow for natural convection within the enclosure.
2. Use panel mount options: For easy access and maintenance, consider panel mount enclosure heaters with accessible side surfaces.
3. Regular inspections: Periodically check your enclosure heater for any indicators of wear and tear, especially in harsh environments. Check the door seals on the enclosure cover for cracks.
4. Clean regularly: Dust and debris can gather on heater surfaces, reducing efficiency. Clean the heater and surrounding areas according to the manufacturer’s recommendations.
5. Verify thermostat operation: Regularly test the thermostat to ensure it’s cycling the heater on and off at the correct temperature points.

Proper installation and maintenance will maintain optimal performance in standard conditions. However, enclosure heaters often face more challenging environments. 

Enclosure Heaters in Extreme Conditions

Enclosure heaters must maintain optimal temperatures in extreme conditions, from arctic cold and corrosive environments to high-altitude installations. For extreme cold, consider higher-wattage heaters, multiple strategic placements, supplemental insulation, and extended temperature range capabilities.

As we’ve seen, enclosure heaters keep electrical and electronic equipment running smoothly in any environment, from swamps to mountains and outer space.

Embracing the Power of Enclosure Heaters

In the world of temperature control, enclosure heaters with thermostats are indispensable tools for maintaining optimal conditions in industrial and residential electrical enclosures. These devices provide reliable heat to protect your valuable equipment and contribute to the longevity of your systems.

Invest in quality, look for the features that matter most for your application, and don’t hesitate to explore custom solutions when standard options fall short.

Protect your valves and manifolds from freezing, even in the most challenging outdoor conditions. Explore Custom Equipment Boxes.