Electronic Enclosure Design Guidelines – The Ultimate Guide

Choosing a suitable electronic enclosure can be an overwhelming task.

A reason I will highlight all the critical aspects you should consider in an electronic enclosure design.

Choose Right Dimensions For Electronic Enclosure

Having the correct dimensions for your electronic enclosure facilitates its effective working. In addition, it allows for proper installation of your enclosure.

Proper ventilation is only possible when you choose the correct dimensions for your electrical enclosure. You have to consider several factors when selecting the correct dimensions for your electrical enclosure.

For instance, you have to consider the application that you will use your electrical enclosure. Large applications usually require large enclosures for them to function correctly.

The reason for this is the large and numerous components that you have to install on your enclosure. You also have to consider how to access the electric enclosure when deciding the dimensions.

Easy access involves having to repair most components of your electrical enclosure.

It Is Impoortant To Choose Right Dimensions For Enclosure

It Is Important To Choose Right  Dimensions For Enclosure

Select Suitable Material For Electronic Enclosure

Electronic enclosures are available in different materials depending on where you want to use them. when selecting the suitable material, you have to consider several factors, including:

Weather Condition

Before deciding which material to use for your electronic enclosure, you have to consider various weather conditions. Weather conditions can vary from snow and rain to excessive heat.

Excessive heat is not ideal for the proper working of your electronic enclosure. This is because there is a need for proper ventilation for its effective functioning.

Environmental Conditions

Environmental conditions of where to use a particular electronic enclosure are essential. Such conditions include chemical and salty surrounding

Environmental surrounding affects the durability of your electronic enclosure and the components inside. It also affects the functionality of the components within your electronic enclosure.

Material EMI/RF Shielding

Electromagnetic and radio frequency interference impacts the proper functioning of your electronic equipment. Such frequencies can also interfere with how your equipment functions.

Selecting a material with proper shielding is vital for the effective functioning of the components on your enclosure.

Material IP Rating Requirement

IP rating details the protective strength of your material against water and dust penetration. You also have to consider the strength of the material against various factors such as external force impact.

IP rating helps to understand the durability of your material.

Further Machining Of The Material

You need material that you can further work on, if need be, during the installation process of your enclosure.

Further work on the enclosure includes drilling holes or cutting the edges for proper installation.

The different materials have varying abilities for machining, which can affect the efficiency of your enclosure.

The common materials for electronic enclosure are:

Aluminum

Aluminum offers a lightweight material for the fabrication of your electronic enclosure. In addition, it has other benefits like weather resistance and ease of machining gives it an edge over stainless steel.

If you are looking for a material with a higher RF shield rating, this is suitable for your enclosure. It also has a better blocking effect against electromagnetic radiations.

Such properties make it possible to use this material to manufacture enclosures for use in sensitive areas. You can also use it in high-temperature applications since it can withstand such temperatures.

Aluminum Electronic Enclosure

An Aluminum Electronic Enclosure

Stainless-steel

The advantage of using stainless steel as the material for your electronic enclosure is its corrosion resistance.

You can therefore use such an enclosure in an environment that is prone to salty water without worrying about its durability.

It is also an easy-to-clean enclosure, making it the best option in an application that requires a high degree of cleanliness. Such areas include food processing and medical industries.

The main limitation to using this material for your enclosure is its relatively high price.

304 stainless steel is standard that you can use to fabricate your electronic enclosure. This is due to its advantages compared to the other grades of stainless steel.

Stainless Steel Electronic Enclosure

Stainless Steel Electronic Enclosure

Fiberglass

The advantage of using fiberglass is its durability compared to plastic materials. However, it is not as strong as aluminum or stainless steel.

The durability aspect makes it cheaper than stainless steel and aluminum but more expensive than plastic. In addition, it allows for machining, making drilling holes during installation relatively easier.

Fiberglass is limited to the application area since it does not tolerate high temperatures.

Fiberglass Electronic Enclosure

Fiberglass Enclosure

Plastic

There are different types of plastics available for an electronic enclosure, each with its advantages. However, the typical type of plastic in use is ABS due to its unique features.

Other plastics that you can use for your electronic enclosure include PVC, PC, PE, and PMMA.

ABS is a hardened type of plastic with a low price than other plastics. In addition, this material is a non-conductor of electricity which minimizes electrocution during the operation of your enclosure.

It is a relatively cheaper material than the others to fabricate your electrical enclosure. You also benefit from machining it using various methods, thus increasing its application.

ABS’s main limitation is its unsuitability to use in areas with high temperatures. This is due to the melting effect it has.

Plastic Electronic Enclosure

Plastic Electronic Enclosure

Be Clear On Desired Electronic Enclosure Mounting Options

Proper mounting of your electronic enclosure ensures its stability and minimizes the risks during its functioning. There are various mounting options you can choose for your enclosure.

The main ones are:

Freestanding Mounting Option

This mounting option involves placing your enclosure on a plain surface. It consists of legs or a platform that holds and secures the enclosure underneath.

Most freestanding electrical enclosures have stainless steel, fiberglass, or mild steel as their primary material.

Freestanding mounting options usually have polyester powder as their surface finish. This makes them ideal options for use in the oil, gas, and pharmaceutical industries.

The use of this option is economical while maximizing performance. They are also relatively easier to install.

Here are various designs of free standing electrical enclosures.

Wall-mount Option

The wall-mount option involves mounting your electrical enclosure on a flat surface, preferably on a wall. This is possible through the use of extended pads and wall brackets.

The advantage of a wall-mount option saves space while maximizing performance. They are also relatively easier to install, which reduces the overall cost of your electrical enclosure.

There are different designs that you can have on a wall-mount enclosure. These designs include single door, double door, and hinge cover designs.

Floor Mounting Option

The floor mounting option is near similar to a freestanding mounting option. The main difference is a floor mounting option; the enclosure does not have a holding base.

When installing using this option, you have to screw or hold it down to the floor of your electrical enclosure. after installing, it is difficult to move it around; hence you have limited design options for your application.

Here is a guide where you can also learn how to mount electrical enclosure.

Design Electronic Enclosure Racks

Depending on various guidelines, there are different types of racks that you can have on your electronic enclosure. For instance, considering the size of your enclosure gives you a clue of which rack to use.

You also have to consider the functionality of your enclosure. The functionality helps you identify the enclosure rack you want and design it on your electronic enclosure.

Cost is another factor for consideration when designing the rack on your electronic enclosure. The different types of racks have varying price tags, including the cost of material and the installation cost.

The availability of these enclosure racks in different materials gives you options when selecting the best one to use. When selecting the material to use, you have to consider the maximum load of the electrical

The common types of electronic enclosure racks are:

Cabinet Electronic Enclosure Racks

This type of enclosure rack features a controllable environment for your electrical components. In addition, it is a freestanding rack that offers stability for your enclosure during operation.

A cabinet electronic enclosure rack has doors on the front and back, offering ventilation. This is vital in controlling the temperature of your enclosure.

You can use this type of rack in enclosures that require adequate electrical components housing. The type of which cabinet electronic enclosure rack depends on the component load and the configuration requirement

Cabinet Electronic Enclosure

Cabinet Electronic Enclosure

Server Electronic Enclosure Racks

Server electronic enclosure racks are ideal in applications that require maximum ventilation, which facilitates temperature control. The rack features front and back doors and sides, which are adequately ventilated.

The advantage of this type of rack is it can withstand huge loads of up to 1200lbs. You, however, have to check the design of your enclosure before deciding the maximum load it can hold.

Fig 7- Server Electronic Enclosure Rack

Server Electronic Enclosure Rack

Seismic Electronic Enclosure Racks

Seismic racks are ideal for use in areas experiencing different vibrations and shocks. This is because they can withstand the effect vibrations and shocks can have on your enclosure.

It is crucial to always anchor to the ground enclosures with seismic racks for stability purposes.

The advantage of this type of rack is the protection it offers to the components present on the enclosure. This minimizes operation disruption of your electronic enclosure.

Fig 8- Seismic Electronic Enclosure Rack

Seismic Electronic Enclosure Rack

Co-location Electronic Enclosure Racks

A co-location electronic enclosure rack is the best option to use when you want a sub-cabinet on your enclosure. It consists of several individual compartments, each with its door.

The advantage of this type of rack is proper ventilation from the front and back. Proper ventilation is a vital aspect of controlling the temperature of your electronic enclosure.

Co-location racks are available in different sizes depending on the specification of your electronic enclosure. Typical sizes range between 24 and 39 inches.

Fig 9- Co Location Electronic Enclosure Rack

Co Location Electronic Enclosure Rack

Open Electronic Enclosure Racks

You can use an open electronic enclosure rack in applications that require quick access to the electronic components. This is because it lacks any side barrier that can hinder its access.

The lack of any barrier makes it an ideal option for use in a high-temperature application. This is due to the maximum ventilation, which helps control the temperature.

However, you cannot use it for heavy applications since it cannot hold heavy loads.

Consider Accessories You Will Install In Electronic Enclosure

There are different accessories that you can install on your electronic enclosure. These accessories facilitate the functioning of your enclosure while reducing risks that can happen during its functioning.

Common accessories you can have on your electronic enclosure are:

Locking Mechanisms

Locking mechanism accessories helps in securing your electronic enclosure. This is by preventing unauthorized personnel from accessing your enclosure.

Different locking mechanisms are available depending on the level of protection you want for your enclosure.

Temperature Monitoring Mechanisms

Temperature monitoring mechanisms are for checking and regulating the operating temperature of your enclosure. Temperature regulation is a critical aspect of the operation of your enclosure since it minimizes overheating of the components.

Venting Accessories

Venting accessories facilitate the cooling process of your electronic enclosure. This is by allowing cool air to flow into your enclosure and hot air to escape it.

Proper ventilation allows for the proper functioning of your electronic enclosure.

Mounting Accessories

These accessories are vital during the mounting process of your enclosure. They ensure that your electric enclosure is appropriately positioned, thereby minimizing the chance of breaking.

Fig 10- An Electronic Enclosure With A Mounting Provision

An Electronic Enclosure With A Mounting Provision

Consider Cable Management In Electronic Enclosure

Cable management is a critical aspect of the organization of your electronic enclosure. Proper management minimizes various risks that can arise within your electrical enclosure.

Various risks can arise due to poor cable management on your enclosure. Such risks include:

Long Installation Hours

Poor cable management on your electrical enclosure can lead to long installation hours. This can delay a timely project and increase its overall cost.

The lengthy installation hours are mainly for figuring out which cable is for which purpose and where you need to install it.

Unscheduled Downtime

unscheduled downtime arises when you have poor cable management within your electrical enclosure. The cause for this can vary from electrical faults to the enclosure not functioning.

The leading cause of this is usually wrong installation or damage to the cables during installation.

Poor Application Performance

The performance of your enclosure reduces due to poor cable management. The leading cause of this is the wrong installation of the cables.

Low performance results in increased operating costs while reducing the overall output.

Regular Maintenance Of Your Electrical Enclosure

You have to maintain your electrical enclosure when poor cable management regularly. Regular maintenance increases the overall operational cost for your electronic enclosure.

You, therefore, have to manage your cables properly during installation and maintenance. The main ways you can manage them properly are:

Cable Bushings

This type of cable management involves protecting the opening of your cables by insulating them. This prevents damage to the cables in case of abrasions or pulling.

Cable bushing also minimizes short-circuiting through the separation of the individual cables. Depending on the situation, there are different types of cable bushing that you can apply to your cables.

These types include snub bushing, strain relief bushing, and open snap-fit bushing.

Cable Clips

Cable clips involve the use of clips to secure your cables along the surface of your electronic enclosure. The advantage of this method is it removes any hanging off the cables, leading to damages.

You, therefore, have a neat arrangement of your cables which facilitates easy identification and installation. In addition, there are two types of cable clips available for your selection.

The first type is a two-part component which includes one component for bundling your cables together.

The other component facilitates the fixing of the clip on your electrical enclosure. This type depends on the mounting surface of your electrical enclosure, which needs to allow or usage of nails.

The second type uses adhesive instead of nails. This type is cost-effective in terms of its purchase and installation.

The limitation to its use is that the adhesive can be loose over time, which leads to the peeling of the entire clip. This leads to the cable hanging out, which can pose a danger in the long term.

The different types of cable clips that you can use include DIN rail cable clips, self-adhesive cable clips, and screw mount cable clips.

Cable Clamp

Cable clamps have the same features as cable clips. However, the main difference is in the area of application.

Cable clamps are ideal for use to manage thicker cables. Their function is to support the cables and help chat their routes on your electrical enclosure.

Route chatting is vital in assisting you during the troubleshooting and maintenance of your cables. It also helps in minimizing inductive coupling, which causes interference issues.

The various types of cable clamps include screw mount and wire harness clamps. You also have the fire tree mount and hinged locking top cable clamp.

Choose Better Surface Finish For Electrical Enclosure

Different surface finishes have different effects on your electrical enclosure. Therefore, you must consider several factors before deciding which surface finish to apply to your electrical enclosure.

These factors include:

Location Of The Electrical Enclosure

Different surface finishes react differently to the environment in which the enclosure is. For instance, a particular surface finish can peel off when you subject it to a hot environment.

Another surface finish can peel if you subject it to a cold environment. But, again, this affects the durability of your electrical enclosure.

There is a need for compatibility of the surface finish you select and the operating environment of your enclosure. This enhances the durability and visual appeal of your electrical enclosure.

Operating Temperature

Understanding the operating temperature of your enclosure can help you reduce risks. For instance, you can quickly use a distinct finish that reacts negatively to high temperatures.

The use of finishes that cannot tolerate particular temperatures results in high operational costs since you have to carry out regular maintenance.

The main surface finish available for your electrical enclosure are:

Polyester Urethane Powder

This type of surface finish is ideal for an outdoor electrical enclosure. It offers a smooth and durable surface finish that adheres properly to the enclosure.

Polyester urethane powder offers protection against various factors like heat and chemicals.

Electrocoat Liquid

Electrocoat liquid uses a cathodic acrylic composition to form a corrosion-resistant surface finish. In addition, it features a rugged finish on your electrical enclosure.

The advantage of this surface finish is its durability. This reduces the overall operational cost.

Epoxy Powder

The epoxy powder features a tough and durable surface finish on your electrical enclosure. The advantage of this finish is its resistance to various factors like corrosion and solvent oils.

You, therefore, have a wide range of areas where you can use this surface finish on your electrical enclosure.

Applying epoxy powder leaves a glossy appearance on the enclosure. However, prolonged exposure to UV light affects its durability.

Fig 11- Choose better Surface Finish Option For Your Enclosure

Choose better Surface Finish For Your Enclosure

Focus On Electrical Enclosure Cooling System

There are two main ways in which you can cool your electrical enclosure. That is natural and forced conventional cooling methods.

Natural, Conventional Cooling

Natural, conventional cooling allows for natural airflow in your electrical enclosure. However, this method depends on the design of your enclosure.

You have to design your enclosure to allow for maximum airflow for maximum cooling. This is done by ensuring ventilation at the top and bottom of your enclosure.

The top and bottom ventilation can either be fixed or flexible such that you can remove it when necessary.

It is an economical way of allowing airflow into your electrical enclosure. This is because it does not increase the operational cost of your electrical enclosure.

The main limitation of natural airflow conventional is it increases the dirt in your enclosure. This can reduce the efficiency of your enclosure as dirt accumulates on the components.

You also have to maintain the enclosure to remove the dirt regularly. This increases the overall operating cost of your electrical enclosure.

Forced Convection Airflow

Forced convectional airflow is an artificial way of allowing maximum airflow into your electrical enclosure.

There are two ways in which this is possible, that is, the use of fans and blowers.

The fan allows air to flow into your enclosure parallel to the blade axis. The advantage of fans is they allow airflow at high pressure.

Fans are common in applications with less resistance inside the enclosure. Blowers allow airflow into your enclosure perpendicularly to your blowers’ axis.

The advantage of blowers is that you can use them with backpressure from the enclosure. In a particular electronic enclosure, you should use a combination of the blower and fans.

Focus On Safety Features Of Electrical Enclosure

Electrical enclosure safety features facilitate its safe handling and operation. You can have different safety features on your electrical enclosure depending on various factors such as its size.

The primary safety features that you can get on your electrical enclosure are:

Conforming To Necessary Standards

Ensuring a particular electrical enclosure attains necessary standards is the first safety feature you should check. Such an enclosure gives you the guarantee that it will operate within the given setup.

You need to ask your manufacturer for the quality standards if you are unsure about them.

Door Locks And Latches

Gaining access to your electrical enclosure by an unauthorized person can lead to unexpected risks. Therefore, it is prudent to ensure your enclosure has all the closing mechanisms safe and secure.

Such mechanisms include having locks and latches on the doors of your electrical enclosure.

Temperature Control Mechanisms

Operating an electrical enclosure usually results in high-temperature production. Failure to maintain this temperature always leads to unexpected failure on your enclosure.

You can prevent this failure by installing proper temperature control mechanisms on your enclosure. There are different temperature control mechanisms that you can install on your electrical enclosure.

For instance, you can have temperature monitoring units, a fan, a blower, or proper ventilation.

Cable Management System

A cable management system prevents short-circuiting from occurring within your electrical enclosure. This is by ensuring there is no interaction between the cables.

It is also vital in facilitating for smooth functioning of your enclosure. You, therefore, have to ensure there is proper cable management to reduce the risks associated with entangling the cables.

Electrical Enclosure Design

You always have to ensure the design of your electrical enclosure is compatible with the different environments in which you install them.

For instance, installing in high-temperature applications, you must ensure that all the components can withstand the temperature.

That includes the surface finish and the cables that you use. Compatibility of the design to the environment minimizes risks that can hinder the proper functioning of your electrical enclosure.

Fig 12- Door Locking Mechanism is One Of The Safety features

Door locking Mechanism Is One Of the Safety features

Check Compliance With Set Standards And Regulations

You need to check various compliance and safety standards and regulations before purchasing your electrical enclosure. These quality standards are:

NEMA

This is a standard that guarantees the quality of your electrical enclosure. Your enclosure should certify its performance and protection features to have this standard.

You have to check different NEMA standards before purchasing your enclosure. Each of these types certifies specific performance on your enclosure.

IP Ratings (IEC 60529)

IP ratings protect your electrical enclosure against dust particles and water. This facilitates the efficient functioning of your enclosure.

An IP rating consists of a two-part digit numbering system. These numbers indicate the level of protection against fluid and dust particles.

RoHS

This standard usually restricts the level of hazardous materials that you can have on your electrical enclosure. In addition, the standard protects your electrical equipment and enclosure by ensuring you install suitable materials.

CE

This standard indicates that your equipment conforms to most EU health and environmental standards.

Therefore, it is a vital standard when importing your enclosure to countries under the European Union.

For all your electronic enclosure designs – contact KDMSteel now.

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