Use Thick-Walled Corrosion-Resistant Enclosures for Marine and Harsh Environments

Living next to a busy port has given me a firsthand appreciation for the challenges posed by marine environments. Saltwater relentlessly eats away at the infrastructure, dust kicked up by trucks and trains settles into every crevice, and liquids from oil to coolant are just one spill away from causing catastrophic damage.

Protecting electronics in conditions like these is no easy task, but enclosures like the 1590Z series from Hammond Manufacturing are up to the job. These thick-walled, die-cast aluminum enclosures meet demanding IP and NEMA ratings while maintaining a design optimized for repeated access. They are suitable for a wide range of applications from marine instrumentation to industrial control systems.

Understanding IP and NEMA environmental ratings

Before diving into the specifications of the 1590Z series, it’s worth looking at the ingress protection (IP) and National Electrical Manufacturers Association (NEMA) environmental ratings used to characterize these enclosures.

IP ratings are an international system that focuses on protecting against dust and water. Some common IP ratings include:

• IP54: Limited protection against dust ingress and protected against water splashes from any direction
• IP65: Dust-tight and protected against water jets from any direction (minimum rating typically considered “water-tight”)
• IP66: Dust-tight and protected against powerful water jets
• IP67: Dust-tight and protected against temporary immersion in water
• IP68: Dust-tight and protected against continuous immersion in water

NEMA ratings are primarily used in North America and encompass broader environmental considerations, including corrosion resistance. Some common NEMA ratings include:

• NEMA 4/4X: Protection against rain, sleet, snow, splashing water, and hose-directed water; NEMA 4X adds corrosion resistance
• NEMA 6/6P: Protection against temporary (6) or prolonged (6P) submersion in water
• NEMA 12/13: Designed for indoor use with protection against dust, falling dirt, and non-corrosive liquids; NEMA 13 adds protection against oil and coolant seepage

Die-cast aluminum enclosures built for harsh environments

The 1590Z series enclosures from Hammond Manufacturing have been designed to meet demanding requirements. These die-cast aluminum boxes with thick walls have been independently tested and certified to meet a wide range of environmental ratings, including IP66, IP67, and IP68, as well as NEMA types 4, 4X, 6, 6P, 12, and 13.

Mechanical durability is another hallmark of the series. Most models meet the IK08 impact rating, as specified in IEC 62262, which protects against accidental collisions and rough handling. In addition, most are UL 508 listed, making them suitable for use in industrial control equipment.

The 1590Z product line spans a broad range of sizes. On the smaller end is the 1590Z060 (Figure 1). Measuring 50.00 × 45.00 × 30.00 millimeters (mm), this unfinished enclosure is well-suited for compact devices and space-constrained installations.

Figure 1: The 1590Z060 is a compact bare-aluminum enclosure measuring 50.00 × 45.00 × 30.00 mm. (Image source: Hammond Manufacturing)

The 1590Z series features a two-piece tongue-and-groove design with a silicone gasket. The enclosures are designed for frequent access, with key components, such as the gasket, engineered for easy replacement.

In addition to bare aluminum, the enclosures are available in either smooth gray or textured black powder-coat finishes. These coatings are formulated to resist chipping during machining and assembly. Examples of the painted enclosures include the gray 1590Z060GY (Figure 2, left) and the black 1590Z060BK (Figure 2, right).

Figure 2: The 1590Z series is available with smooth gray (1590Z060GY, left) or textured black (1590Z060BK, right) powder-coat finishes. (Image source: Hammond Manufacturing)

Flexible mounting and options for rugged enclosures

The 1590Z series also includes large enclosures with generous space for industrial control boards, power supplies, and other bulky components. A typical example is the 1590Z162 (Figure 3), which measures 260.00 × 160.00 × 90.50 mm.

Figure 3: The 1590Z162 is a large enclosure measuring 260.00 × 160.00 × 90.50 mm. (Image source: Hammond Manufacturing)

To simplify system integration, Hammond offers matching inner panels such as the 1590Z162PL (Figure 4). This aluminum panel measures 242.70 × 147.52 mm and provides a convenient mounting surface.

Figure 4: The 1590Z162PL aluminum panel can be used within the 1590Z162. (Image source: Hammond Manufacturing)

All models in the 1590Z series come with the necessary assembly hardware. The lid is secured using four recessed stainless steel machine screws, which fit into pre-tapped holes. Most models are designed so the screws become captive after first use, reducing the risk of hardware loss during maintenance.

Mounting to external surfaces is straightforward. The enclosures feature blind through-hole construction located outside the gasket path, allowing them to be wall-mounted without compromising environmental sealing.

Conclusion

Harsh environments demand durable, well-sealed enclosures, and the 1590Z series from Hammond Manufacturing meets both requirements. With a wide range of IP and NEMA ratings, robust mechanical construction, and flexible mounting options, these enclosures offer a dependable solution for protecting electronics in industrial, marine, and outdoor applications.