During the development of an automation system, attention is usually focused on programming, software architecture or control systems. However, the ‘home’ that houses the system’s intelligence – the electrical cabinet – plays a decisive role in the reliability and longevity of the entire production cycle.

At Zanardo, thanks to our decades of experience in the field of industrial metal carpentry, we have identified the critical issues that often put the technological heart of companies at risk. 

What are the 5 mistakes to avoid when designing an automation control cabinet?

1. Underestimating Heat Dissipation

Heat is the biggest enemy of electronic components. Designing a control cabinet without calculating the thermal load generated by inverters, power supplies and drive units means setting the system up for malfunctions or sudden downtime.

The risk in a nutshell: reduced lifespan of electronic components and frequent maintenance.

Zanardo’s advice: don’t just choose the dimensions. Always seek advice and technical consultancy: it is essential to calculate the thermal delta and always design the correct ventilation or air-conditioning system, leaving the necessary space for air flow.

2. Creating an Overcrowded Internal Layout

The urge to reduce the overall size is strong, we know, but an overly compact layout is a strategic mistake. An ‘overcrowded’ electrical cabinet makes wiring operations extremely difficult and, above all, makes future maintenance work a challenge.

The risk in a nutshell: the inability to quickly and effectively intervene in the event of a fault or isolated overheating.

Zanardo’s advice: follow the ‘expansion margin’ rule. It is essential to design the electrical cabinet by always leaving a 20% margin of free space for future expansions or structural modifications.

3. Ignoring the Installation Environment

A common mistake is to assume that steel is always the universal solution, or alternatively, to underestimate the corrosiveness of certain environments. If the cabinet is intended for use in a chemical plant or coastal area, standard options may not be sufficient.

The risk in a nutshell: premature corrosion of the structure and loss of internal protection.

Zanardo’s advice: carefully consider the aggressiveness of the environment. If standard painted steel is not enough, always request a careful assessment to choose the most suitable finish and treatment. In this regard, cataphoresis treatment guarantees uniform anti-corrosion protection. Another solution is AISI 316L to achieve total resistance in saline or highly chemical environments.

4. Improper Cable Management

The importance of accessories is often underestimated. A messy cable run is not just an aesthetic issue: it puts electrical safety and the integrity of the installations at risk.

The risk in a nutshell: difficulty in tracing faults and potential electrical arcing or overheating of conductors.

Zanardo’s advice: always request dedicated accessories, strong fastening systems and custom-designed cable entry plates to maintain maximum order and facilitate the entry of cables in complete safety.

5. Choosing Non-Certified metal carpentry

Saving money on the structural framework is often a false economy. Metal carpentry that does not meet rigorous standards cannot guarantee long-term protection against dust, water or impact.

The risk in a nutshell: loss of IP (International Protection) and IK (mechanical protection) ratings, resulting in damage to internal components.

Zanardo’s advice: rely exclusively on certified metalwork. Choosing certified products, designed to optimally meet the technical and environmental requirements of every business, means having the certainty of constant watertightness and verified robustness.

So, how do you choose the best electrical cabinet?

There is no one-size-fits-all solution, but there is the right solution for every specific operating environment. Choosing the ideal electrical cabinet means analysing the thermal challenges, the complexity of the wiring and the harshness of the environment before even laying the first cable.

At Zanardo, we don’t just supply cabinets, we offer technical expertise to help you navigate IP ratings, cataphoresis treatments and special steels. Our mission is to ensure your technology is protected by a structure that matches its performance.

Contact our technicians for a specialised consultancy and download the catalogue to explore the details of Zanardo’s solutions.