Installation of electronic enclosures may not appear to be all that much it’s basically attaching a box to something and placing a few things inside, yes?
But in fact it’s one of the most crucial steps we can take to ensure the safety, reliability and longevity of any electrical or electronic system.
I am a service professional in the industrial automation, HVAC and outdoor power industries and have seen numerous instances where minor installation missteps resulted in catastrophic system failures, water infiltration or even lost equipment.
In this article will discuss the top 5 mistakes that people make when installing their electronics enclosures, and how you can avoid making them too. Protect your investment. Whether you’re a professional installer or beginner, this guide is going to help you
get it right the first time.
One of the biggest and most common mistakes during installation is not paying attention to the enclosure’s protection rating.
Why It Matters
Each electronic enclosure is engineered for a particular environment. That’s because if you ignore the rating, you’re exposing this radio to risks it was never intended to take.
IP (Ingress Protection) and NEMA (National Electrical Manufacturers Association) ratings specify how well an enclosure prevents:
Dust and dirt
For example:
IP20 or NEMA 1: Indoor use, basic protection against touch and large objects.
Real-World Example
I saw an outdoor control box mounted in an indoor-rated plastic enclosure once. After 3 months water was corroding the terminals, causing a short. It is broken on the whole because the installer didn't know or care to know about IP rating.
How to Avoid It
You need to check the rating, IP, or NEMA before installation.
Pro Tip:
If you have any inkling of water exposure in your future, make sure to one-up yourself when it comes to ratings.
This one’s a silent killer of waterproofing integrity. Even the best-rated enclosure can fail if cables are installed incorrectly.
Why It Matters
The cables are common areas for water and dust to get in. If they’re not sealed properly, or if holes are drilled sloppily, their enclosure’s protective barrier is compromised.
· Using standard plastic fittings in place of IP-rated glands.
· Gland nut too loose or too tight.
· Drilling holes and not getting them sealed.
· Running the cables from the top and having water drip down.
· Use approved type cable glands suitable for your enclosure or rating.
· Choose the right gland material:
· Route cables from the bottom or sides, not the top.
· Seal washers and lock nuts for watertight connections.
· Do not overtighten it can distort the gland and leak.
Technician Insight
I’ve also opened a lot of “waterproof” boxes that were full of condensation because someone used cheap, non-rated glands. You see, it’s not the box that let it down but all the little bits.
You’ve made it this far, now let’s discuss how you mount and orient the enclosure! You have more influence over the performance and longevity of your enclosure than many folks understand.
Why It Matters
Incorrect mounting can cause:
· Water pooling on the lid or around seals.
· Internal components to overheat.
· Torsion on the case over a span of time.
· The horizontal mounting instead of the vertical edge water pool on the gaskets.
· Setting enclosures in full sun with no screen (especially those made of plastic).
· The use of substandard mounting hardware, which rusts or vibrates freely.
· Not leaving room for clearance for venting or wires.
· Install vertically so that the rainwater or condensed water can be easily precipitated.
· Make use of the required mounting kits or brackets supplied by the manufacturer.
· And allow for cabling and air around the cavity.
· Stay away from places with direct heat or that shake violently.
· Apply anti-vibration cushions or rubber mounts in industrial applications.
Bonus Tip:
When fitting outside, it is always recommended to lean the enclosure slightly forward so water does not pool on top of/around the door seal.
This is one of the most hazardous and commonly unrecognized errors, particularly in metal boxes.
Why It Matters
Proper grounding ensures:
User safety is ensured by directing stray electrical currents away.
Without grounding, a simple insulation fault could turn the entire enclosure into a live hazard.
Forgetting to connect the ground terminal inside metal boxes.
Always use a dedicated ground stud or bonding lug inside the enclosure.
Technician Note
I’ve had complete control panels fried out by lightning storms just from the ground wire not being connected. Don’t skip this step, it’s the first line of defense.
Even if you install your enclosure perfectly, it won’t last long if you ignore seal maintenance. Gaskets are what make an enclosure waterproof and they need attention.
Why It Matters
The gaskets are subject to environmental factors such as heat, UV radiation and pressure changes that rub them out.
Dry out or crack.
If the gasket leaks then suddenly no matter how smooth things are, your enclosure isn't protecting anything.
Using low-quality or non-original gaskets.
· Check gaskets each service interval.
· If you see cracks, deformation or stiffness, then replace them.
· For greater longevity, employ silicone or EPDM gaskets.
· Clean gasket lips and make sure surface is debris-free.
· Wipe with a light silicone lubricant to prolong gasket life.
Technician’s Real Advice
I always tell clients, “A $10 gasket can save a $1,000 system.” Don’t neglect it. It’s small, but it’s your waterproof guarantee.
Here are a few other mistakes I’ve seen during my years of work:
· Holes after installation: Always cut and seal openings before installing.
· Not considering ventilation requirements: You'll need vents or a cooling system if your builds contain heat-like components.
· Using incorrect screws: Always use compatible corrosion-resistant fasteners.
· Not labeling your hookups: A bit of proper labeling now will save you in troubleshooting greatly later.
· Failure to do Environmental Testing prior to launch: ALWAYS check for any pending leaks and seal closure after install.
By avoiding these additional pitfalls, your enclosure setup works perfectly right out the gate.
To make this practical, here’s a quick checklist you can follow for reliable installations:
Verify IP/NEMA rating for the environment.
Mount vertically and securely.
Inspect for leaks, cracks, or misalignments.
Pro Tip:
Always follow the manufacturer’s installation instructions; they’re written based on extensive testing and safety standards.
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When the topic is electronic enclosures, it’s not simply a task of mechanical installation there are considerations regarding long-term system reliability and safety.
All those small little things that you shouldn’t have done, like using the wrong gland, or not grounding yourself, they come back to haunt you.”
After years of practice, I’ve discovered this fundamental fact:
“Everything under the enclosure is a protected system, and how you install will control how well it does that,” he continued.
So go slow, high-quality parts, right procedure and no cutting corners on protection. A few extra minutes of caution during installation can save hours, or even days, of more-expensive repairs down the line.
Q1: What is the most common mistake in enclosure installation?
A: Ignoring IP or NEMA ratings, leading to water or dust damage.
Q2: Can I drill holes in a waterproof enclosure?
A: Yes, but only if you reseal them using certified cable glands or plugs.
Q3: How often should I check enclosure gaskets?
A: Inspect them annually or whenever you open the enclosure.
Q4: Why is grounding so important?
A: It prevents electric shock and protects components from surges.
Q5: What’s the best material for outdoor enclosures?
A: Polycarbonate or stainless steel are best for UV and corrosion resistance.
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