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Causes and risks in condensation in electrical panels

Protect your electrical panels from moisture with customised heating solutions

In the industrial environment, condensation and humidity inside electrical cabinets represent a critical yet often underestimated issue. The presence of moisture within electrical enclosures can lead to unexpected failures and high maintenance costs. For this reason, dedicated systems such as anti-condensation heaters for electrical cabinets have become essential tools to ensure operational continuity and equipment safety.

In this article, we explore why condensation occurs in electrical panels, the main risks for components, and how heating solutions for condensation in electrical cabinets can effectively prevent serious problems.

Why Condensation Forms in Electrical Cabinets

Condensation in electrical cabinets results from a combination of environmental and structural factors. In areas where ambient temperature fluctuates rapidly or where relative humidity is high, the internal air of the cabinet tends to be warmer against metal walls and cables, causing droplets to form on internal surfaces. Risks to electrical components are significant, including corrosion of contacts, oxidation of tracks, degraded insulation and the possibility of sudden malfunctions increase significantly. In these cases, the choice of dedicated heating solutions allows the internal temperature to be maintained above the dew point, effectively counteracting the formation of condensation.

What Is an anti-condensation heater and how it works

An anti-condensation heater is a heating device specifically developed for installation inside electrical cabinets and control panels, maintaining an internal temperature that prevents condensation on inner surfaces.

The anti-condensation heating films for electrical panels are made up of a thin PET substrate silk-screened with conductive and heating inks, thanks to the possibility of making the heater an adhesive film it is possible to apply it directly to the affected surface which requires heating. Heating films, therefore, allow rapid assembly in compact environments, offer customized solutions when specific powers and particular geometries are required. The advantages of implementing anti-condensation heating elements in industrial electrical panels include compact dimensions (they do not reduce usable space), direct adhesion to walls, and the possibility of customising the power and shape according to the application. In particular, thanks to heating film technology, it is possible to achieve uniform heat distribution and installation that does not alter the internal dimensions of the panel.

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The Alper Solution – High-Efficiency Polyester Heaters

The polyester heaters developed by Alper .r.l. represent an advanced solution for condensation control in industrial electrical cabinets. Thanks to their ultra-thin and flat construction, heat is delivered exactly where it is needed, minimizing energy waste.

The polyester material is the substrate for silver tracks and carbon conductive ink, ensuring uniform heating and a slight PTC effect that limits and stabilises the temperature.

When used in electrical cabinets, this structure allows the heating film to be integrated directly onto the cabinet wall, leaving the interior space free for wiring and components. Anti-condensation heating films are positioned near the points most prone to cooling or humidity. Their flat and adhesive form allows for direct installation without the need for brackets or supports. The customisation of power ratings makes this solution suitable even for particular environmental conditions or for applications in European markets with specific requirements.

Technical and Application Features

Alper polyester heating film stands out for its extremely thin thickness (up to 0.2 mm), making it ideal for compact installations in modern electrical panels. Thanks to the screen printing of silver-based tracks and carbon inks, the product ensures temperature uniformity and the possibility of customised dimensions. The power supply and cabling options are configurable, allowing adaptation to European requirements and industrial conditions. The solution is a discreet but crucial element for protection against humidity. In European B2B applications, these heating elements play a key role in mitigating risks related to condensation and sensitive components, allowing full operation even in environments subject to temperature variations. Furthermore, the sustainability of this approach is evident in reduced consumption (targeted heat) and component longevity. Raising the internal temperature by a few degrees above the dew point involves a modest investment compared to the indirect costs of breakdowns and plant downtime.

Ultimately, the Alper heating solution combines technology, reliability and sustainability, allowing electrical panels to be protected from condensation and humidity with a tailor-made approach, ideal for those looking for an efficient and long-lasting anti-condensation system for electrical panel applications.