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Metal and Mining

The metal and mining industry is known for its intense nature, with large-scale production processes and challenging working conditions. Facilities operating in this sector typically work with complex processes involving stages such as mining, processing, and metal production. Especially heavy machinery and large-scale processing equipment require high energy consumption, making energy management a critical element.

In mining and metal production facilities, power outages can disrupt production processes and pose safety risks. Therefore, energy supply systems in these facilities must be reliable and durable. Ensuring energy efficiency is also crucial for reducing operational costs and enhancing environmental sustainability. Moreover, effective cooling solutions are required to prevent overheating of the machinery and equipment used in such facilities.

In the metal and mining sector, potential failures can significantly disrupt production processes. Therefore, maintenance-friendly systems and energy distribution solutions that allow for quick interventions are essential. Being able to continue production with minimal downtime during a failure enhances operational efficiency in this sector. Additionally, the equipment used in mining and metal processing must be durable against environmental conditions, provide long-lasting solutions, and be suitable for tough working conditions.

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The Need for Forming for High Security:

The safe operation of panels is crucial for this sector. Therefore, it is recommended to form electrical panels for enhanced security.

The process known as forming or internal separation in electrical panels aims to enhance safety measures within the panel, ensuring the safety of both personnel and equipment. This process limits faults (such as fires) to a specific area and prevents technical personnel from coming into contact with live parts during intervention, thereby maximizing safety.

There are different levels of forming in electrical panels. These levels determine the internal structure of the panel and how the compartments are separated. The highest level of internal separation is called Form 4b. Form 4b means that all compartments within the panel are completely separated from each other, providing the highest level of security.

Panels with Form 4b forming are particularly preferred in high-risk environments and critical applications. These panels prevent the spread of faults, thereby protecting both personnel safety and equipment security. Additionally, they provide a safe working environment during maintenance and repair operations.

Panels with Form 4b forming typically also recommend the use of split covers. Split covers facilitate access to only specific sections of the panel, ensuring the safety of the compartments while maintaining security.

In summary, forming or internal separation is an important practice to enhance safety in electrical panels. Different forming levels offer solutions tailored to various needs and risk levels. To provide the highest level of security required in this sector, Form 4b forming and split cover applications are recommended.

You can click here to read our related blog post and learn more about forming.

The Need for High Corrosion Resistance:

The need in this sector for corrosion resistance is met by EAE Elektroteknik products, which stand out for their high corrosion resistance in harsh environmental conditions.

Corrosion is the process of wear and degradation of metals or metal alloys due to oxidation or other chemical effects. Electrical panels need to be protected from these corrosive effects based on the environmental conditions in which they are located.

• Paint application on cold-rolled sheet metal (DKP): This method provides limited protection against corrosion. While external environments are more corrosive, similar corrosive effects can also occur in internal environments over time. Therefore, the corrosion resistance achieved by applying paint on cold-rolled sheet metal should not be preferred for use in internal environments.

• Galvanized sheet metal or paint application on galvanized sheet metal: This method, commonly used in industrial environments, provides effective protection against corrosion. It should generally be preferred for both internal and external applications. When evaluated in terms of cost and performance, it is highly advantageous.

All EAE Elektroteknik products use ready galvanized sheet metal, even if they are painted, which is the second option. This feature increases the corrosion resistance of the products in harsh environmental conditions as described above.

Need for Proper Ventilation:

Especially frequency converters in MCC panels used in this sector cause excessive temperature increase. For this reason, there is a need for proper ventilation to prevent the panels from heating up.

Temperature rise directly affects the performance of the devices in the panel or rack cabinet. Temperature rise tests, which are as important as short circuit in panel type tests, are critical for the safe and efficient operation of the devices. Since the temperature increase reduces the current carrying capacity, the temperature inside the panel/rack cabinet must be brought to the ideal level with proper ventilation.

The temperature inside the panel/rack cabinet rises due to the ambient temperature and the heat emitting devices (breaker, busbar, server, etc.) inside. This temperature increase is calculated by considering the electrical loss power values in the catalogs of each device used.

The IP degree of protection also contributes to the temperature increase by preventing the heat from escaping. Therefore, it is important to choose the right IP level for the enclosure/rack cabinet, not a high one. A higher IP protection rating does not always mean better protection and the wrong choice can lead to excessive temperature rise and therefore damage to the devices.

After determining the temperature increase, the panel or rack cabinet can be cooled by the following methods according to the value obtained:

• Natural Ventilation
• Fan Cooling
• Cooling with Air Conditioning

As EAE Elektroteknik, you can use our PanelTemp heat software for cooling calculations inside the panel up to 1600A. Click here for more information about PanelTemp. You can also find our blog post about fan cooling here. You can contact your Customer Representative for our air conditioning solutions.

You can also read our blog post on fan cooling by clicking here.

The Need for Accurate Determination of IP Protection Rating:

The protection of electrical panels against environmental factors and the determination of the degree of protection against solid and liquid objects is provided by performing the tests specified in the IEC 60529:1989 standard. These tests are expressed in numbers (IP code) indicating that the panels provide certain levels of protection.

The first digit in the IP code indicates the level of protection against solid objects, the second digit against liquids.

A high IP rating does not provide sufficient assurance for outdoor use, i.e. it does not mean that enclosures with a high IP rating are EXTERNAL!

There is a misconception in the market that products with a high IP protection rating can be used outdoors.

Products with a high IP protection rating have a shorter exposure time to corrosion in outdoor environments, even if dust and water resistance is specified. The radiation effect of the sun must also be taken into account. These factors are not taken into account in the IP classification.

In addition, as IP increases, the heat inside the panel also increases. This reduces the current carrying capacity of the products. For this reason, it is important to determine the optimum IP value for the panel, neither high nor low.

High Durability Requirement with the right IK value:

The level of impact protection is called IK test in IEC 62262:2002 standard. In this test, a value is determined by checking that the damage caused by an object dropped from a certain height hitting the enclosure does not affect the IP protection degree of the enclosure. This value indicates the IK level of the cabinet. EAE Enclosures are IK10, which is the highest level.

Need for Seismic Resilience:

Turkey's location in an earthquake zone makes it mandatory to manufacture non-structural products such as electrical panels and rack cabinets resistant to seismic movements. In order to ensure energy continuity and protect life safety in the event of an earthquake, it is of great importance to use industry-independent seismic certified products and to strictly follow the manufacturer's installation instructions.

Seismic certification demonstrates that electrical enclosures and rack cabinets can maintain their structural integrity and functionality during earthquakes. At the same time, these certifications prove that the products have been tested in accordance with international standards and are designed to withstand a specific earthquake intensity.

The correct installation of seismic certified products in the field directly affects the performance and safety of the product. Failure to follow the installation rules set by the manufacturer can reduce the seismic resistance of the product and even cause it to be damaged during an earthquake.

At EAE Elektroteknik, we attach great importance to seismic resistance. Our products are tested and seismically certified in accordance with international standards. In addition, we have prepared detailed installation instructions for our products, aiming to ensure a safe and accurate installation for our customers.

In addition:

In the metal and mining industry, it is critical to choose systems with high standards in terms of energy continuity, safety and durability. EAE Elektroteknik offers solutions that meet these requirements and can be used safely in the sector.

PanelMaster Low Voltage Type Tested Panelboard Systems;

It offers high safety and durability for use in metal and mining industrial plants.The durability and reliability of the system has been proven with certificates from internationally accredited laboratories.  In this way, the performance, reliability and compliance of our enclosures with standards are internationally proven. Designed for harsh environmental conditions, our panels have high corrosion resistance.

You can click here to examine our PanelMaster Panel System in more detail.

PanelMaster Low Voltage Drawer Type Tested Panelboard Systems; 

Designed to meet the requirements of high safety, flexibility and easy maintenance in power circuits and motor starting circuits, it is widely used in these projects.

•  IEC 61439-1-2 Type Test Standard
•  IEC 60068 Seismic Test Standard
•  IEC 61641 Internal Arc Test Standard

You can click here to examine our PanelMaster Drawer Panel System in more detail.

E-Cabinet Type Tested Empty Panel Systems;

It offers solutions to the needs of control, control and many different applications in the internal and external environments of the metal and mining industry, including 304-316 stainless steel, with a wide range of products. With its international accredited standards, E-Kabin panel products are suitable for the heavy and harsh working conditions of the metal and mining industry, providing high corrosion resistance and long-lasting use.

• IEC 62208 Type Test Standard for Empty Enclosures
• IEC 62208 Boş Panolar İçin Tip Test Standardı
• IEC 62262 Protection against External Mechanical Impact

E-Cabin solutions that can stand out for this sector can be Stainless and External Solutions.

E-Kabin Stainless Series Panels:

Our products can be produced in 304 or 316 quality upon request. Depending on the standard product design, size change, material thickness change and desired hole operations can be applied. 

It is also possible to manufacture painted or varnished in desired RAL codes. If desired, a lock system made of 316 quality stainless steel can be selected instead of the standard pendulum arm lock system with high chemical resistance. 

Interior accessories such as mounting profiles, mounting plates, front cover system etc. used in all E-Cabin series can also be used for stainless products.

Thanks to our manufacturing techniques, the welding bolts used for various in-door components are applied in such a way that they leave no trace on the outside of the door. This ensures a clean and smooth surface appearance.

You can click here to examine our stainless panels in more detail.

E-Cabin External Panels:

The external factors that panels are exposed to in external environments are much more than internal environments. Snow, rain, dust, mud, sand, etc. The panel must maintain its structural integrity and function in all these factors. Therefore, external panels should be designed accordingly.

One of the most important accessories in these products is the roof. The roof needs to be properly designed so that it does not let in water that accumulates when the door is opened, and it also needs to prevent water seepage or water walking from the opposite angle.

There is a misconception in the market that a high IP protection rating in external panels means external, but a high IP protection rating does not mean external. Although the relationship of products with high IP protection degree with dust and water is defined, the corrosion time in external environments is shorter, and the radiation effect of the sun should also be taken into account, which is not used in IP protection degree. Corrosion resistance is one of the most important points in external panels. You can find our article on corrosion resistance above.

E-Kabin H series external panels are produced as modular or monoblock for external environments. You can click here to review our E-Kabin external panel series.

You can click here to view the entire E-Kabin product portfolio in more detail.

KabinPLUS IT Infrastructure Solutions;

offers the infrastructures solutions necessary for the sustainability of a healthy data processing system in facilities that are very difficult due to the environmental conditions of the metal processing and mining industry. It offers durable, modular, long-lasting, high-security, aesthetic and user-friendly solutions, especially supported by seismic products.