Bud Industries, Inc.

Enclosure
Design Tips
Handbook

A guide to selecting cabinets, enclosures and

other packaging systems for electronic products.

INTRODUCTION

The selection of a cabinet, enclosure, or other packaging for an electronic

product presents the designer or systems integrator with a
variety of choices, in addition to certain criteria that will be dictated by
the nature of the application.
This booklet summarizes some of the more important issues of packaging
for electronic systems and products, with the goal of helping you
evaluate your options quickly, and then select the optimum solution for
your application. Enclosure types are summarized in Table 1.
Many enclosure solutions can be delivered with
custom features or modifications.

TABLE OF CONTENTS
1. ENCLOSURE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cabinet racks (incl. NEMA 12)

............................

........................................

Co-location racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seismic racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open racks (Large open racks, table-top racks,

swing-frame, relay racks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wall mount cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rack mount enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Card racks

Server racks

.........................................

Portable cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Small metal enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cast metal enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Plastic boxes, NEMA 4x enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. ACCESSORIES (Panels, shelves,

brackets, casters, feet, levelers, fans) . . . . . . . . . . . . . . . . . . . . . . . . 14

3. MATERIALS & FINISHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. BASICS OF COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5. TYPICAL RACK DIMENSIONS & TOLERANCES . . . . . . . . . . . . . . . . . . 18

6. COMMONLY USED STANDARDS

7. STANDARDS ASSOCIATIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1. ENCLOSURE TYPES
Table 1. Summary of Enclosure Types.
ENCLOSURE

MAJOR FEATURES

TYPICAL APPLICATIONS

SEE PAGE

Cabinet Racks,
including NEMA 12.

Fully enclosed floor-standing cabinets. Floor-mount enclosure for general3

Provide a controllable environment.
purpose mounting of instruments
Front and rear doors for security.
and equipment with 19, 23, or 24
NEMA 12 cabinets have gasketed
wide panel space.
doors and sides.

Server Racks

Similar to floor mount cabinet racks,

except with heavily ventilated side
panels and rear door.

Used where protection and security

are needed for mounting of deeper
instruments and communication
equipment.

Co-Location Racks

Overall cabinet divided into

individual compartments. Heights
from approx. 24 to 39.

Use where independent

sub cabinets are required.

Seismic Racks

Heavy duty.
Applications that may be subjected
Designed and tested to Bellcore
to shock and vibration.
Zone 4 requirements (#GR-63-CORE,
Issue 1).

Open Racks
Table-top Racks
Swing-Frame Racks

Open framework designed to mount

19 and 23 panel widths.
Includes smaller swing-frame and
wall-mount racks.

Applications requiring maximum

6
free-air ventilation, or easy access
to equipment sides and rear panels.

Wall Mount Cabinets

Small, relatively shallow wallmountable enclosure with door.

Network hubs & mounting of

telecom, datacom, industrial
controls & equipment.

Portable Cabinets

For assembling desktop 19 systems

in heights of approx. 18 to 26.

Small systems where portability

is needed.

Card Racks

Modular packaging system for

mounting circuit boards and
custom electronics.

Data acquisition, telecom

Small Cabinets

Available in a wide range of sizes

and styles, including sloping front,
cases with handles, tilting feet, and
computer-styled enclosures.
Typical materials: steel, formed
aluminum.

Used for housing of prototype

or finished, medium to small
electronic products, instruments,
telecom devices.

11

Chassis

Aluminum formed and welded

construction, with optional bottom
plate.

Construction of products and

prototypes. Provides protections
and structure.

12

Accessories

Fans, fan trays, blowers, handles,

feet, casters, levelers, slides,
panels shelves, power strips,
internal cable brackets.

Provide cooling, mobility, slide-out

access to instruments, power
distribution, etc.

14

Small Metal Enclosures Available in a wide range of sizes

Cast Metal Enclosures
and styles. May include covers,
gasketing, screws, rubber feet, or
other hardware.
Typical materials: aluminum.

Used to house and protect small

electronic products, components,
instruments, telecom devices, etc.

13

Plastic Boxes
NEMA, UL & IEC
Enclosures

Used for housing of small or

hand-held electronic products,
component packaging,
instruments, telecom devices, etc.

13

Available in a wide range of sizes

and styles. May include plastic or
metal covers, gasketing, screws,
rubber feet, or other hardware.
Typical materials: polycarbonate,
polystyrene, ABS plastic.

10
9

CABINET RACKS
Floor-mount enclosed cabinet racks are among
the largest enclosures used in electronic applications, and are offered in many styles and with a
wide range of accessories. Cabinet racks are
available with a 19, 23, or 24 wide panel
space.
An enclosed cabinet is a good choice where
rack-mountable equipment needs to be housed
safely and securely. An enclosed rack offers a
controllable environment for equipment cooling.
Ventilated panels and various types of fan trays
and arrays are available to manage airflow,
which has become increasingly critical as the
power demands of some types of systems escalate. Many enclosed cabinet designs accept
lockable accessory front and rear doors to provide equipment security, or transparent doors to
permit equipment monitoring.
The choice of a specific model depends on
load, accessibility cosmetic and configuration
requirements, and any applicable
standards.

Cabinet Rack

CABINET RACKS

Applications

General electronic rack mounting applications, telecom, datacom, industrial

controls, test and measurement systems.

Dimensional
Considerations

Typical ext dimensions to 86 H, 36 D (approximate)

19 wide panel space is most common. 23 is used in the telecom/datacom.
24 is used for factory automation systems.
Adapters enable 19 equipment to mounted with 23 or 24 equipment.

Load
Considerations

Maximum equipment weight is approximately 1200 pounds.

Racks utilizing a welded steel internal frame offer the highest weight-bearing
capacity. Aluminum frames provide slightly less weight capacity.

Construction

Steel and/or aluminum.

Fully assembled cabinets can reduce product costs by eliminating cabinet
assembly time.
Knock-down (user-assembled) cabinets provide a lower-cost alternative
where less weight capacity is needed, or where it is impossible to transport a
pre-assembled cabinet to the location where it will be used.
Additional choices and considerations:
Width panel openings (23 or 24)
Adequate access holes to simplify cable routing.
Removable side panels that can provide additional access to equipment.
Adjustable rear mounting rails that can be used to support heavy equipment.
NEMA 12 cabinets have gasketed doors and sides.

SERVER RACKS & CO-LOCATION RACKS

Server and Co-location racks are
ideal for applications requiring
maximum ventilation and air flow.
Server racks are similar to cabinet
racks, except that side panels and
doors are heavily ventilated. A locking, solid metal or transparent front
door may be used for protection and
security. Extra cabinet depth
permits mounting of deeper
instruments or equipment.
Co-location racks resemble server
racks that have been divided up into
individual compartments. Individual
sections are designed to be fully
independent and secure, and are
available in heights ranging from
approximately 24 to 39 inches.
Typically, each section has its own
door. Side panels may be one-piece
units that extend the full height of the
cabinet rack assembly.

SERVER RACKS & CO-LOCATION RACK

SERVER RACKS & CO-LOCATION RACKS

Applications

Telecom, datacom, communication systems, general electronic rack mounting

applications. Server cabinets provide extra depth. Equipment mounting rails are
designed to support a variety of commercial servers. Co-location racks are ideal
where independent, securable sub cabinets are required.

Dimensional
Considerations

19 wide panel space.

Server racks - typical ext dimensions to 86 H, 42 D (approximate).
Co-location racks - typical ext dimensions to 86 H, 34 D (approximate).

Load
Considerations

Typical weight capacity: 1200 lb for Server Racks.

Typical weight capacity: 1200 lb for Co-location Racks.
Consult the vendor to confirm load bearing capacity.

Construction

Steel and/or Aluminum.

Available pre-assembled.
Available with transparent front doors
Complementary designs enable Server and Co-location racks to be used together.
Kits may be available to enable Server Racks to be joined for additional
equipment capacity and stability.
Anchoring to the floor is recommended.

SEISMIC RACKS
Seismic racks offer the maximum
level of seismic protection for equipment to be operated under conditions of shock or vibration. Seismic
cabinets are rated according to
Telcordia (formerly Bellcore)
#63-GR-CORE standards, with Zone
4 representing the most demanding
requirements.
The rated weight carrying capacity
of a cabinet is normally based on a
uniformly distributed load. If your
cabinet will be used in a shock or
mobile environment (i.e. aboard
trucks or ships), testing under the
actual or simulated load conditions
may be necessary.
Seismic cabinets should be anchored
to the floor with a suitable anchor kit.
SEISMIC RACK

SEISMIC RACKS

Applications

General equipment rack mounting in environments that may be subjected to shock

or vibration.

Dimensional
Considerations

19 wide panel opening

External dimensions to 75 H, 30 D (approximate). Check with your vendor for
other sizes.

Load
Considerations

Rated weight capacity is normally based on the uniformly distributed

load that the cabinet was tested and rated for. If cabinet will be used in a shock
or mobile environment, testing under the actual or simulated load conditions may
be necessary.

Construction

Welded steel
Use floor anchor kits to secure cabinet.

OPEN RACKS
Open frame racks are a good
choice in applications requiring maximum cooling, or free and immediate
access to the front, rear, and sides of
equipment no doors or side covers
are used. Open frame racks are
available to accept 23 as well as
19 wide instrument panels. If
security is a concern, open frame
racks should be used within lockable
rooms.
Wall-mount and Desktop racks are a
shorter version of the open rack for
use where floor space is not available. Wall-mount designs include
fixed types, as well as swing-frame
types that open away from the wall
to provide rear panel access.
Loads are supported completely by
the rails comprising the rack frame.
Make sure that the load capacity is
adequate for the application, and
that the base is large enough to provide stability for the rack as it will be
populated.
OPEN RACKS

OPEN RACKS

Applications

Most suitable for light-weight, shallow-depth equipment mounting. Useful for

telecom, datacom, phone switching systems, network components.

Dimensional
Considerations

19 and 23 wide panel openings

External dimensions to 100 H, 30 D (approximate). Check with your vendor for
other sizes.

Load
Considerations

Load capacity ranges from a few tens of pounds for desktop units, to
approximately 1000 lb for full-size racks. Consult the manufacturer.

Construction

Steel and/or aluminum.

Typically knock-down, bolt-together construction, for assembly by the user.
Check for availability of kits to permit joining racks.

WALL MOUNT CABINETS

Wall mount cabinet enclosures are a
cost-effective alternative where equipment needs are modest and not likely
to increase for an application.
Double-hinged split cabinets are also
available, which open like a book to
offer access to rear panels, or to
provide multiple layers of rack
mounting space. Lockable and
transparent doors are available with
some models to provide security or
visual access to equipment panels.

WALL-MOUNT CABINETS

WALL-MOUNT CABINETS

Applications

Mounting and enclosing a limited amount of relatively shallow equipment directly

to a wall or other vertical surface.

Dimensional
Considerations

19 wide panel opening

External dimensions range from 24 to 48 H, 6 to 22 D (approximate).

Load
Considerations

Typical weight capacity 75 lb. to 400 lb.

Construction

Steel and/or aluminum.

Preassembled

RACK MOUNT CHASSIS

Rack mount chassis provide a range
of enclosures for the assembly of
rack-mountable equipment and instruments. Some rack mountable equipment may also be used as desk-top
or portable equipment, so detachable handles, rack mounting brackets, or other hardware may be desirable. Availability of ventilation panels
is also important to maintain safe
operating temperatures.

RACK MOUNT CHASSIS

RACK MOUNT CHASSIS

Applications

Packaging for electronic instruments, circuits, and components that will typically be
installed in a 19 rack.

Dimensional
Considerations

Mounts in a 19 wide panel opening.

Height 1U to 8U (1.75 to 14).
Depth 8.5 to 22 (approximate)

Load
Considerations

Light loads unless supported by external brackets.

Construction

Steel, aluminum
Handles can provide convenience during rack mounting.

CARD RACKS
Card racks are chassis-like enclosures
used to assemble circuit boards and
components into modular electronic
instrumentation. The card rack itself is
designed to mount in a 19 rack.
Modules can be changed or
rearranged to permit quick, convenient equipment modifications.
Modular systems can hold a number
of individual sub-modules, each of
which must mesh with rails, guides,
connectors, lock screws, and other
hardware within the modular chassis.
Dimensional precision and stability
are important to eliminate the
possibility of binding and
misalignment.

CARD RACK

CARD RACKS

Applications

Packaging of electronic circuit cards in modular units that can be installed or

removed from a 19 sub-rack.
Modular cabinets are often used in mission-critical applications (data acquisition,
telecom, and industrial control) that are governed by regulations and standards
for construction, vibration, fire worthiness, and other factors.

Dimensional

Sub-rack unit mounts in a 19 wide panel opening. Individual plug-in modules

vary in width.
Height 2U or 3U (3.5 or 5.25).
Depth 11.5 to 14 (approximate)
Modules accept cards up to 4.4 X 10.78

Load
Considerations

N/A.

Construction

Aluminum
Internal card rack construction includes card guides, locks, mounting rails, and
other structural members.
Individual modules are independent enclosures with front panels, top, bottom,
sides, and back.

PORTABLE CABINETS
Portable cabinets are small cabinet
racks used to house a limited amount
of 19 wide instrumentation or
equipment. Internally, portable
cabinets offer limited space for
power strips and other accessories.
Generally, no internal framework is
present. Externally, portable cabinets
accept rubber feet, but not casters,
levelers, or anchor kits.
The weight capacity may be up to
500 pounds. Heavily loaded
cabinets should be supported on
sturdy surfaces.

PORTABLE CABINET

PORTABLE CABINETS

Applications

Mounting and enclosing a limited amount of equipment for desktop, portable, or

semi-portable applications where enclosed equipment and instruments do not
exceed approximately 20 in depth.

Dimensional
Considerations

19 wide panel opening.

External dimensions range from 7 to 30 H, and to 21 D (approximate).

Load
Considerations

Typical weight capacity up to 500 lb. Check for weight limits when using built-in
handles to lift and carry the cabinet.

Construction

Steel and/or aluminum.

Fully assembled.
Front or rear doors and panels, and rear mounting rails may be available
check with your vendor.
Handles and other accessories may be available to aid in portability of
fully loaded cabinets.

10

SMALL METAL CABINETS

Small cabinets are used to package
instrumentation and equipment requiring a maximum volume of approximately 1 cubic foot. Small cabinets
include convenience features such as
strap handles, sloping fronts, tilting
bails, and latches, to name a few.
They are generally not intended for
rack mounting, although mounting
hardware may be available for some
types.

SMALL METAL CABINET

SMALL METAL CABINETS

Applications

Practically an unlimited range of applications.

Used for prototypes or finished, medium to small electronic products, instruments,
telecom devices, computer peripherals, and control panels, etc.

Dimensional
Considerations

Extremely wide range of dimensions and styles.

Typical height and width to 12 x 12 x 15

Load
Considerations

N/A.

Construction

Typical materials: steel, formed aluminum, extruded aluminum.

11

CHASSIS
Metal chassis provide support and
protection for electronic circuits. A
bottom cover is often available.
Check dimensions and accessories
for specific chassis models.

CHASSIS

CHASSIS

Applications

A platform for construction of circuits and subassemblies that generally fit within a
larger case, rack, or cabinet.
Used as a basic building block in a very wide range of applications.

Dimensional
Considerations

Extremely wide range of dimensions and styles.

Typical height and width from approximately 4 x 4 to 17 x 17; depth from
1 up to 6.

Load
Considerations

N/A.

Construction

Aluminum

12

Small Enclosures
TYPE

TYPICAL FEATURES

APPLICATIONS

Die Cast Metal

Aluminum boxes and covers.

Sizes range to approximately 9 x 6 x 3.

Housing of electronic and electrical

assemblies.
Pneumatic and hydraulic devices.
Applications requiring a sturdy
enclosure.

NEMA 4 Die Cast

NEMA 4 aluminum enclosures typically

offer sealed construction and/or gasketing
for resistance to atmospheric contaminants,
spray, and corrosion.
Designed to IP65 of IEC529 and NEMA 4
specifications.
Available with wall mounting holes and cover.
Attaching screws are outside the sealing area
to prevent entry of moisture and dust. Cover
incorporates a recessed gasket Most models
have internal guides for mounting PCBs. Cover
mounting holes are roll threaded; screws are
captive and recessed.
Finishes: natural finish or gray.

Housing of sensitive electronic and

electrical assemblies.
Pneumatic and hydraulic devices.
Applications requiring a sealed
enclosure.

UL, NEMA 4X,

Polycarbonate, &
ABS Enclosures

Similar in appearance to NEMA 4 aluminum

enclosures, except they are constructed from
polycarbonate or ABS plastic, and satisfy
specific NEMA, UL, or IEC codes. May
contain aluminum panels, PC board guides,
or mounting bosses. Transparent doors or
covers may be available.
Sizes range to approximately 24 x 16 x 10.

Housing of sensitive electronic and

electrical assemblies.
Applications requiring a sealed
enclosure.

Molded ABS
Plastic Cases

Cases are available in various shapes and sizes, Instrumentation

with features such as sloped or flat panels,
Telecom equipment
removable panels, interlocking clamshell
Data acquisition
case halves, and internal reinforcements.
Molded plastic cases provide a finished
appearance and are available in a variety
of colors. They are generally usable without
further painting.
Guides and bosses may be present for mounting
PC boards. Rubber feet may be included.
Sizes range to approximately 24 x 16 x 10.

Hand Held
Enclosures

Enclosures are designed for portable hand-held

and pocket applications, including ergonomic
shapes, interlocking lids, access panels for
batteries, and windows that can be used for
opto displays. Many features of standard
molded plastic cases also apply.

Consumer electronic devices

Hand-held remote controls

Economy, Utility,
and Potting Boxes

This class of enclosures offer basic packaging

and protection for small circuits and
components. It includes economy metal and
plastic boxes which are generally offered
unfinished, or in a limited number of colors.
Covers are usually available.
Sizes range to approximately 6x 6x 6.

Small electronic devices

Electronic accessories
Prototypes
Component packaging
Potted assemblies

13

2. ACCESSORIES
Rack accessories such as shelves, panels, handles, desk tops, and drawers provide a finished
appearance, add security, and improve convenience and work efficiency for the user. Accessories
for the interior, such as cable clamps, brackets, fans, and other cooling accessories can help reduce
clutter and improve system operation. Pre-drilled holes for mounting of casters, levelers, and eyebolts
eliminate the need for system integrators to drill or modify the cabinet, which can save considerable
time on the assembly floor.
ACCESSORIES

Cooling

Fans, fan trays, & blowers

Temperature controls

Power
Management

Cable management brackets

Power strips and distribution

Internal Slide
Hardware

Mounting flanges, brackets, and adapters

Slide brackets & mechanisms

External Panels
and Hardware

Blank filler panels

Handles & locks
Screws, nuts, washers & clip nuts

Shelves and
Drawers

Transport & Anchoring

Hardware

Casters, feet & levelers

Seismic anchors
Anti-tilt bars & other safety equipment

Fixed and sliding shelves

Sliding drawers
Keyboard and mouse shelves
Fixed and folding desk tops

ACCESSIBILITY
Lift-off and reversible (left or right hinged) doors that can be moved out of the way can simplify and
speed equipment installation. Side panels that can be removed from outside will greatly enhance
accessibility to interior components and cabling at the interior sides of a cabinet.

EXPANDABILITY
Two or more cabinets may be required to house all the equipment associated with an application.
Kits are available that allow cabinets to be ganged together into a suite. This offers a number of
advantages, including greater stability, and easier management of interconnecting cables.
The user must insure that the cabinets can be ganged together easily and the manufacturer supplies
the proper hardware kit.

CABLE MANAGEMENT
Sufficiently large external access holes on the top and bottom of a cabinet are a must for cabling in
most applications. Knock-outs in the front and rear of the cabinet frame are desirable for bringing in
power cables.
Internally, the routing and anchoring of cables is extremely important in making a system neat and
serviceable, and for assuring the highest signal integrity. Various types of cable clips, straps, and
panels are available for this purpose.
Also, pay close attention to the routing of analog signals, digital signals, and power, as well as the
type of cabling being used to carry each. Be aware of the possibility of noise coupling, hum, crosstalk, and other undesirable conditions that can occur when cables are bundled together. In audio
applications, for example, power and digital signals are often routed to one side of the cabinet,
and audio signals to the other side.

14

3. MATERIALS & FINISHES

COMMONLY USED MATERIALS METALLIC
Material

Cost

Strength

Corrosion
Resistance

Suggested Uses and

Applications

Carbon Steel

Low

High

Poor

General indoor and outdoor

applications requires
painting or powdercoating

Galvannealed
Steel (steel with
electrocoated
zinc finish on
both sides)

Low
to
Moderate

High

Good

General indoor and outdoor

applications requires painting
for some indoor applications
and all outdoor applications

Stainless Steel

High

High

Excellent

General indoor and outdoor

applications does not require
painting
Food and pharmaceutical
applications
Marine applications

Aluminum

Moderate

Moderate

Good to
Excellent

General indoor and outdoor

applications does not require
painting
Food applications
Marine applications

COMMONLY USED MATERIALS NON-METALLIC

Material

Cost

Chemical
Resistance

Suggested
Uses and Applications

ABS

Low

Low

General indoor applications

ABS/PC Blend

Low

Low to Moderate

General indoor applications

Polycarbonate

Moderate

Moderate

General indoor and outdoor

applications

PC/PBT Blend

Moderate

Moderate

General indoor and outdoor

applications
Marine applications

Fiberglass

High

High

General indoor and outdoor

applications
Indoor and outdoor applications
where extreme chemical,
temperature, or moisture are of
concern
Marine applications

Comparisons above reflect the basic resins. Enhancements can be made to all of the above resins to
improve their flammability, electrical properties, chemical resistance, UV resistance, mechanical properties,
and thermal properties.

15

COMMONLY USED FINISHES FOR METALLIC ENCLOSURES

Finish

Used On

Cost

Advantages

Disadvantages

Suggested Uses

Anodize

Aluminum

Moderate

Enhances
appearance
Moderately nonconductive

Easily marred
Not recommended
for castings

General indoor and

outdoor applications

Zinc Plating

Steel

Moderate

Improves
appearance
Protects against
corrosion
Can be colored

Can enhance
imperfections in
material
Part size limited
Limited colors

Component parts for

indoor and outdoor
applications

Paint

Aluminum
and Steel

Moderate
to High

Improves
appearance
Increases
corrosion
resistance and
weatherabilty
Unlimited color
choices

Moderately mar
resistant

General indoor and

outdoor applications

Powdercoat

Aluminum
and Steel

Low to
Moderate

Improves
appearance
Increases corrosion
resistance and
weatherability
Unlimited color choices
Improves mar resistance

General indoor and

outdoor applications
Extreme exposure
applications

COMMONLY USED FINISHES FOR NON-METALLIC ENCLOSURES

The color of non-metallic enclosures is part of the resin and is molded into the part. Except for internal coatings for EMI/RFI protection, secondary finishes are usually not required. Certain grades within the basic
resin families can be plated or painted, if necessary.

16

4. BASICS OF COOLING
Waste heat generated by equipment within a cabinet is the single factor most affecting equipment
reliability. Therefore, an effective cooling strategy can be critical. The most commonly used cooling
methods, in order of increasing cost, are:
Natural convection
Forced convection (Exhaust fans and blowers)
Air conditioning
Heat may also be lost through conduction between objects in contact, or through radiation (heat
transfer that occurs through electromagnetic waves). Most systems manage heat through a combination of methods, even though one may be emphasized. For example, a processor chip may be
cooled using a heat sink (conduction) that includes a fan (forced convection). Enclosure manufacturers can provide guidance to users in selecting the proper cooling approaches.
Natural convection cooling is adequate for most applications that generate mild heat, provided the
cabinet offers an unrestricted internal air path. The user must insure that the cabinet has sufficient
venting at both the top and bottom to promote airflow and a chimney effect. Louvers are a popular
form of air entry and exit for convection cooling because they provide some protection against dust
entry, and hide the contents of the cabinet.
Where natural convection is inadequate, forced convection can be used. An exhaust fan can be
added at the top of the cabinet. Alternately, a blower can be used at the bottom of the cabinet to
create high internal pressure within the cabinet. Hot air will then be exhausted at the top of the cabinet through vents, or an exhaust fan at the top can be added to improve air flow. Static back pressure requirements need to be determined through empirical measurement they cant be calculated.
The high pressure inside the cabinet also prevents entry of dust and lint.

BASIC AIR FLOW CALCULATIONS

The amount of airflow that must be provided to achieve a desired cooling performance is expressed
by the following equations:
For
T in F:

AIR FLOW (ft3/min) =

For
T in C:

AIR FLOW (ft3/min) =

Typical values for
T are 10C or 18F. Add a 25% for safety margin (12.5C and 23F). Note
that
T represents the temperature rise over ambient air temperature. If ambient is too high, it may
be difficult or impossible to maintain a safe operating temperature without air conditioning. Air conditioning is used in critical high-heat generating environments, and allows cooler-than-ambient air to
be circulated through the cabinet.

17

5. TYPICAL RACK DIMENSIONS & TOLERANCES

The following dimensions and tolerance are according to standard EIA-310-D, and govern rackmount cabinet and panel dimensions. For a complete specification, contact the Electronic Industries
Association, Engineering Department, 2500 Wilson Blvd., Arlington, VA 22201.

INCHES

PANEL
WIDTH

MILLIMETERS

19 0.016

482.6 0.4

23 0.016

584.2 0.4

24 0.016

609.6 0.4

30 0.016

762.0 0.4

INCHES
EQUIPMENT
FRONT
PANEL
HEIGHT

CABINET
PANEL & CHASSIS
SPACE
DIMENSIONS
(19 RACK)

MILLIMETERS

(N X U) 0.315

(N X U) 0.8

N = RACK UNITS

N = RACK UNITS

U = 1.75

U = 44.45

INCHES

MILLIMETERS

MIN. HORIZ.
CHASSIS OPENING

17.716

450

HORIZ.
HOLE CTRS.

8.307 0.059

MIN. HORIZ.
PANEL SPACE

19.031

MIN. VERTICAL

18

(N x U) + 0.031

465 1.5
483.4
(N x U) + 0.8

Standard Vertical Hole Centers in Panels

Hole Centers
mm

inches

1U

2U

3U

4U

5U

6U

7U

8U

9U

10U

11U

12U

hole position, measured from top edge of panel

6.0

0.236

37.7

1.484

82.2

3.236

94.9

3.736

126.6

4.984

139.3

5.484

171.1

6.736

183.8

7.236

215.5

8.484

228.2

8.984

272.7

10.736

280.0

11.024

304.4

11.984

317.1

12.484

361.6

14.236

406.0

15.984

450.5

17.736

494.9

19.484

Panel Hole Styles & Dimensions

STD. OPEN SLOT

STD. CLOSED SLOT

MILLIMETERS

INCHES

MILLIMETERS

INCHES

7.1mm 0.3mm

0.279 0.012

7.1mm 0.3mm

0.279 0.012

14.7mm 1.2mm

0.579 0.047

10.3mm 0.4mm

0.405 0.0157

13.7mm 0.4mm

0.527 0.0157

19

USABLE CABINET DEPTH

The usable depth in a cabinet rack is the maximum usable space between the equipment front
mounting surface and the rear mounting surface, and varies from approximately 17 to 42. The
addition of connectors and cabling from the rear panels of equipment or instruments can add several
more inches to cabinet depth requirements. You will also need to factor in all accessories such as
power strips, cooling devices and mounting brackets.

MOUNTING RAILS
One of the most important features in a rack is the design of the equipment mounting rail. Most
mounting rails are pre-tapped with #10-32 or #12-24 threads, although some manufacturers use
metric thread (M5 or M6) fasteners. Some manufacturers provide round or square holes in their
mounting rails that require the insertion of clip nuts or cage nuts prior to the installation of equipment
in the rack. Pre-tapped holes are preferred because they save significant time in assembly. However,
clip or cage nuts are easy to replace individually, and may offer advantages where there is any possibility that threads may be damaged or worn through frequent equipment changes.
The shape of the mounting rail is also important because it contributes to rigidity, and to the ease of
mounting other hardware and accessories inside the cabinet. L-shaped rails provide only one mounting flange at the front of the cabinet, so additional brackets may be needed for adding accessories
inside the cabinet. Some manufacturers provide a question mark shaped rail that has an accessory
mounting flange in addition to the equipment mounting flange. This flange makes it easy to mount
accessories such as shelves and slides behind the front panel. Mounting rails that can be adjusted
forward or backward in the cabinet allow additional flexibility in equipment mounting.

L Shaped Mounting Rail

Mounting Rail with

Accessory Flange

20

6. COMMONLY USED STANDARDS

NEMA, UL, CSA, and IEC RATINGS
NEMA, UL, and CSA are organizations that write standards commonly used in North America. They
are similar in their descriptions, applications, and performance. IEC produces similar standards that
are used in Europe, but increasingly referenced in North America. Even though the IEC performance criteria is similar to NEMA, the interpretation of the performance and the testing conditions can
vary, thereby, making an exact comparison difficult.
UL and CSA require testing by qualified testing facilities, while NEMA and IEC do not require this
testing and leaves adherence to the standard up to the manufacturer of the product. Shown in Table
1 below are abbreviated descriptions of the commonly used NEMA, UL, and CSA environmental
standards and ratings associated with the enclosure industry, and governed by these organizations.
Table 2 shows the IEC or IP ratings for the similar types of standards. Table 3 is an approximate
cross-reference between the IEC and NEMA ratings.These tables are to be used for general reference only. Consult the appropriate organization and standard prior to specifying your enclosure.

Table 1
Enclosure
Rating
Type 1

NEMA
Standard 250
For indoor use to
provide a degree of protection
against incidental contact with
the enclosed equipment; and
to provide a degree of protection
against falling dirt.

UL
CSA
Standard 50 and 508
Standard C22.2 No.94
For indoor use primarily to provide
For indoor use to protect
a degree of protection against limited against accidental contact
amounts of falling dirt.
with live parts.

Type 2

For indoor use to provide a

degree of protection against
incidental contact with the
enclosed equipment; and to
provide a degree of protection
against falling dirt, dripping and
lightly splashing liquids.

For indoor use primarily to provide

a degree of protection against
limited amounts of falling
water and dirt.

For indoor use to provide

a degree of protection
against dripping and
light splashing of
non-corrosive liquids
and falling dirt.

Type 3

For either indoor or outdoor use

to provide a degree of protection
against incidental contact with the
enclosed equipment; to provide a
degree of protection against falling
dirt, rain, sleet, snow, and
windblown dust; and be
undamaged by the external
formation of ice on
the enclosure.

For outdoor use primarily to provide

a degree of protection against rain,
sleet, wind blown dust and damage
from external ice formation.

For indoor or outdoor

use; to provide a degree
of protection against rain,
snow, and windblown
dust; to be undamaged
by external formation
of ice on enclosure.

Type 3R

For either indoor or outdoor use

For outdoor use primarily to
to provide a degree of protection
provide a degree of protection
against incidental contact with the against rain, sleet, and damage
enclosed equipment; to provide a
from external ice formation.
degree of protection against falling
dirt, rain, sleet, snow; and be
undamaged by the external formation
of ice on the enclosure.

21

For indoor or outdoor

use; to provide a degree
of protection against rain,
snow; to be undamaged
by external formation
of ice on enclosure.

Table 1 cont.
Enclosure
Rating

NEMA
Standard 250

UL
Standard 50 and 508

CSA
Standard C22.2 No.94

Type 4

For either indoor or outdoor use

to provide a degree of protection
against incidental contact with the
enclosed equipment; to provide a
degree of protection against falling
dirt, rain, sleet, snow, windblown
dust, splashing water, and hosedirected water; and be undamaged
by the external formation of ice on
the enclosure.

For indoor or outdoor use primarily

to provide a degree of protection
against windblown dust and rain,
splashing water, hose-directed water,
and damage from external
ice formation.

For indoor or outdoor

use; to provide a degree
of protection against
rain, snow, windblown
dust, splashing and hosedirected water; to be
undamaged by external
formation of ice
on enclosure.

Type 4X

For either indoor or outdoor use to

provide a degree of protection
against incidental contact with
the enclosed equipment; to provide
a degree of protection against
falling dirt, rain, sleet, snow, windblown dust, splashing water,
hose-directed water, and corrosion;
and be undamagedby the external
formation of ice on the enclosure.

For indoor or outdoor use primarily

to provide a degree of
protection against corrosion,
windblown dust and rain,
splashing and hose-directed
water, and damage from external
ice formation.

For indoor or outdoor

use; to provide a degree
of protection against
rain, snow, windblown
dust, splashing and hosedirected water; to be
undamdiaged by
external formation
of ice on enclosure;
resists corrosion.

Type 6

For either indoor or outdoor use to

provide a degree of protection
against incidental contact with the
enclosed equipment; to provide a
degree of protection against falling
dirt, hose-directed water, and
entry of water during an
occasional temporary submersion
at a limited depth; and be
undamaged by the external
formation of ice on the enclosure.

For indoor or outdoor use primarily

to provide a degree of
protection against hose-directed
water, and the entry of water during
occasional temporary submersion
at a limited depth and damage
from external ice formation.

For indoor or outdoor

use: provides a degree
of protection against
entry of water during
temporary submersion.

For indoor use to provide a

degree of protection against
incidental contact with the
enclosed equipment; and to
provide a degree of protection
against falling dirt, circulating
dust, lint, fibers, and flyings; and
against dripping and lightly
splashing liquids.

For indoor use primarily to provide

a degree of protection against
circulating dust, falling dirt,
and dripping non-corrosive liquids.

For indoor use: provides

a degree of protection
against circulating dust,
lint, fibers, and flyings;
and against dripping
and lightly splashing
of non-corrosive liquids;
not provided with
knockouts.

For indoor use to provide a

degree of protection against
incidental contact with the
enclosed equipment; and to
provide a degree of protection
against falling dirt, circulating
dust, lint, fibers, and flyings; and
against spraying, splashing, and
seepage of water, oil, and
non-corrosive coolants.

For indoor use primarily to

provide a degree of protection
against dust, spraying of water,
oil, and non-corrosive coolant.

For indoor use: provides

a degree of protection
against circulating dust,
lint, fibers, and flyings;
seepage and spraying
of non-corrosive liquids,
including oils and
coolants.

Type 12

Type 13

22

Table 2
Protection against hazardous parts
and solid objects
Hazardous Parts

Solid Object

Non-protected

Non-protected

IP Protection Rating

Protection against water

1st Figure 2nd Figure

Water

Non-protected

Protected against vertically

falling water drops

Protected against
access to hazardous
parts with a finger

Protected against
2
solid foreign objects
of 12.5mm
diameter or greater

Protected against vertically falling

water drops when enclosure
tilted up to 15 degrees

Protected against
access to hazardous
parts with a tool

Protected against
3
solid foreign objects
of 2.5mm diameter
or greater

Protected against spraying

water

Protected against
hazardous parts
with a wire

Protected against
4
solid foreign objects
of 1.0mm diameter
or greater

Protected against splashing

water

Protected against
hazardous parts
with a wire

Dust-protected

Protected against water jets

Protected against
hazardous parts with
a wire

Dust-tight

Protected against powerful water

jets

Protected against the effects of

temporary submersion in water

Protected against the effects of

continuous submersion in water

Protected against access Protected against

to hazardous parts with solid foreign
the back of a hand
objects of 50mm
diameter and
greater

Example of IP classification: IP23 would mean protection against touching hazardous parts with either a finger or a
solid object greater than 12mm in diameter (the #2 in the example), and protection against spraying water (the #3
in the example).

Table 3
NEMA
RATING

Type 1

Type 2

Type 3

Type 3R

Type 4

Type 4X

Type 6

Type 12

Type 13

IP
RATING*

IP23

IP30

IP64

IP32

IP66

IP66

IP67

IP55

IP65

*Approximate cross reference

TELCORDIA (FORMERLY BELLCORE)

Telcordia Technologies (formerly Bellcore) plays an important role in the development of standards for the telecommunications industry. The primary specification that is used for standard enclosures is #GR-63-CORE. This specification lists, among other requirements, the preferred overall sizes of racks and enclosures, but more importantly is
the seismic risk zone ratings established for different parts of the United States and the testing requirements for
these ratings.
In general, the United States is divided up into four Earthquake Risk Zones ranging from Zone 0 through to Zone
4. The geographical areas designated as Zone 0 present no substantial earthquake risk. Areas that are designated Zone 1 though Zone 4 represent an increasingly higher risk of earthquake activity, with Zone 4 being the
greatest risk.
Consult this specification prior to choosing an enclosure, if there are any concerns about earthquake activity.

23

7. STANDARDS ASSOCIATIONS
American National Standards Institute (ANSI)
1819 L Street, NW
Washington, DC 20036
www.ansi.org
Canadian Standards Association (CSA)
178 Rexdale Boulevard
Toronto, Ontario, Canada
M9W 1R3
www.csa.ca
Conformite Europeene (CE)
European Economic Community
Electrical/Electronic Manufacturers Association of
Canada (EEMAC)
10 Carlson Court, Suite 500
Rexdale (Toronto), Ontario, Canada
M9W 6L2
Electronic Industries Association (EIA)
2500 Wilson Blvd
Arlington, Virginia 22201
www.eia.org
Federal Communications Commission (FCC)
445 12th St. S.W.
Washington DC 20554
Institute Of Electrical And Electronics Engineers
(IEEE)
445 Hoes Lane
Piscataway, NJ 08855-1331
www.ieee.org
International Electrotechnical Commission (IEC)
3 Rue de Varemb
CP131
CH-1211Geneva 20
Switzerland
www.iec.ch

24

International Society Of Automotive Engineers (SAE)

400 Commonwealth Drive
Warrendale, PA 15096-0001
www.sae.org
Joint Industry Council
7901 Westpark Drive
McLean,VA 22101
National Electrical Manufacturers Association (NEMA)
1300 North 17th Street
Suite 1847
Rosslyn, Virginia 22209
www.nema.org
National Fire Protection Association (NFPA)
1 Batterymarch Park
Quincy, MA 02269-9101
www.nfpa.org
Telcordia Technologies
(formerly BellCore)
445 South Street
Morristown, New Jersey 07960-6438
www.telcordia.com
TV Product Service
Segensworth Road
Fareham Hampshire
P015 5RH
United Kingdom
www.tuvps.co.uk
Underwriters Laboratories Inc. (UL)
333 Pfingsten Road
Northbrook, IL 60062
www.ul.com

25

Bud Industries, Inc.

Bud Industries, Inc., founded in 1928, is the nation's leading

manufacturer of enclosures and related products for the
electronics and data industries. The Bud line includes products
ranging from small hand held boxes to large cabinet racks,
products made from plastic as well as metal, and standard
electronic products as well as those that meet NEMA and
Seismic requirements. Bud's standard line of over 2500 products is heavily stocked by distribution as well as the company,
allowing same day shipment on over 90 percent of the
enclosures sold. Modified standard and custom products are
also available, as is complete design support.

tel.
fax.
e-mail

440-946-3200
440-951-4015
[email protected]

www.budind.com