Why Electrical Enclosures Demand IP Waterproof Testing？

No design engineer or technician desires their design to fail in practice, resulting in customer dissatisfaction and requesting a return. Water poses a threat to electronic and electrical components. It may lead to rust and electrical short circuits. Luckily, the proper waterproof enclosure will safeguard your design and reputation.

If your design will be used in areas exposed to factory washing, rainwater, ocean moisture, and humid conditions, a NEMA or IP waterproof enclosure with sufficient ratings is crucial. A deeper understanding of how these casings undergo water intrusion testing can help you make informed choices in terms of protective design.  

Understand IP rating

Before starting the testing, it is necessary to clarify the meaning of IP rating.When your device gets flooded, it will ultimately lead to catastrophic failures. For metal enclosure solutions that protect critical infrastructure (from factory distribution boxes to outdoor control panels), IP testing is not optional; This is survival verification. 

The IP rating system established by the International Electrotechnical Commission (IEC) provides a unified method for classifying the degree of defense of solid materials and liquids. This system can assist manufacturers and engineers in selecting suitable enclosures for specific applications, ensuring that the equipment can withstand the environmental conditions it will encounter. 

Without IP authentication, you are gambling on environmental physics. Water always wins. Unless your metal casing has a proven certificate.IP65 rating means that the casing is dust-proof and can prevent low-pressure water jets, making it an ideal choice for outdoor equipment and factory cleaning processes.  

The Science Involved in Waterproof IP Enclosure Testing

When an engineer indicates a waterproof IP enclosure, they aren't merely accepting the manufacturer's claim that the enclosure is waterproof. These enclosure designs go through thorough testing processes to obtain their ratings. So, what specifically occurs during IP enclosure tests?

The IP (Entrance Protection) level consists of two numbers: the first number represents protection against solid objects, and the second number from 0 to 8 represents protection against water. For waterproof purposes, we usually consider ratings ranging from IP65 to IP68.

IP Sealing Evaluations

As per IEC 60529, the global standard outlining IP testing, each tier necessitates progressively tougher assessments:

IP65 Testing: The housing is exposed to water sprayed by a 6.3 mm nozzle from all angles. The examination employs a flow rate of 12.5 liters each minute at a pressure of 30 kPa from a distance of 3 meters for a minimum of 3 minutes. The enclosure needs to avert any damaging water intrusion.

IP66 Testing: Like IP65, but employs a 12.5 mm nozzle with a flow rate of 100 liters per minute at 100 kPa pressure, generating intense water jets. The test usually lasts 3 minutes, putting the enclosure's seals under considerable pressure.

IP67 test: The casing is completely immersed in water at a depth of 1 meter for 30 minutes. After the testing phase is completed, remove the waterproof IP casing and check for any signs of water ingress that may affect normal functionality.

IP68 Testing: This includes prolonged submersion under conditions outlined by the manufacturer (usually deeper and longer than IP67). The manufacturer should clearly specify the precise test parameters—depth and duration—since this rating can differ considerably among products.

In these IP enclosure tests, technicians position actual electronics or a testing device within the enclosure that can identify water ingress using electrical continuity sensors. They then position the enclosure in a specialized testing chamber that generates carefully regulated water spray patterns and immersion conditions.