From Brains to Brawn: Control Panel and Enclosure Best Practices

FROM BRAINS TO BRAWN

CONTROL PANEL & ENCLOSURE BEST PRACTICES

REXELUSA.COM

From Brains to Brawn

Best Practices for Control Panels & Enclosures

In industries like manufacturing, control panels are the brains of the operation. They’re what make all the
heavy-duty machinery (the brawn of your operation) run. And just like our brains, they need protection—that’s
where enclosures come in. This guide provides you with best practices that will keep your automated processes
running smoothly.
This best practice guide is designed to help you better build control panels and select the right enclosures.
These tips will save you both time and frustration. If you are new to panel building and unfamiliar with some of
the associated terminology, we’ve created a glossary in section three of this book.
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CONTROL PANEL & ENCLOSURE BEST PRACTICES

Control Panel & Enclosure Guide

Part I – Control Panels: The Brains of Your Operation Page 04
Page 04
Options for Building Your Control Panel Page 06
Page 09
Layout & Design Considerations Page 10
Layout Checklist Page 10
Part II – Enclosures: Protecting Control Panels Page 11
Keeping Control Panels Safe Page 14
Enclosure Sizing Page 14
Part III – Glossary: Components & Terms Page 16
Basic Components
Control Panel Terminology

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Part 1 – Control Panels:
The Brains of Your Operation

When you are installing a new control panel, there is a lot to consider. First, your
manufacturing and engineering teams must make decisions about the overall panel
function. Control panels are designed to do two things:
⏹ Provide and control the flow of electrical power to equipment, typically electric motors

⏹ Control how your equipment operates within the framework of your distributed control system (DCS).

To break it down further, that means making sure:
⏹ Any safety devices you have on your plant floor properly talk to your control panel, which in turn will talk to

a motor to shut it down as required.
⏹ Your control panel can talk to your enterprise and production systems to communicate what is happening at

the machine and equipment level.
Production personnel can gather data to monitor and improve manufacturing processes.

Options for Building Your Control Panel

How you handle your electrical control panels depends on several things, including time, experience, and cost
considerations. Let’s look at the three basic options for building your control panel.

#1. OUTSOURCE

Partner with a third-party contactor like Horizon Solutions, a Rexel banner,. When you work with us, we can
modify your enclosures and fabricate your panels to your specifications.
⏹ Enclosure Modifications – Custom holes, cutouts, knockouts, and other modifications

⏹ Panel Build – Component installation and wiring

#2. DIY

DIY means do it yourself, and that’s exactly what this option entails. You purchase an off-the-shelf, standard-
sized stock enclosure. You purchase all the different components: drives, a PLC, power supplies, fuses, DIN rail,
panel duct, ethernet cable, glands, mounting plates, etc. Your team uses hand power tools to make cutouts,
openings, and access points in the enclosure. Your team drills and taps holes and starts installing components.
And then your team does the electrical wiring for both the control components and power.

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CONTROL PANEL & ENCLOSURE BEST PRACTICES

#3. PLUG & PLAY

This is an inbetweener. It is not as hands-off as an outsourced option, but some of the involved work from a DIY
option is taken off your plate. You order a custom enclosure. You provide a rough idea of what components will
be involved. You receive a partially finished panel, an enclosure with some amount of DIN rail, duct, pre-drilled
and pre-tapped holes, and components pre-installed. Your team can then complete the field wiring.
Many end-users in the world of automated manufacturing take advantage of the plug-and-play option. It allows
them to take the pre-fab and pre-install work that isn’t in their wheelhouse off their plate. It keeps the critical
work under their supervision and control. They are not entirely reliant on a third-party contractor, which helps
them manage in-house maintenance and upgrades.
If you’re interested in options two or three, but lack experience building and working with control panels, this
guide packed with information and advice from our in-house experts will help.

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Layout & Design Considerations

SPACE

Your control panel will contain any number of components based on your needs (drives, circuit breakers, ducts,
PLCs, power supplies, wires, etc.). And they all need to go somewhere. When you start designing your panel,
there are a number of things to consider.

Dimensions

Measure and do the math. Whether
you’re pulling out a tape measure or a
manual, you need to get the dimensions
for each item to ensure proper fit and
functionality. They are also an important
aspect of selecting the right enclosure
(more on that in the Enclosure section).

Clearance

Some components such as drives require
minimum mounting clearance to ensure
proper performance. Be sure to factor
clearance requirements into your layouts.

Temperature

Heat dissipation is critical to the function of your control panel. Try to place heat-sensitive components such as
drives lower in the panel to escape rising heat. And, when necessary for thermal management, consider adding
heat sinks, fans, and air conditioners. Another way to help reduce heat-related issues is to use flange-mounted
drives. These are designed to have the heat sink fins outside the enclosure, putting the major heat source away
from your electronics.

Future Additions: Do your future self a favor and consider what additions to your control panel may be needed
down the line. Leaving adequate space can make future modifications easy (and keep costs down).

Note: Triple check the physical fit of your componentry. Buying and modifying the wrong size enclosure is a costly
mistake and best avoided. There are many types of 3D modeling software out there that you can use to help you
perfect your panel design. A few we like are SOLIDWORKS and Inventor®. Using 3D modeling software can also
bring together all the benefits of programs like ProposalWorks and files from enclosure manufacturers (like nVent
HOFFMAN).

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CONTROL PANEL & ENCLOSURE BEST PRACTICES

GROUNDING & BONDING

In today’s industrial environment, proper grounding and bonding are essential. Modern manufacturing
environments use computers, precision instrumentation, data collection, and internet connections—all of which
require electricity.

Grounding

Grounding means connecting current-carrying elements to earth to protect the power system’s equipment and
provide a return path to the power source. There are several ways to ground your system, but the best practice
is delta/wye with grounded wye neutral. Doing this increases safety by providing a direct path for common
mode current, and it controls common mode noise current.

Bonding

Bonding means connecting the conductive elements that don’t normally carry current to put them all at the
same potential, creating a low impedance path back to the source. Bonding alone does not increase safety;
the system still needs to be grounded. However, it does protect equipment by reducing current flow between
pieces of equipment.
A properly grounded and bonded system is safe and helps control common mode noise.

ROUTING WIRES & WIREWAY

Additional considerations for your control panel layout are wireway and voltage routing. Mixing together power,
signal wire, unshielded cables can result in failures. Within your enclosure, try to keep the most space possible
between your various cables and wires. Even something as simple as a shield between your wireways can help
prevent issues.

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TRICKS WITH TERMINAL BLOCKS

Terminal blocks are common components of control panels. There are a variety of types and ways to use them
in your panels to save you both time and space.

Modular Design

The modular aspect is interesting because it gives panel builders great flexibility for fit and arrays. For example,
you could arrange a row of terminal blocks 20 long or design two banks of ten each. Your panel design should
focus on the critical components first, meaning things that require cooling, or special connections/cabling, or
priority placement in the mechanical layout. Once you’ve determined that, the modularity of terminal blocks
makes your placement quite a bit easier.

Saving Space with 2-Tier Terminal Blocks

The modularity and configurability of terminal
blocks are great when you are creating a
brand-new control panel. But let’s say you are
an electrical or controls engineer tasked with
either retrofitting new control elements into an
existing panel or making all your automation
components fit into a specified standard-sized
enclosure. Both can be challenging.

One way to save space is to go double-decker,
more commonly known as 2-tier, also known
as multiple level feed-through and double-
level. There are also 3-tier and 4-tier varieties.
Multi-level terminal blocks provide a means of
plugging-in discrete electronic components,
circuit protection fuses, or circuit isolation
disconnect plugs to help save valuable panel space.

Essentially, banks of terminal blocks like this double the amount of available discrete wiring points without
changing the actual physical footprint of square inches used in your back panel. They snap in and out easily to
DIN rail mount systems. They’re modular and configurable.

Saving Time with Push-In Terminal Blocks

If you or your team spends hours every week putting wires into terminal blocks, you might consider that a task
that you’d like done faster. Push-in devices give you and your team a quicker connection that requires no double
checking. The push-in connections significantly exceed UL pull-out standards.

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CONTROL PANEL & ENCLOSURE BEST PRACTICES

Layout Checklist

We’ve designed the following checklist to save you time and frustration. It’s something to go through while
you’re still in the planning phase to ensure you’ve considered all the constants and variables of a control panel
build. Consider it a map of where components will go.

Your goal should be to create a panel that delivers the power required to equipment, keeps your people/plant
safe, and communicates correctly with your control systems. This checklist will help you do all of this.

Double-check physical fit of overall panel footprint on the factory floor
Double-check physical fit of componentry, actual sizes
What material will your enclosure be? Three common options:
— Painted carbon steel (mild steel) **Most common
— Stainless steel (SS)
— A non-metallic composite (e.g., polyester, fiberglass, or polycarbonate)
Review other physical considerations
— Heat dissipation (drives)
— Mounting options – drilled & tapped holes
— The weight of components and how they are mounted
— Strain relief for the cord(s)
Confirm field entry; i.e. where does the power come IN to the panel?
Confirm knockouts and mounting options
— Where is power going OUT? What is it going to?
— What types of cables are going OUT? Do they need shielding?
Investigate possible sources of electrical noise
Consider power isolation
— Review power and devices, i.e. low power / high power (also known as low voltage / LV and high voltage / HV)
— Some devices can be located near to each other, some cannot
— A general best practice is to put high-power devices by like devices
— A general best practice is to put low-power devices by like devices (for example, 24V)
— There is an emerging trend of using barrier panels (like this one from HOFFMAN)

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Part II – Enclosures:
Protecting Control Panels

Protecting your equipment is important and challenging in a manufacturing
environment. Automated equipment and machines are typically controlled with a
combination of electrical and mechanical systems. These systems consist of motion
(e.g., moving, turning, picking, and placing) and a host of other applications. The
brains behind these systems are typically found in a nearby control panel housed in an
enclosure.

Keeping Control Panels Safe

For a plant electrician or a factory maintenance person, the question is: How do I keep the brains in that control
panel 100% safe? These control panels are typically found on a factory floor. There are an elevated number
of mechanical hazards on a floor—everything from inattentive line workers to fork trucks and other material-
handling vehicles. Depending on your industry, the factory environment might be very hot and/or humid. If you
are in a factory that manufactures food or beverages, you face additional challenges like washdown (also known
as wash down or wash-down) procedures.

ENVIRONMENT

The environment can kill when it comes to control panels and
their components. Where you place your enclosure matters. Best
practice is to house your enclosures in a controlled environment,
eliminating exposure to dust, water, heat, cold, and potentially
corrosive and other harmful gasses. In reality, that’s not always
possible.

If your panels must reside on the plant floor, it’s critical that you
are aware of the potential for exposures (e.g., grease, particles,
gasses, chemicals, food, liquid, heat, cold, etc.) Then you select an
enclosure that is properly rated for the environment, protecting
both your panel and people working in the area.

For heat and cold exposures, don’t forget to consider both seasons
and time of day. When evaluating the environment, consider using a
data logger to pick up on issues like afternoon sun exposure.

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MATERIAL AND RATING

Enclosures can be made of a variety of materials, including painted carbon steel, stainless steel 304 (also known
as type 304), stainless steel 316 (or type 316), fiberglass reinforced polyester, and polycarbonate. They also have
NEMA ratings and IP codes to specify the level of protection from the surrounding environment each enclosure
provides.

Stainless Steel Electrical Enclosures

If your enclosure is a 304 or 316 stainless material, your in-house team might have a hard time doing these
cutouts in a timely fashion—it takes a while to cut stainless steel. Or, if you make a cut wrong and have to scrap
a piece, stainless steel enclosures can be a costly piece to waste. Sometimes, it just makes sense to have your
enclosures hit your factory floor ready for wiring, with all the custom machining already done. The plug-and-play
option is often easier for stainless steel enclosures.

WASHDOWN

Washdown is a high-pressure cleaning with water and/or chemicals designed to kill bacteria and other
microorganisms. The enclosure of each control panel will have a NEMA rating. Even though there might
be high-pressure water near to your control panel, there are ratings in place to help you use an enclosure
appropriate for your environment. Stainless steel is typically the material of choice for washdown environments.

Enclosure Sizing

If you can’t fit all the components of your control panel into your enclosure, all you have is a very expensive
cabinet—and another enclosure to buy. All the measurements you took when you designed your control panel
should come in handy, but don’t forget depth. Whereas your design plans were flat, two-dimensional drawings,
you need to account for all three dimensions when selecting an enclosure.

Most enclosures are cube shaped, with three dimensions, namely: height (H,
A), width (W, B), and depth (D, C). The A, B, C styled dimensional naming is
common to HOFFMAN enclosures.
⏹ Small enclosures run from 8”, 10”, and 12” dimensions up to the 24-30” range.

You can typically get them shipped by most major parcel carriers.

⏹ Medium enclosures are classified at 24-30” on one end up to 48” on the
bigger end. They can typically ship via major parcel carriers when you order one
or two, more than that may require a pallet.

⏹ Large enclosures cover anything 60” and up, with the 72” dimension
being quite common in industrial control panels. These sizes will need
their own dedicated skid or pallet.

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LOGISTICS FOR LARGE ENCLOSURES

When you need to ship a small enclosure via most postal carriers, it’s a relatively straightforward task.
HOFFMAN enclosures come in a perfectly sized and matched package, along with appropriate cardboard
spacers and corner edging for extra protection. Put a UPS label on it and done. Medium-sized enclosures can
usually fit on a standard 48” x 40” wooden pallet.

Large enclosures can weigh several hundred pounds. With one of this size and weight, you’ll want to think about
a few extra steps: doors, heights, eye bolts, banding, and strapping.

Dock Doors

Make sure your shipping and/or receiving area has clearance to unload the enclosure. Here are some of the best
guesses for clearance: take the dimensional height of the enclosure itself, add six vertical inches for the pallet,
and add three vertical inches for the forklift. Those are bare minimums. A rule of thumb is that most of the
height issues we see tend to happen between 86” and 102”.

Accessories

You should also meet with your engineering department to double-check if there are any accessories pre-
mounted or pre-installed to the top of the enclosure. This might include transformers, braking resistors, and/or
stack lights. They will all add height to the overall piece. You really don’t want to shear any of these items off the
top.

Banding

All medium and large enclosures must be banded to the skid.
Banding is also known as strapping or steel strapping. It is typically a
very thin metal product that goes around the enclosure. Be careful not
to bend, ding, blemish, or mar your metal enclosure. Avoid applying
too much pressure when you ratchet down. There are some very
helpful published guidelines for how to move a banded enclosure/
skid, and when to remove banding.

Eye Bolts

Many HOFFMAN enclosures come standard with eye bolts
installed, also known as lifting eyes. Typically, there are either two or
four. This makes it easier for transportation, loading, and unloading.
HOFFMAN recommends a (minimum) 3,000 lb.-rated chain or
strap be used through the eye bolts. Keep your eye bolts in mind for
the overall height, as well. They may add another three to four inches
vertically. Most eye bolts are removable, so you can reduce height if
facing a short clearance, but that does represent additional work.

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Bolt Down

This is another option for added security in shipping. Some enclosures may require bolting down to a custom
pallet with added hardware. The hardware connects through predetermined pass-through points on either the
back, bottom, or another point. This helps prevent damage to both the enclosure itself and to individuals tasked
with moving it. A bolt down option is not standard but can often be added upon request.

Custom Pallets and Crating

This is another option for added shipping security. Essentially, a custom wooden framework is built and sized for
your exact enclosure dimensions. If your job requires multiple enclosures ganged together, or perhaps a hybrid
enclosure + wireway + mechanical system, then custom pallets and crating might be a fine idea. These methods
are not standard and must be custom quoted.

SAFETY FOR LARGE ENCLOSURES

A large enclosure may need to be moved and processed, and that should only be done by a trained and
qualified individual. Here is our quick list of the top ten safety tips:

1. There is a tip-over hazard. Always be aware that large enclosures can crush you, resulting in serious injury or
death.

2. Stabilize the enclosure before removing strapping.

3. Before moving it, make sure that the route is clear of all obstructions.

4. The enclosures must be handled by a trained and authorized forklift operator only. This is required by
OSHA Standard 1910.178 and ANSI Standard B56.1.

5. Know the safe lifting capabilities of the lifting equipment; be certain it can handle the weight and size.

6. Carefully position the enclosures on the forks, noting that they are top-heavy.

7. Keep the load against the carriage. Always tilt the load backward towards the fork’s mast.

8. Start and stop the forklift slowly and gradually; avoid jerking movements.

9. A person should assist the forklift operator at a safe distance (i.e., more than the height when guiding or
directing movement of large, top-heavy enclosures).

10. Other workers should be away from the enclosure and at a distance that is more than the overall height.

When we ship them, we like to include a very helpful eight-page document. It is titled, “Large Enclosure Safe
Handling Requirements.”

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Part III – Glossary:
Components & Terms

Basic Components

The internal and external components for your control panel will depend on your
applications. The numbers, sizes, and functionality of parts will vary widely between
panels. This section provides basic descriptions for common components. This list is
by no means exhaustive, but it will familiarize novices with terms they’ll encounter as
they begin exploring control panels.

INTERNAL

Cable Glands – Glands are used to manage cable entry, meaning pass pre-terminated cables through an

enclosure sidewall with no cutting or splicing. Cables may be of varying widths. You may need a water-tight seal.
(Learn more about cable glands from icotek®.)

Circuit Breakers – Automatic devices for stopping electrical current flow in a circuit as a safety

measure. It generally has a disconnect on the outside of the enclosure.

DIN Rail – Metal rail used widely for mounting industrial control equipment such as circuit breakers

inside equipment racks. Typically made from steel, they are only for mechanical support.

Drives – Industrial drives include variable frequency drives (VFD) to control AC motor speed and

torque and servo drives to control, amplify, and transmit electronic current.

Ethernet Cable – Networking hardware to connect equipment and allow communication (also

known as patch cords).

Fuses – There are a variety of fuse types from fast-acting to inductive loads to timing delays. Before making a

selection, find the right fuse for your application.

HMI – Human-machine interfaces (HMI) allow users to interact with a machine using physical input

hardware (e.g., a keyboard) and output hardware (e.g., computer monitor).

Mounting Plates – Plates used to mount equipment to the enclosure (also known as sub-panel or sub-plate).

PLC – Programmable logic controllers (PLC) are industrial digital computers for controlling automated

manufacturing processes.

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Power Supplies – These are used to convert AC to DC voltage, converting electric current from a

source to the required voltage, current, and frequency for the load.

Signal Conditioners – Signal conditioners manipulate analog signals to meet the requirements

for further processing. In industrial environments, they isolate, transmit, convert, split, and amplify to
improve process reliability.

Terminal Blocks – Insulated blocks that secure two or more wires together
Transformers – Used to convert voltage and provide isolation.
Wire Duct – Rigid trays used for routing and organizing cables and wires within an electrical

enclosure.

EXTERNAL

Disconnect Handles or Switches – External means to safely disconnect power to the control panel

inside the enclosure.

Enclosures – Cabinets to hold the control panel and its components and protect them from the

surrounding environment.
Push Buttons – Buttons installed or connected to an enclosure to externally control operations.

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Control Panel Terminology

Now that you’re acquainted with the basic components of common control panels, it’s a good time to dig into
lingo. Below we we’ll explain basic terms you may encounter as you design, layout, and build a panel.

CIRCUIT PROTECTION

The goal of circuit protection is to provide appropriate protection for downstream devices using fuses or circuit
breakers. Keep in mind any overall SCCR (short circuit current rating) requirements for the entire system.
SCCR does require calculations, which can sometimes be complex.

CUTOUTS, KNOCKOUT, AND CUSTOM HOLES

Enclosures need cutouts, knockouts, and custom holds to support a variety of functions, including wiring, push
buttons, HMI, and handles and switches. These holes and cutouts need to be appropriately spaced to allow for
proper control panel design and operation. You can create these on your own if you have the right tools, or you
can outsource this work to save time and prevent costly errors. The HOFFMAN Certified Modification Center
at Horizon Solutions, a Rexel banner, makes precise, custom modifications every day.

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ENCLOSURE TYPES

NEMA Ratings

NEMA (National Electrical Manufacturers Association) defines enclosure types based on various factors
including environment, elements, hazards, degree of protection, potential exposures, and more. Each rating
starts with protection against hazardous parts and then varies further based on additional environmental
conditions. You can see a full listing of enclosure types and their definitions on the NEMA website. NEMA 1,
NEMA 12, and NEMA 4X are frequently specified for electrical enclosure applications. NEMA type 4 and 3R
are also common.

IP Codes

IP Codes (or Ingress Protection Code) are another type of enclosure rating. These codes classify and rate
degrees of protection from intrusion, accidental contact, water, and dust. The first digit of the code refers to
intrusion protection and the second digit is for moisture protection.

HEAT DISSIPATION

Drives create heat, and if your panel gets too hot, it can damage other components. Heat dissipation is key to
ensuring your control panel is functional.

Cooling

You can use fans on the drives to move air to cool them down. You can also use heat sink devices. You can even
use heat sink devices that mount externally on your panel. This keeps the heat out of your panel.

Spacing

Most drives will come with very specific published user
guidelines about space (i.e., how much space to leave
above or below or behind the drives to ensure they are
properly ventilated which will help keep them properly
cooled). It’s critical to know the minimum mounting
clearances for each drive in your panel.

Layout

Heat rises. The temperature is higher at the top of
a panel versus the bottom regardless of where you
mount the heat-generating devices. Heat-sensitive
components should be mounted as low as possible in
your panel. PLCs and drives are heat sensitive.

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MINIMUM MOUNTING CLEARANCES

Referenced previously under Heat dissipation, following minimum mounting clearances is critical. Most
commonly, you will mount drives upright on a flat, vertical, level surface. Prior to designing and laying out your
control panel, be sure to verify the manufacturer’s clearance recommendations.

POWER COMING INTO THE PANEL

Identify what your incoming power requirements are and verify that all your back-panel components are rated
for that power. If they are not, provide the appropriate measures (e.g., transformer or power supply) to convert
the incoming power to the voltage needed.

STAINLESS STEEL

Stainless steel (also known as SS) enclosures are very common in wet environments: water, chemicals, machine
fluids, cutting oils, etc. Stainless steel is designed to be resistant to corrosion, which makes it a natural choice to
house a control panel in a plant that requires washdown. The same properties that make it resist corrosion also
make it very tough to cut and machine properly.

THERMAL MANAGEMENT

There is only so much you can do to mitigate temperature with the heat dissipation methods mentioned above.
Heat inside the enclosure can be impacted by other factors, including high ambient outdoor temperatures and
manufacturing areas with hot materials. In these instances, air conditioning solutions can help.
Heat isn’t the only factor in thermal management. There are also scenarios where you need to combat cold
environments, like outdoor or refrigeration panels. In these instances, you’ll have to heat your panel.

WASHDOWN

Washdown refers to process of washing or cleaning surfaces for sanitation, appearance, and/or contaminant
removal. Though pressure washing may be involved, washdown can simply involve rinsing. The process can use
fresh water or the use of detergents and other chemicals.

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From Top to Tail: Horizon Solutions, a
Rexel Banner, Can Help

We’re here to help. From panel design to custom enclosures to plug-and-play to full
outsourcing—Horizon Solutions, a Rexel banner, offers the products and services
you need.

Custom Control Panels

We can save you time and money. Our custom control panel services provide built-to-order, performance-
tested panels based on the needs of your applications, systems, and facility. Partner with us to take the
guesswork out of your estimates and utilize a fixed-cost solution for your control panel fabrication challenges.

For a complete overview of our custom control panel services see our Custom Control Panel Fabrication
Services Overview Brochure.

HOFFMAN Certified Modifaction Center

Get custom enclosures on your schedule. We have the sizes and materials you’re looking for with the
modifications you need. Our HOFFMAN Certified Modification Center will save you time and money with
affordable, custom enclosures.

IN-STOCK AND READY-TO-GO

As an authorized HOFFMAN on Demand distributor, we have ready-to-ship stock based on local needs. This
core set of products covers virtually every application, including:
⏹ Pushbutton, junction box, wall-mount, free-stand, floor-mount, and modular enclosures

⏹ HMI and industrial wireway

⏹ Thermal management solutions

⏹ Accessories

FLAWLESSLY MODIFIED TO MEET YOUR REQUIREMENTS

As your local HOFFMAN Certified Modification Center, we can make rapid holes and cutout modifications
so you can also get faster access to pre-modified enclosures and back panels. You can rely on us to have the
products you need available now.

Whether you need an out-of-the-box enclosure or a custom modification, we can meet your needs. Contact us
today: [email protected].

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[email protected] Rexelusa.com

©2022 Horizon Solutions, a Rexel Banner. All Rights Reserved. All supplier trademarks are the property of their respective owners. – 12/22/2022