# IP65 vs. IP67 vs. IP68: Which Enclosure Rating Do You Need?
Selecting the right IP (Ingress Protection) rating for electrical enclosures isn’t just about checking a specification box—it’s about ensuring equipment reliability, safety compliance, and avoiding costly failures. Yet many engineers and procurement professionals struggle to distinguish between common ratings like IP65, IP67, and IP68.
This comprehensive guide explains the IP rating system, decodes the differences between popular ratings, and provides practical selection guidance for industrial electrical applications.
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## Understanding the IP Rating System
### What IP Codes Mean
**IP = Ingress Protection** (International Protection Marking)
**Format: IP + First Digit + Second Digit**
| Position | Meaning | Range |
|———-|———|——-|
| First Digit | Protection against solid objects | 0-6 |
| Second Digit | Protection against liquids | 0-9K |
### First Digit: Solid Protection
| Rating | Protection Level | Object Size |
|——–|—————–|————-|
| 0 | No protection | — |
| 1 | Protected against solid objects >50mm | Hand |
| 2 | Protected against solid objects >12.5mm | Finger |
| 3 | Protected against solid objects >2.5mm | Tools/thick wires |
| 4 | Protected against solid objects >1.0mm | Small tools/thin wires |
| **5** | **Dust protected** | Limited dust ingress |
| **6** | **Dust tight** | No dust ingress |
### Second Digit: Liquid Protection
| Rating | Protection Level | Test Condition |
|——–|—————–|—————-|
| 0 | No protection | — |
| 1 | Protected against dripping water | Vertical dripping |
| 2 | Protected against dripping water (15° tilt) | Tilted 15° |
| 3 | Protected against spraying water | 60° spray |
| 4 | Protected against splashing water | Any direction |
| **5** | **Protected against water jets** | 6.3mm nozzle |
| **6** | **Protected against powerful water jets** | 12.5mm nozzle |
| **7** | **Protected against immersion (1m, 30min)** | Temporary submersion |
| **8** | **Protected against continuous immersion** | Continuous (depth specified) |
| 9K | Protected against high-pressure/steam jets | High-temperature washdown |
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## Detailed Comparison: IP65 vs. IP67 vs. IP68
### IP65: Dust-Tight + Water Jets
**What It Means:**
– **6:** Complete dust protection (no ingress)
– **5:** Protected against water jets from any direction
**Test Conditions:**
– Water flow: 12.5 L/min
– Nozzle diameter: 6.3mm
– Distance: 3 meters
– Duration: 3 minutes per position
**Real-World Interpretation:**
– Survives heavy rain and hose-downs
– Not submersible
– Ideal for outdoor installations with washdown requirements
**Typical Applications:**
– Outdoor electrical panels
– Industrial washdown environments
– Agricultural machinery controls
– Commercial HVAC equipment
—
### IP67: Dust-Tight + Temporary Immersion
**What It Means:**
– **6:** Complete dust protection (no ingress)
– **7:** Protected against temporary immersion (1m depth, 30 minutes)
**Test Conditions:**
– Immersion depth: 1 meter below surface
– Duration: 30 minutes
– Water temperature: +5°C to +35°C
**Real-World Interpretation:**
– Survives accidental flooding or submersion
– Suitable for areas prone to standing water
– Not designed for continuous underwater operation
**Typical Applications:**
– Underground installations
– Pump control panels
– Marine environments (above waterline)
– Flood-prone areas
– Outdoor equipment with pooled water risk
—
### IP68: Dust-Tight + Continuous Immersion
**What It Means:**
– **6:** Complete dust protection (no ingress)
– **8:** Protected against continuous immersion (manufacturer-specified depth and duration)
**Critical Difference:**
Unlike IP65 and IP67 with standardized test conditions, IP68 requires the manufacturer to specify:
– Maximum immersion depth (typically 1-3 meters)
– Duration of submersion (typically 30 minutes to continuous)
**Real-World Interpretation:**
– Designed for continuous underwater operation
– Used in deep water or permanently submerged applications
– Must verify manufacturer’s specific rating
**Typical Applications:**
– Submersible pump controls
– Underwater lighting
– Marine equipment (below waterline)
– Wastewater treatment
– Deep well monitoring
—
## Selection Guide by Application
### Indoor Industrial Environments
| Environment | Recommended Rating | Rationale |
|————-|——————-|———–|
| Clean office/controls | IP40 | Dust protection, no liquid risk |
| General factory floor | IP54 | Dust and splash protection |
| Dusty manufacturing | IP65 | Complete dust-tight, washdown capable |
| Wet processing areas | IP66 | Powerful jet protection |
### Outdoor Applications
| Environment | Recommended Rating | Rationale |
|————-|——————-|———–|
| Covered outdoor | IP54 | Rain splash protection |
| General outdoor | IP65 | Rain and hose-down protection |
| Extreme weather | IP66 | Heavy rain, pressure washing |
| Flood risk areas | IP67 | Temporary submersion protection |
### Specialized Applications
| Application | Recommended Rating | Notes |
|————-|——————-|——-|
| Food & Beverage | IP66 or IP69K | High-pressure washdown |
| Marine (above water) | IP66 | Salt spray and wave protection |
| Marine (submerged) | IP68 | Verify depth rating |
| Mining | IP65 minimum | Dust and pressure wash |
| Wastewater | IP67 or IP68 | Submersion likely |
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## NEMA vs. IP Ratings: Cross-Reference
For North American projects, you may encounter NEMA ratings. Here’s the approximate conversion:
| NEMA | Approximate IP | Application |
|——|—————|————-|
| NEMA 1 | IP10 | Indoor, clean |
| NEMA 3 | IP55 | Outdoor, rain-tight |
| NEMA 3R | IP32 | Outdoor, rain-resistant |
| NEMA 4 | IP66 | Watertight, hose-down |
| NEMA 4X | IP66 | Watertight, corrosion-resistant |
| NEMA 6 | IP67 | Submersible (temporary) |
| NEMA 6P | IP68 | Submersible (prolonged) |
| NEMA 12 | IP52 | Indoor, dust-tight |
| NEMA 13 | IP54 | Indoor, oil-tight |
**Important:** These are approximate equivalents. Always verify specific project requirements.
—
## Product Applications at SNT Elec
### Our IP-Rated Product Range
**IP65 Metal Enclosures:**
– Available sizes: 200×150×100mm to 800×600×300mm
– Material: Cold-rolled steel (RAL7032/7035)
– Applications: Outdoor distribution, motor control centers
**IP66 Junction Boxes:**
– Hinged and screw-cover options
– Cable gland compatibility: M20, M25, M32
– Applications: Heavy washdown environments
**IP67 Distribution Boxes:**
– Sealed construction with gasket
– Terminal block integration available
– Applications: Underground installations, flood-prone areas
**Solar PV Combiner Boxes:**
– Rating: IP65 standard, IP66 optional
– Features: DC rated, UV-resistant
– Applications: Rooftop and ground-mount solar
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## Common Selection Mistakes
### ❌ Mistake 1: Over-Specifying
**Scenario:** Specifying IP67 for a standard indoor panel
**Problem:** Adds 30-50% cost with no operational benefit
**Solution:** IP54 sufficient for indoor, non-washdown areas
### ❌ Mistake 2: Under-Specifying
**Scenario:** Using IP54 for outdoor equipment
**Problem:** Water ingress during heavy rain, premature failure
**Solution:** Minimum IP65 for exposed outdoor installation
### ❌ Mistake 3: Ignoring Temperature
**Scenario:** Selecting standard IP67 enclosure for high-heat environment
**Problem:** Gasket degradation, seal failure
**Solution:** Specify high-temperature gaskets (silicone vs. neoprene)
### ❌ Mistake 4: Cable Entry Neglect
**Scenario:** IP66 enclosure with unsealed cable entries
**Problem:** Water ingress through cable glands
**Solution:** Use rated cable glands matching enclosure IP rating
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## Installation Best Practices
### Maintaining IP Ratings During Installation
**1. Gasket Handling:**
– Never remove or damage door gaskets
– Verify gasket is properly seated before closing
– Replace gaskets every 5-7 years (or per manufacturer)
**2. Cable Glands:**
– Use glands rated for the enclosure IP level
– Install with proper torque (not too tight, not loose)
– Use thread sealant on metal-to-metal connections
– Blank off unused entries with rated plugs
**3. Mounting Orientation:**
– Mount IP65 enclosures with door hinges at side or bottom
– Avoid mounting with door facing directly upward
– Ensure drainage holes (if any) face downward
**4. Maintenance Access:**
– Plan for regular gasket inspection
– Document torque specifications for covers
– Keep spare gaskets on-site
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## Testing and Verification
### Field Verification Methods
**Visual Inspection:**
– Check gasket integrity (no cracks, compression adequate)
– Verify all fasteners tight
– Confirm cable glands properly sealed
**Spray Test (IP65/66):**
– Use garden hose with spray nozzle
– Spray all seams and joints for 3 minutes
– Check interior for moisture immediately after
**Submersion Test (IP67 – Controlled Environment Only):**
– Fill with paper towels
– Submerge to 1m for 30 minutes
– Check towels for moisture
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## Cost Considerations
### Price Premium by Rating
| Rating | Typical Premium vs. IP54 | Cost Driver |
|——–|————————-|————-|
| IP54 | Baseline | Standard construction |
| IP55 | +10-15% | Gasket upgrade |
| IP65 | +25-35% | Full sealing, gaskets |
| IP66 | +40-50% | Reinforced sealing |
| IP67 | +60-80% | Submersion sealing |
| IP68 | +100%+ | Specialized design |
**ROI Analysis:**
– Over-specifying: Wasted 30-50% with no benefit
– Under-specifying: Equipment failure, replacement cost 3-5× enclosure cost
– Right-specifying: Optimal protection at minimum cost
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## Conclusion
Selecting the correct IP rating balances protection requirements with cost considerations:
**Choose IP65 when:**
– Outdoor installation
– Washdown environments
– Heavy rain exposure
– Dusty industrial settings
**Choose IP67 when:**
– Temporary submersion risk
– Underground installation
– Flood-prone areas
– Occasional standing water
**Choose IP68 when:**
– Continuous submersion
– Deep water operation
– Permanent underwater use
**Remember:** Higher IP ratings always add cost. Specify only the protection level required by actual installation conditions.
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## Quick Selection Reference
| Application | Minimum Rating | Recommended |
|————-|—————|————-|
| Indoor office | IP20 | IP40 |
| Indoor factory | IP54 | IP54 |
| Outdoor protected | IP54 | IP55 |
| Outdoor exposed | IP55 | IP65 |
| Heavy washdown | IP66 | IP66 |
| Marine deck | IP65 | IP66 |
| Underground | IP67 | IP67 |
| Submersible | IP67 | IP68 |
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