Purchasing a harsh environment enclosure can be a tricky business. The components need to be protected but it is also important not to overkill the protection and waste costs. All too often, the enclosure is not considered until the last minute in any design, the focus going on the active components. This can lead to a quick decision that often negates many cost savings in other areas. Therefore, we have developed five ways to save money on your harsh environment enclosure purchase that will also allow you to be better prepared and best of all, save money.
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1.
As simple as it seems, use a standard enclosure.
In the rush to enclose the product, the quick response is for an exact match to engineering specs. However, by choosing a standard, off the shelf, enclosure, the lead time and cost both decline significantly. It is important to remember that using a slightly larger enclosure does not impact the functioning of the internal components, so buying a box that is an inch larger could actually save money if it is a standard compared to the costs of developing the requested custom box. This is particularly true when buying plastic enclosures with significant tooling costs.
2.
Consider using a less expensive material.
As an example, steel or aluminum are more expensive than plastic. In the United States, for NEMA/IP rated enclosures, steel is the preferred material. In the rest of the world, plastics are more popular in no small part due to their low cost and more than adequate strength. If the application does not require the box to withstand constant physical abuse, plastic provides a lower cost and even more corrosion resistant option.
3.
Do you need specific ratings on the enclosure or can you utilize the unit without those ratings?
For example, does the unit need a UL rating or is the manufacturers NEMA ratings sufficient? For example, Bud offers a NEMA/IP rated enclosure line with several alternatives included an ABS plastic version that does not come with the UL ratings. For most applications, this box provides a perfect combination of value and function. In a similar vein, can you use a box with a lower level of protection? For example, a NEMA 1 box may suffice where traditionally one has used a NEMA 12 box. Alternatively, if only a specific internal component needs to be EMI/RFI shielded, it is better to protect that component than to shield the entire enclosure.
4.
Review which accessories are included so that the price comparisons are accurate.
Some manufacturers offer a turn-key enclosure such as having mounting panels included in NEMA steel or plastic boxes, mounting provisions for wall mounting or equipment mounting an enclosure, and bails or handles for easy maneuverability. Consideration of these features can save significant cost and also insure that all components work well together.
5.
If modifications are required, consider having them done at the manufacturer.
The manufacturer knows the best approaches for drilling or punching based on the product materials and can avoid cracking or chipping the box itself. It avoids having to find a local source for the work, saving time and potential damage in multiple shipments of the product. The manufacturer can provide a turn-key product, speeding installation of the components and providing a rapid up-time.
Nothing is more frustrating than paying more than is necessary for a quality harsh environment enclosure. With these steps, you can insure that your project does not cost more than it should or slow down your work. Dont overlook the simple solutions to your complex problems.
by Simcona on Mar 13, 9:59:31 AM
If you fail to plan, you plan to fail.
Whether you build control panels in-house or outsource the manufacturing, its important for the buyer and user to understand the why behind the enclosures design.
Yes, were specifically speaking of the boring-looking metal box on the outside. Dont think of enclosures as trivial, interchangeable parts what works for a server rack may fail horribly for mining equipment.
These six electrical panel enclosure design guidelines will ensure your precious equipment reaches the life expectancy you have in mind.
Buying an Electrical Panel Enclosure That Matches Your Design
A good design accounts for regulatory and application needs both physical and electrical:
- Ratings & standards
- Environment
- Heat
- Space now and later
- Integration & accessibility
- Installation
1. Ratings & Standards
Organizations worldwide have built strict standards and regulations to ensure that enclosures protect components and people from the dangers of compromised electronic devices.
If youre sourcing through a contract manufacturer, make sure it has UL508A certification for control panels. UL-rated enclosures must pass strict independent testing. Making wiser design choices through adherence to UL standards can reduce expensive customizations later.
Both parties should also follow IECs minimum requirements for product safety, as well as National Electrical Code (NEC) listing requirements for safe installation of wiring in the U.S. Finally, consider any other organizations standards (like RoHS and REACH) for your target market.
NEMA ratings, self-certified by the manufacturer, also provide helpful electronic enclosure design guidelines by clearly defining types of box builds and where to use them. To summarize:
Electronic Enclosures (Non-Hazardous Applications)
Enclosure
Location
Features
Type 1
Indoors
Basic protection from dirt, dust, & falling objects
Type 2
Indoors
Type 1 + dripping and splashing protection
Type 3
Indoors & outdoors
Safe in outdoor weather, including ice and windblown dust in some variants
Type 4
Indoors & outdoors
Type 3 + protection against hose-directed water.
Type 5
Indoors
Dust-tight
Type 6
Indoors & outdoors
Types 1-5 + protection against submersion in up to 6 ft. of water
Type 12
Indoors
Protects assembly from dust, fibers, oil, and coolant
Type 13
Indoors
Type 12 + protection from oil and coolant splashing and spraying
Electronic Enclosures (Hazardous Applications)
Enclosure
Location
Use
Type 7
Indoors
Contains an internal explosion and protects against submersion in water
Type 8
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Indoors & outdoors
Additional protection from dripping and splashing corrosives; prevents combustion through the use of oil-immersed equipment
Type 9
Indoors & outdoors
Prevents ignition of combustible dust; endures strong jets of water
Type 10
Outdoors
Built to meet MSHA electronics requirements; contains internal explosions, remains dust-tight, and protects against rushing water
You can fabricate Type 1 by following UL508A guidelines. All other types are usually purchased from a dedicated manufacturer, or custom fabricated and tested for a particular rating.
No matter your classifications, make sure theyre printed on a metal plate and attached to the enclosure for quick identification.
2. Working Environment
Any UL safety rating or NEMA classification your enclosure has should influence your material and design choices. Much of that comes down to the products need for:
- Outdoor use
- Water resistance
- Dust & solid contaminants-proofing
- Hazardous-conditions rating
- Explosion-proof rating
If the overall installation will reside in a hazardous or classified location included in Articles 500-506 of NEC installation requirements, the enclosure must offer additional protection.
The long and short is that your assembly should stay dry, clean, and isolated from interference. Material choice goes a long way toward that:
Electronic Enclosure Materials
Carbon Steel
Galvanized Steel
Aluminum
Stainless Steel
Corrosion Resistance
Low
Moderate
Good
High
Impact Resistance
High
High
Low
Moderate
Ability to Modify
Difficult
Difficult
Easy
Difficult
Magnetic?
Yes
Yes
No
Yes
Thermally Conductive?
No
Low
High
No
Stainless steel panel enclosures are best for many industrial applications due to the materials strength and superior corrosion resistance vs. carbon steel. Painting a plain steel enclosure offers cheap protection, but it wont last long in many industrial uses.
Aluminum enclosures may be more cost-efficient for protecting industrial control panel components thatll be subject to a low-to-moderate moisture or dust levels.
To extend your industrial enclosures life span, specify a custom finish like anodizing (for aluminum) or powder coating (for any of the above). Ask a control panel enclosure manufacturer which combination of material and finish will best meet your projects quality and budget needs.
3. Heat
No matter the exterior environment, any enclosed device must manage its heat output.
A strangely overlooked part of industrial control cabinet design is the heat generated within the panel. The control panel builder may need to install extra cooling features depending on.
- The temperature rating of components inside the enclosure
- The heat output of those parts
- The thermal conductivity of your enclosures materials
There are many ways to manage heat in an electronic device:
- Material selection aluminum alloys dissipate heat better than stainless steel
- Air conditioning
- Exterior color
- Compressed air cooler typically a self-contained vortex tube that injects cold air
- Heat sink
- Sun shield
- Back panels with internal vents
- Increased enclosure size see #4 for more
Heat isnt always a bad thing. Warming features may be necessary for cold locations, or for humid locations where you need to increase the interior temperature just enough to stop moisture buildup.
One more underappreciated aspect of thermal management: planning for modifications. If you might add features later to a panel, consider the heat generation of these new components. Its often more efficient to account for that earlier in the design process, rather than trying to play catchup.
4. Space & Future-Proofing
We often call them safety enclosures, but when it comes to spacing, safety is far from the only quality an enclosures design influences. Proper spacing is also essential for:
- Accurate readings
- Heat efficiency
- Installation & access
- Expansion
The number of doors necessary (usually 1-2) often determines the overall size of an industrial enclosure. Youll also have to consider the minimum and maximum dimensions for meeting the manufacturers (even if its you) design-for-manufacturability requirements. Modeling the box build with 3D software helps stamp out space and interference concerns.
Obviously, the enclosure must be big enough to fit the components inside, and the enclosure itself must fit in your available installation area. Some manufacturers recommend that 20% of the enclosures area goes to spare space, depending on your application.
Consider this checklist for proper sizing:
- Allows proper space between components without overheating or hampered functionality?
- Allows sufficiently sized wire ducts?
- Allows proper space between cable entry and ducts or components?
- Enough space around the panels edge?
- Easy to access key components?
- Allows for ideal grouping of signal types?
- Enough internal working space for operators?
- Touch safety of parts greater than 50V (AC parts) or 60V (DC parts)?
All that advice is great for today, but what about when you want to adapt or expand your enclosure to meet new needs? If theres room for it to grow, leave room for the enclosure to grow too.
One example is the increasing reliance on the Industrial Internet of Things (IIoT) for machine connectivity. Not all IIoT technology is software-based you may want to leave room in the control panel to include new smart hardware.
5. Integration & Accessibility
What (and who) is going in and out of the enclosure?
Entry and exit points matter to both operators and components.
Component access into and out of the panel comes with a few design to-dos:
- Most applications need sufficiently sized cable-access holes on the top and bottom of the box. For power cables, knockouts in the front and back of the frame are also wise.
- When using air conditioners or fans, direct warm air out the top of the enclosure and bring cool air in from the bottom. This aids the natural convective transfer of heat.
- If switches and buttons will penetrate the enclosure, youll likely need to seal the area.
Operator-access factors for control cabinet design may include:
- Handles, through-door disconnects, and interlocks can provide tagout points for extra safety. They prevent the door from opening until the user turns off the external power.
- The ability to move lift-off and reversible doors out of the way speeds up equipment installation. After installation, access to interior devices and cabling will be easier if your enclosure uses side panels the operator can remove from outside.
Remember that accessibility can have a financial impact. Removing doors and struggling to work around tight spaces are time-consuming tasks. Consistent and obstruction-free design across assemblies meaning they dont require forklifts, cranes, or multiple workers to manage save time and money.
6. Mounting & Installation
The NEC is a good guiding light for proper control panel installation.
In the United States, panel enclosure installation requirements generally come from the NEC or the National Fire Protection Agencys NFPA 70 standard. These standards lay out the design practices that lead to safe installation:
- Wire size
- Spacings
- Permissible equipment
Poor configuration of the installation from mounting to wiring to integration can cause machine downtime and operator injury.
Your enclosures size and purpose will influence the success of the installation method:
- Floor-mounted common for large or heavy enclosures
- Wall-mounted for small designs and saving floor space
- Wall standoffs and floor-mount legs for cleaning access in sanitary applications
There are kits available that let you group cabinets into a modular suite. Advantages of this include higher stability and easier cable management. Your box build manufacturer should help you determine whether your enclosures are worth grouping and which kit will work best.
The Assemblys Role in Operational Efficiency
Enclosed industrial control panels are a specialty product. Buying or designing one successfully means more than simply picking some parts and bolting them onto a box.
To best balance performance and cost, consider how your requirements and environments play off each other. For example, you may need extra airflow in an enclosure with compact dimensions. But what if you want to add features later?
Getting the enclosure right the first time saves you money up-front as well as later when you experience fewer repairs, upgrades, and downtime. To really hit the mark with your design, you might benefit from involving outside experts who can streamline the process.
To learn more about the role of electronics in your operational efficiency, visit our resource hub:
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