Types of Protected Distribution Box
Suppliers offer these types of robust enclosure cabinets for electrical or electronic distribution systems to wholesale buyers of a protected distribution box. Iron-lattice safe distribution boxes are sometimes called PDUs (power distribution units).
Type 1, indoor protected distribution box
This box is suitable for indoor installations requiring IP (ingress protection) ratings of 54 or higher and IK (impact protection) ratings of 02 or higher. Internal micro-circuit breakers power the cables to provide additional protection. The heat generated inside the cabinet by the breakers and their associated wiring can be vented through limited openings or grilles. The distribution boxes often supplied with shrouded circuit breakers that snap into place without tools to reduce the risk of accidental contact with live parts. They perform capacitively or inductively insulated to allow periodic maintenance without breaking the cabinet's safety seals.
Type 1, outdoor protected distribution box
The features and specifications of this type of protected distribution box are similar to type 1, with the only difference that they are intended for outdoor installation. The outdoor version often has higher IP ratings and corrosion-resistant materials. Type 3 enclosures can also be combined with type 1 enclosures to improve electrical safety. They can be offered with padlock, locking bars, or bars for combination locks for extra security.
Type 2, outdoor protected distribution box
This type of protected distribution box is suitable for installations that require IP ratings of 54 or higher. Type 2 distribution boxes are sometimes used for building facades or safety fencing around construction zones.
Examples of outdoor protected distribution boxes suitable for type 2, 3, or 4 profiles include low-voltage power lines that cross over bridges, scaffolding, or other structures, as well as cable trees, which are temporary protective coverings for cables.
Industrial Applications of Protected Distribution Box
Chemical and petrochemical plants
Chemical and petrochemical plants have these kinds of distribution boxes because they house potentially harmful chemicals. The protected boxes keep the wiring safe and organized, which is important for safety and efficiency. They also help maintain the structure and integrity of the cables in areas exposed to heat, dust, or humidity, and they can help extend cable longevity.
Water and sewage treatment facilities
Distribution boxes at water and sewage treatment facilities where water is aggressive or contains particulates protect wiring and help professional maintenance of complex electrical systems. Boxes can have higher IP ratings for water and dust protection and IK ratings for impact protection.
Underground mining operations
Many remote operations or areas with extreme weather conditions use these heavy-duty enclosures. The enclosures help maintain electrical safety and system reliability in hazardous environments. Mobile mining equipment needs a type 1,2, or 3 enclosure to keep circuit boards safe while mining.
Maritime and offshore oil and gas platforms
Distribution boxes on oil refineries, maritime operations, and gas platforms value the protection these boxes give against IP water, corrosion, and heavy impact. The harsh marine environment can challenge electrical systems, so these enclosures help maintain safety and reliability.
Renewable energy systems
Protected distribution boxes are integral parts of solar farms that manage the output of multiple solar inverters and wind farms, balancing power flow and protecting electrical components from overload or fault currents. They combine modular design with easy installation, allowing faster connections for cables without needing specialized tools.
Industrial automation and robotics
In smart factories, enclosures route power and data cables to keep them organized and safe, helping to reduce downtime and improve efficiency. They are a cost-effective solution for maintaining electrical safety and reliability in systems where space is limited and easy access is required for maintenance. Many box types also support thermal management features, preventing overheating during high-intensity operations.
Product Specifications and Features of Protected Distribution Box
Technical specifications/key features
Protected distribution boxes usually house plated or unplated terminals, a choice of 3 or 5-pin series connectors, or socket-outlet connectors for internal appliance inlets. They are made of galvanised steel, mild steel, or MS powder-coated steel in a wide variety of sizes or standard IP ratings for steel enclosures.
Some have add-on insulated shielding plates for wire routing and separating, which improves the PD box's thermal performance. Other features include:
- Sockets or pigtails: A turbine ventilator works to improve thermal airflow through the HDPE cabinet. Strong ventilators help cool hot cables. Ventilators exist as factory-fitted or aftermarket upgrades.
- Mounting system: Roads with potholes, heavy rain, debris, or other transportation challenges are very bumpy. A well-designed mounting system is vital to keep the distribution box from breaking or damaging what's inside.
- Breakers: Even harsh environments can overload circuits. Circuit breakers prevent overloading and damage by automatically switching off any overloaded circuits. A breaker also makes it easy to reset and return things to normal after a power overload.
- Lock/code: For safety reasons, most enclosures are locked, and only authorized personnel can access the contents. The locking mechanism is often a protected key or special tools to prevent people from tampering with not easily found or duplicate locks.
- Thermal shielding: Extreme temperatures, like summer heat, can damage cables and equipment. Thermal shielding is an insulated barrier that protects the internal components from too much heat. The shield redirects or dissipates heat away from cables and devices, keeping them safe and functional. This protects the distribution box in hot climates or environments with high heat exposure.
How to install/use
The way to install and use a protected distribution box depends on several factors, such as the type and application, the installed equipment, and environmental considerations. Here are general guidelines:
- Installation: The primary outlet and input conductor must connect to the internal terminal strips where the main electrical source feeds in and distributes out power. Ensure the wires are tightly secured and connected to avoid any loose connections, which can cause problems. Away from any damp or wet environment, mount the PD boxes on solid walls with enough room around them for easy access to the terminals, cables, and any maintenance needs.
- running cables: After placing the distribution box securely, running the wires is the next step. Cables should be secured internally to prevent them from moving around or getting tangled. When running cables, avoid placing power and data cables next to each other to prevent interference with the electrical installation.
- System checks: After completing all installations and wiring, performing checks is recommended. Turn on the main power to the box slowly and watch for any issues. Check that all circuit breakers and safety components work correctly, and ensure there are no signs of overheating or strange odours when powering on the system for the first time.
Maintenance and repair
Proper maintenance and repairs of the protective distribution box ensure it remains in good working condition and lasts for many years. Here are guidelines on how to do so:
- Regular checks: Over time, dust and moisture can get inside the distribution box, so it's good to check it often. Look at the seals, vents, and fans for any wear or damage. Also, check the wires and connectors to ensure everything is right and secure. Keeping the box clean and dry will help prevent problems.
- Cooling system: The ventilator and any other cooling parts should work properly and aren't blocked by dust or anything else. The ventilator should spin easily and not make any strange noises. If the ventilator looks worn out or slows down, it might need to be replaced or oiled if supported.
- Lock and lock: Locks and seals help keep the box safe from tampering, important for security. Oil any locks so they don't rust, and check for signs of damage or other things getting inside the box. The seal around the door should be smooth, without cracks or other issues. If it has any, replace them so the box stays secure.
- Repairs: If something inside the box is broken or worn out, the first step is figuring out what exactly went wrong. Small repairs can sometimes be tackled independently, but more complex issues or dangerous situations are best left to the experts. Always ensure that the correct spare parts and components are used when repairs are done, so everything works smoothly again.
Quality and Safety Considerations for Protected Distribution Box
Quality considerations
- IP ratings: Ensure the enclosure has the right ingress protection rating to keep the internal components safe from water and dust.
- Materials: Most external distribution boxes are made with steel or aluminium alloys. Those made from steel provide a higher IK rating than boxes made of thin materials. Stainless steel boxes provide extra corrosion protection in harsh environments, while steel boxes shield electromagnetic fields.
- Thermal features: Select PDs with special vents, fans, or thermal shields to help cool everything and keep it from overheating, especially in box types with circuit breakers that generate heat.
- Modular design: Some boxes have a modular design with removable panels that make it easier to access the inside to add new cables or equipment or do maintenance. Wholesalers should consider such boxes to allow installers to make changes quickly without completely taking apart the whole unit.
- Custom enclosures: If the PD enclosures the customer requires do not have the right specifications or configurations, consider getting an enclosure manufactured in custome designs and sizes, materials, mounting options, thermal features, and IP/IK ratings.
Safety considerations
- Electrical safety: Only use PD boxes with proper electrical safety features like circuit breakers, ground fault interrupters, and overcurrent protection to help prevent electrical accidents or damage. Ensure that the safety features meet all relevant electrical codes and standards.
- Proper seals: Locks, seals, and gaskets should fit properly and snugly against the enclosure to keep it fully secure from intruders. Make sure any opening is sealed tightly and that there are no gaps large enough for someone to reach in or tamper with the wires. Corrosion-resistant materials help ensure proper sealing even in damp or salty ocean air conditions.
- Smooth edges: Inspect the box's interior and exterior for sharp or jagged edges that could pose a cut hazard to workers. Sand down or install rubber edge guards on any areas that are rough or pointed. This will help prevent laceration injuries when handling the box or reaching inside.
- Cable strain relief: Entry point fittings or cable glands should firmly secure incoming cables to relieve strain and pulling force off internal wires. This protects electrical connections from loosening due to movement and prevents hazards from exposed live wiring.
Q&A
Q1. Can a protected distribution box be sampled for quality before bulk buying?
A1. Yes, buyers can purchase one or two boxes for quality checks. Having a couple of these enclosures is a great way to see how they handle various tasks in real life without committing to a huge amount at first.
Q2. What materials can coaxial-updated protected distribution boxes be made of?
A2. They can be made of mild steel, fibreglass, or aluminium. Each material has pros, like how wired boxes are extra tough, aluminium is lighter and won't rust, and fibreglass handles chemicals and salty air well.
Q3. Do protected distribution boxes have different IP ratings?
A3. Yes, various IP ratings are available, such as IP54, IP66, and IP67. IP67 enclosures are temporarily submersible in water, while IP54 protects against limited dust and water splashes.
Q4. Who are the main customers for these types of distribution boxes?
A4. Large manufacturers, electrical contractors, utility companies, commercial building managers, oil and gas companies, marine businesses, renewable energy operators, telecommunications firms, and industrial park managers are interested in purchasing these enclosures.
Q5. Do protected distribution boxes have thermal management features?
A5. Many modern PD enclosures have ventilated panels, heat sinks, airflow baffles, and other thermal management features to cool the contained equipment and cables during high-temperature spills.
