Climate Control Solution For KBR: An Environmental Control Unit Designed for Durability & Efficiency

Climate Control Solution For KBR: An Environmental Control Unit Designed for Durability & Efficiency

Introduction

KBR, the leading provider of U.S. government cyber and electronic security solutions, approached Air Innovations to engineer a custom environmental control unit (ECU) to protect its ERILS radar systems. The company selected Air Innovations for its decades-long experience completing environmental control projects with unique requirements.

The Challenges

Air Innovations needed to design an ECU around several challenges:

First, rather than build a portable solution connected to the radar system through ductwork and plugged into an external power source, the ECU would need to be mounted directly to the radar.

Second, since radar components are big and bulky, space for the climate control solution would be limited to a narrow footprint on the front of the radar cart.

Next, the client’s radar systems would be exposed to extreme ambient conditions while in the field. The ECU would need to operate without fail to protect radar systems from the same harsh conditions.

Finally, integration into the radar cart meant the ECU would be subjected to the same gravitational forces as the trailer. The unit would need to tolerate being bounced around on the back of a truck.

The Solution

The Air Innovations team that engineered, manufactured, and tested the ECU had over 100 years of combined experience designing highly complex climate control solutions.

All thermal and electrical components, including cooling coils and compressors to circuit breakers and hardware, were customized for KBR.

The unit was configured to recirculate conditioned air to the client’s ERILS unit at 260 cubic feet per minute (CFM). The system comprises a single-piece vertical unit similar to an electric enclosure cooling system. The 24” high, 18” deep, and 23” wide unit was built to fit the narrow footprint and is easily bolted onto the radar by the client.

The ECU operates in ambient conditions between -30℉ (-34℃) to 125℉ (52℃). The outdoor cabinet is epoxy-painted aluminum, all internal metal components are painted aluminum or stainless steel, and all hardware is stainless steel to make the unit sound for outdoor use in extreme conditions.

The unit includes a 1KW electric heater to keep the radar warm and a 4,000 BTU compressor to keep it cool.

To protect the ECU and therefore the radar system from bouncing through rough terrain, Air Innovations increased the gauge size of the aluminum parts and integrated extra corner brackets, high-strength fasteners, and minimized welded joints. In addition, the team used anti-vibration mounts to stabilize critical components.

Lastly, the ECU was designed to receive power through the radar trailer.

Air Innovations was proud to collaborate with the KBR team on such an exciting and important project.

The Result

The environmental control unit included the following:

• The ability to operate in specified ambient conditions -30℉ (-34℃) to 125℉ (52℃)
• The capacity to control temperatures between 75℉ to 90℉ in cooling mode, and below 40℉ in heating mode
• 260 CFM design airflow
• 100% recirculating air system
• Air-cooled condenser with coated coil
• Epoxy-painted aluminum outdoor cabinet and stainless-steel hardware
• 1KW electric heater
• Nominal 4,000 BTUH compressor
• 1 R/A mounted combination T sensor
• 115/1/60-15 amps
• A light construction less than 150 pounds
• A design that meets or exceeds UL standards

If you’re ready for a custom solution from Air Innovations, like this custom environmental control unit, contact us by submitting a Project Inquiry or calling 1-800-835-3268 today.

For case studies on other industries, view our general case studies page. We also have whitepapers covering the aerospace industry, semiconductor industry, and MyZone Systems product line. The whitepaper page can be found here.

Environmental Control Unit For Multi-Function Radar: Delivering Precision Temperature Control for Detection Systems

Introduction

A manufacturer of multi-purpose radar detection systems was in the market for precision climate control that could protect sensitive equipment from hostile surroundings. The company retained Air Innovations to build a customized environmental control unit (ECU) that could maintain pristine temperatures amid unpredictable ambient conditions.

The Challenges

Radar detection systems operate in any environment during any time of year. As a result, Air Innovations had to overcome several challenges to protect sensitive equipment.

First, the ECU would need to keep up with a radar system that ran continuously with short bursts of high power. Oscillation would happen at unpredictable times, requiring a climate control unit that could tolerate temperature spikes when the radar equipment was activated.

Second, the client’s radar systems would be exposed to unrelenting sun and heat or darkness and cold. The ECU would need to be able to operate without fail in these hostile ambient conditions to protect radar systems from these extreme climate conditions.

Ease of use was another important consideration when customizing a solution since these portable radar systems would need to be set up quickly once transported to a location. This meant that remotely operating the ECU was also essential.

Finally, the custom climate control solution would need to fit within narrow space constraints. Unlike commercial HVAC systems that can be obtrusive, Air Innovations would have to adhere to strict ergonomic requirements since the radar systems were portable. Designing a durable ECU was just as important as its cooling function.

The Solution

Air Innovations engineered, manufactured, and tested a custom ECU configured to recirculate conditioned air to the client’s radar pedestal.

The unit operates in ambient conditions between -30℉ (-34℃) to 120℉ (49℃). Crank-case heaters keep the refrigeration components, like the compressor, warm. Secondary heating elements protect the electronics within the ECU from extremely cold conditions. A thermostat monitors the ambient temperature and signals the heaters to kick on to keep the electronics warm, so the ECU is ready to protect the radar system from oscillatory loads. The supplemental heater plugs into the power supply.

The cabinet and all internal metal components are powder-coated aluminum, and all hardware is stainless steel to make the unit sound for outdoor use. The ECU is painted high gloss to absorb some ambient heat and also reflect it as needed.

The unit was packaged to facilitate quick set-up. It sits on a cart with wheels and handles to be moved like a wheelbarrow. Two people can grab handles on the sides of the ECU to easily maneuver the unit on the back of a truck with the radar. Clamps and insulated ductwork support quick installation.

The unit is equipped with ethernet connection so an operator can cool or heat the radar from a remote location up to 50 feet away.

To meet stringent ergonomic requirements, Air Innovations designed a single-piece horizontal ECU mounted to the exterior of the radar system and ducted to and from the pedestal.

The Results

The environmental control unit included the following:

• The ability to operate in specified ambient conditions -30℉ (-34℃) to 120℉ (49℃)
• The capacity to control temperatures above 60℉ (16℃) in cooling mode and below 40℉ (4℃) in heating mode
• 90-150 CFM design airflow
• 8” WC external static pressure
• Air-cooled condenser
• 2KW electric heater
• Powder-coated aluminum and stainless-steel construction
• Hot gas bypass refrigeration control
• Nominal 1 ton R-134a Scroll Compressor
• Ethernet connection for all controls to be run from the client
• A design that meets or exceeds UL standards

If you’re ready for a custom solution from Air Innovations, like these custom environmental control units, contact us by submitting a Project Inquiry or calling 1-800-835-3268 today.

For case studies on other industries, view our general case studies page. We also have whitepapers covering the aerospace industry, semiconductor industry, and MyZone Systems product line. The whitepaper page can be found here.

Environmental Control Units: Innovation In Emergency & Military Response Vehicles

KBR, a leading provider of U.S. government cyber, military, and electronic security solutions, approached Air Innovations for help updating earlier-generation military trucks and utility vehicles into portable air traffic control systems. These humvees needed significant climate control system improvements to protect sensitive equipment and Air National Guard and U.S. Air Force personnel being deployed to emergency situations.

The Challenges

One primary challenge was to revamp the existing system to increase output significantly within the footprint of the vehicles. The current configuration included two environmental control units (ECU) within the humvee and an auxiliary unit being pulled behind, which utilized a high volume of power. Moreover, KBR required the redesigned solution to be retrofitted to technology that was several decades old. These improvements would also need to fit within an exact space and integrate into the overall system.

In addition to upgraded technology occupying exactly the same space, the Air Innovations solution would be required to tolerate exposure to extreme environments. The new systems would provide heating and cooling to emergency-response vehicles being airlifted to potentially rugged locations with temperatures up to 130℉.

Specialized controls were also central to the plan upgrades since the humvees would be operated by personnel wearing NBC suits.

Lastly, our engineers would need to ensure that the units adhered to stringent military requirements. (MIL Specs)

The Solution

Air Innovations re-designed and tested two ECUs that were integrated to the interior of each military and utility vehicle. In total, 44 units transformed 22 humvees into airports-on-demand. Output was increased by 50% in the same footprint, eliminating the need for an auxiliary unit to be pulled from behind, thus, saving on fuel and improving logistics. Re-thinking the solution was a combination of incorporating newer, more sophisticated, ruggedized components and integrating them thoughtfully into the less versatile, existing system.

To ready these mission-critical operations vehicles, the first step was to move the electric heater out of the discharge opening above the evaporator coils. Spreading out the heat—versus targeting it—made it easier to match the rate of evaporation. As a result, airflow was increased in the ECU and the heater ran more efficiently and required less power. The evaporator fan was replaced with the Continental motorized impeller, which also contributed to 50 to 60% improved CFM fixed airflow capacity.

An obsolete compressor was replaced with a current, more efficient compressor, lending improved performance and reliability. The newer compressor is also compatible with a current, more environmentally friendly refrigerant versus the obsolete one used in the previous ECU. The final component upgrade came in the way of the ebm-papst condenser fan, which facilitates much stronger airflow across the more restrictive condenser coil. The strength of the airflow is essential to maintaining a consistent temperature in the humvee no matter how extreme the ambient temperature.

The re-engineered ECUs also had to adhere to rigorous military (MIL) standards. For instance, Air Innovations utilized Chemical Agent Resistant Coating (CARC) paint to make the exterior of the ECUs resistant to corrosion associated with exposure to rugged environments and hostile temperatures. CARC paint also prevents microbial growth that can further degrade metal equipment.

Air Innovations is honored to have worked with KBR to help deliver world-class solutions that will be relied upon by U.S. military entities in emergency response situations. The quieter, more robust vehicles will be deployed in life-saving relief efforts when natural disaster strikes and leaves communities vulnerable, as well as in military applications.

The Result:

Forty-four environmental control units that included the following:

• Improved cooling and heating
• Refrigerant R407C
• Updated evaporator & condenser
• Designed to withstand temperatures up to 130℉
• Meets all Air National Guard and U.S. Air Force requirements

If you’re ready for a custom solution from Air Innovations, like these custom environmental control units, contact us by submitting a Project Inquiry or by calling 1-800-835-3268 today.

If you would like to see case studies for other industries, view our general case studies page. If you are interested in seeing more case studies for the semiconductor industry, look at the items below. We also have whitepapers available covering the aerospace industry, the semiconductor industry, and our Micro Environments product line. The whitepaper page can be found here.

Military HVAC Systems: Withstanding Harsh Conditions

The Challenge:

A defense contractor that designs and manufactures electronic enclosures for avionic, mobile and fixed applications came to Air Innovations for a solution to make its devices more rugged and capable of withstanding harsh field conditions. The military HVAC system would be located in a workstation that is typically in the back of a humvee. It would be used for direct surveillance drones that operate in warfare under extreme weather conditions including the desert, where extreme heat, blowing sand and driving rains would be the norm.

The Solution:

Air Innovations solution was a military environmental control unit built to withstand not only desert extremes, but variations in temperature and humidity found around the world. This military HVAC unit was designed to handle extreme climatic ranges, from -31°C to +50°C (-24°F to +122° F), conditioning those extremes to a consistent air quality and ensuring proper performance of the workstation. The HVAC system was designed according to various mil-spec requirements, its packaging was restricted to the most stringent of weight and size limitations, and the system was subjected to – and successfully passed – repeated drop testing.

The Result:

1. All design specifications were met.

2. The military HVAC system was built to withstand extremes in temperature and humidity from around the world – ranging from –31°C to +50°C (-24°F to +122° F), while maintaining consistent air quality and proper performance.

3. The environmental control system met all mil-spec requirements, weight and size requirements and was able to withstand repeated drop testing.

4. The solution was designed, tested, prototyped, and manufactured at Air Innovation’s facility.

If you’re ready for a custom solution from Air Innovations, contact us by submitting a quick Project Inquiry or by calling 1-800-835-3268 today.

If you would like to read case studies for other industries, view our general case studies page. If you are interested in reading more case studies for the military industry, look at the items below. We also have whitepapers available covering the aerospace industry, the semiconductor industry, and our Micro Environments product line. The whitepaper page can be found here.

Aerospace: Portable Cleanroom Control

The Challenge:

A prime aerospace and defense corporation came to us with a calibration system challenge in their airborne laser defense system. The calibration system needed to mount inside a modified Boeing-747 designed as a missile defense system to destroy tactical ballistic missiles. The missile defense system used two kilowatt-class Target Illuminator Lasers for target tracking. These lasers needed to remain precisely calibrated to ensure accuracy at all times, and their calibration had to be performed under highly controlled environmental conditions.

Read our aerospace whitepaper: Neutralizing Nature

[An inaccurate missile defense system means inbound missiles are more likely to make it through defenses – the exact thing the missile defense system is trying to prevent!]

The Solution:

Air Innovations designed a portable, self-contained portable cleanroom air conditioner system that sits outside the plane and is connected via flex duct to the avionics that carry the laser-guided missiles. After each sortie, optics in the lasers are recalibrated in the cleanroom-level conditions the Air Innovations environmental control unit creates. This aerospace environmental control system is equipped with high-static blowers that push through not only the required HEPA filters but also through extensive ducting.

The Result:

1. All design specifications were met.

2. The portable cleanroom control system includes cooling, heating, humidification, HEPA filtration and all necessary controls.

3. The solution was designed, tested, and manufactured at the Air Innovation’s facility.

4. Air Innovations’ largest unit built with wheels.

If you’re ready for a custom solution from Air Innovations, contact us by submitting a quick Project Inquiry or by calling 1-800-835-3268 today.

If you are interested in viewing more case studies for the aerospace industry, look at the attached case studies below. If you would like to see case studies for other industries, view our general case studies page. We also have whitepapers available covering the aerospace industry, the semiconductor industry, and our Micro Environments product line. These whitepapers can be found here.