How to Choose the Right Enclosure for Electrical Safety

Electronics enclosures are housings designed to protect electronic circuits and components from environmental hazards. They provide a barrier between external elements (such as dust, moisture and impact) and sensitive internal equipment. Selecting an enclosure involves considering the material, size, protection ratings, and certification requirements to ensure a safe, durable installation.

Types of Electronics Enclosures

Plastic and Thermoplastic Enclosures

Plastic enclosures (made from ABS, polycarbonate or polyester) are lightweight and corrosion-resistant, suited to many electronics projects. Solera’s range of Polibox polyester enclosures and Multibox thermoplastic enclosures illustrates this versatility. For example, the Polibox series of fibreglass-reinforced polyester boxes is IP66/IK10 rated, offering exceptional resistance to water and impact. Similarly, the Multibox series provides IP65/IK10 protection for harsh environments. These plastic enclosures come in various sizes (up to 600×800×300) with either opaque or transparent doors, ensuring easy inspection and robust protection for sensitive electronics.

Solera also offers IP68-rated waterproof enclosures (Black Series) for submersible applications and high-pressure washdowns. These ultra-durable plastic boxes can protect electronics even underwater.

Metal Enclosures and Distribution Panels

Metal enclosures are valued for their strength and electrical shielding. They are commonly used in distribution panels and switchboards. Solera’s Metalbox flush distribution boards are one example. These flush-mount metal panels come in module counts from 14 to 56 and feature a removable frame for easy installation. They are rated to IP40 and IK07, providing robust protection for indoor installations. Solera also offers weatherproof metal cabinets (Vera series, IP65) and heavy-duty steel panels (Steelbox series) for outdoor or industrial use.

DIN Rail and Junction Box Enclosures

DIN rail enclosures and junction boxes are used in many electronics and control systems. These are often plastic housings with built-in DIN rails for mounting terminal blocks or modules. Solera’s IP65 waterproof connection boxes (Ybox series) can be supplied with or without cable knockouts, and many include a 35 mm DIN rail. For example, the Ref. 817G is a sealed IP65 junction box (160×135×70 mm) with an integrated 35 mm DIN rail. A larger model, Ref. 886AG (220×170×140 mm), also contains a 35 mm DIN rail and is rated IK08. These enclosures allow quick mounting of control modules and terminals, making them ideal for industrial automation and control panels.

Key Selection Criteria

When choosing an enclosure, evaluate these critical factors:

• Material and Construction: Select plastic, fibreglass, aluminium or steel based on strength and environment. Fibreglass-reinforced polyester offers excellent UV and chemical resistance, thermoplastic is lightweight and non-corrosive, and steel/aluminium provide maximum mechanical strength.
• Ingress Protection (IP Rating): Determine the IP rating needed (per IEC 60529). For example, IP65 means fully dust-tight and protected against water jets, suitable for outdoor or dusty conditions. Lower IP (e.g. IP40) may suffice for clean indoor settings. Always match the IP rating to the application environment.
• Impact Resistance (IK Rating): Consider mechanical impacts. IK08 or higher is recommended where the enclosure could be struck or subjected to vibrations. Many Solera enclosures achieve IK10, which protects against high-energy shocks.
• Size and Layout: Ensure the enclosure is large enough for all components, wiring and any future expansion. Distribution enclosures specify module capacity (e.g. Metalbox boards with 14–56 modules). Allow space for terminal strips, connectors, and cooling.
• Mounting and Features: Enclosures may have wall-mount flanges, DIN rails or special fixtures. If control electronics require DIN rails, verify that the enclosure includes or allows them (as with Solera’s Ref. 817G). Also consider cable entry points, hinge types and locking mechanisms.
• Environmental Conditions: Assess temperature range, humidity, UV exposure and corrosive elements. For hot or crowded installations, choose enclosures with ventilation or heat dissipation. In wash-down or outdoor areas, select fully sealed enclosures with resilient gaskets to maintain protection levels.
• Compliance and Certifications: Verify the enclosure meets relevant standards (IP, IK, BS EN 62208, etc.) and has required markings (CE/UKCA). Solera’s enclosures are tested to these standards, ensuring reliability and safety.
• Accessories and Customisation: Check for available accessory kits (mounting plates, gland plates, DIN rail sets). Using Solera’s accessories ensures a perfect fit. If stock boxes require modifications, Solera can often provide custom options or recommend minor changes to save cost.
• Door and Lid: Choose between transparent or opaque covers and the closure method. Transparent doors enable visual inspection without opening. For example, Solera offers Polibox and Multibox boxes with either plain or transparent screw-on lids.
• Entry Options: Decide if you need enclosures with pre-punched knockouts or smooth walls. Solera’s sealed junction boxes (Ybox series) offer versions both with and without cable knockouts, helping tailor the box to your cabling needs.

Applications and Industry Sectors

Different applications place different demands on enclosures:

• Industrial Automation: Factories require sturdy enclosures for control cabinets, PLCs, drives and sensors. IP65-rated plastic or metal boxes (Polibox, Multibox, Indubox) protect electronics on the factory floor.
• Power Distribution: Buildings and commercial facilities use distribution panels and breaker boxes. Flush-mounted metal panels (Metalbox, Arelos, Clasica series) are common for circuit breakers and busbars.
• Outdoor Infrastructure: Street lighting, telecoms and utilities require weatherproof enclosures. Solera’s Indubox IP65 range includes outdoor distribution boxes and junction enclosures for these applications.
• Renewable Energy: Solar and wind installations use specialized enclosures for inverters and combiner boxes. Indubox string control panels and PV junction boxes are designed for photovoltaic systems and battery storage. Polibox cabinets are explicitly validated for photovoltaic use.
• Electric Vehicle Charging: EV charging stations and equipment need durable enclosures (typically IP65 or higher). Solera’s Indubox series offers EV charger panels engineered to protect control electronics in charging installations.
• Pool and Recreation: Pool pumps and controls must be completely waterproof. Solera provides pool protection panels (IP65) to ensure safety of outdoor leisure equipment.
• Commercial/Residential Installation: Switch and outlet boxes (e.g. Mechanism and Deribox ranges) are used in the walls of homes and offices. These flush or surface boxes support lighting, power sockets and small control devices.

Standards and Compliance

IP (Ingress Protection) and IK (impact resistance) ratings are key specifications for enclosures. An IP rating (per IEC 60529) indicates the enclosure’s sealing against dust and liquids. For example, IP65 means the enclosure is dust-tight and protected against water jets from any angle. The IK rating (IEC 62262) measures impact resistance. These codes complement standards like BS EN 62208, ensuring enclosures meet rigorous safety requirements.

Electrical enclosures must meet relevant safety standards:

• BS EN 62208 (IEC 62208): Requirements for empty enclosures of low-voltage switchgear and controlgear. Ensures the enclosure safely houses electrical components.
• BS EN 60529 (IEC 60529): Ingress Protection (IP) rating code. For example, IP65 means dust-tight and protected against water jets.
• BS EN 62262 (IEC 62262): Impact protection (IK) code. IK08 or IK10 indicates high resistance to mechanical shocks.
• BS EN 61439 (IEC 61439): Standards for low-voltage switchgear assemblies. Relevant when enclosures form part of larger panelboards; Solera’s distribution boards are built accordingly.
• CE and UKCA Marking: Indicates conformity with EU/UK directives (safety, EMC, RoHS). All Solera enclosures carry the appropriate marking.
• Material Specifications: Fire resistance, flammability and UV stability can also be important. Always check material datasheets (for example, flame class V0 for plastics).
• Electrical Safety: Some enclosures are rated Insulation Class II (double insulated) and made from halogen-free materials for higher safety. For example, Solera’s Polibox cabinets are Class II (no internal grounding needed) and halogen-free.

Ensuring an enclosure meets these standards gives confidence in its performance. Solera rigorously tests its products against these benchmarks, guaranteeing certified protection and quality.

Why Choose Solera Enclosures?

Solera is a trusted manufacturer of electrical enclosures and accessories, known for quality and innovation. Key advantages include:

• Extensive Product Line: Solera’s catalog covers everything from small junction boxes (Polibox, Indubox) to large panel enclosures (Metalbox, Arelos, Clasica). This breadth ensures you can source all your enclosure needs from one vendor.
• Manufacturing Expertise: Products are made with durable materials and precision engineering. Even Solera’s smallest enclosures (e.g. Ybox sealed junction boxes) are built to withstand tough conditions. Solera’s commitment to quality means its enclosures are reliably robust and long-lasting.
• Regulatory Compliance: All enclosures are CE/UKCA marked and tested to IEC/EN standards. By choosing Solera, you get products that are already compliant with European regulations.
• Customization & Accessories: Solera offers accessories (mounting plates, DIN rails, cable glands) and can modify enclosures to your specification. Custom or modified solutions are often achieved faster and more cheaply by adapting stock units.
• Technical Expertise: With decades of experience, Solera provides technical guidance and documentation. Its blogs and datasheets (for instance on enclosure selection and IP/IK ratings) help engineers make informed decisions.
• European Manufacturing: Solera’s enclosures are produced in Spain under ISO 9001 quality control. This local production ensures consistent quality, quick delivery and compliance with EU standards.
• Customer Service: Solera’s global presence and support team ensure reliable delivery and service. Partnering with Solera means access to responsive technical assistance and after-sales support.

In summary, selecting an electronics enclosure means matching your application’s requirements with a suitable design. Consider the operating environment, required protection levels, and relevant standards, then choose an enclosure from a reputable range. Whether you need a robust IP66 polyester case, a compact IP65 DIN-rail junction box, or a modular metal distribution panel, Solera’s catalog has a solution.

For more information, Solera’s technical blog provides articles on enclosure selection, IP protection and related topics. Solera also provides CAD models, datasheets and sizing guides for all its enclosures to simplify design and installation. Browse the Solera enclosures catalog to find the product that meets your technical and compliance requirements. Always consult Solera’s product catalog and technical literature for detailed information.

Solera’s technical support team is available for assistance with any project-specific questions.