December 1999

Process Industry Practices

Process Control

PIP PCSEL001
Instrument Junction Boxes Specification
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence over
this Practice. Determinations concerning fitness for purpose and particular matters or
application of the Practice to particular project or engineering situations should not be
made solely on information contained in these materials. The use of trade names from
time to time should not be viewed as an expression of preference but rather recognized as
normal usage in the trade. Other brands having the same specifications are equally
correct and may be substituted for those named. All Practices or guidelines are intended
to be consistent with applicable laws and regulations including OSHA requirements. To
the extent these Practices or guidelines should conflict with OSHA or other applicable
laws or regulations, such laws or regulations must be followed. Consult an appropriate
professional before applying or acting on any material contained in or suggested by the
Practice.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies and subscribers may copy this Practice
for their internal use.

Not printed with State funds

 December 1999

Process Industry Practices

Process Control

PIP PCSEL003
Instrument Junction Boxes Specification
Table of Contents

1. Introduction ..................................2 6. Detail Specifications for

1.1 Purpose ............................................2 Fiberglass Junction Boxes ......... 4
1.2 Scope ...............................................2 6.1 Scope............................................... 4
6.2 Detail Specifications ......................... 4
2. References....................................2
2.1 Process Industry Practices ................2 7. Detail Specifications for
2.2 Industry Codes and Standards ..........2
Aluminum Junction Boxes.......... 4
7.1 Scope............................................... 4
3. General Requirements .................2 7.2 Detail Specifications ......................... 4
4. Detail Specifications for Carbon
Steel Junction Boxes ...................3
4.1 Scope ...............................................3
4.2 Detail Specifications .........................3

5. Detail Specifications for Stainless

Steel Junction Boxes ..................4
5.1 Scope ...............................................4
5.2 Detail Specifications .........................4

Process Industry Practices Page 1 of 5

PIP PCSEL001
Instrument Junction Boxes Specification December 1999

1. Introduction

1.1 Purpose
This Practice covers the minimum requirements for junction boxes used for
instrumentation signals, thermocouples, and resistance temperature detectors (RTDs).

1.2 Scope
This Practice is only for junction boxes installed in general purpose or Division II area
classifications with wiring and terminals in accordance with the National Electric
Code (NEC). Junction boxes per this Practice are not to be used for electronics or
other active elements without additional consideration.

2. References

Applicable requirements in the latest edition of the following industry codes and standards
shall be considered an integral part of this Practice. Short titles will be used herein when
appropriate.

2.1 Process Industry Practices (PIP)

– PIP PCFEL100 - Instrumentation Electrical Fabrication Details
– PIP PCIEL000 - Instrumentation Electrical Details

2.2 Industry Codes and Standards

• National Electric Manufacturers Association (NEMA)

– NEMA 250 - Enclosures for Electrical Equipment (100 Volts Maximum)
– NEMA ICS6 - Enclosures for Industrial Control and Systems
• National Fire Protection Association (NFPA)
– NFPA 70 - National Electric Code

3. General Requirements

3.1 NEMA Type 12, dust and drip tight design boxes shall be used only in dry, indoor
locations.
3.2 NEMA Type 4X, water and dust tight design boxes shall be used in wet, outdoor, or
corrosive locations.
Comment: See NEMA 250 and NEMA ICS6 for Type 4/4X and Type 12
requirements.
3.3 Junction boxes shall be fabricated per PIP PCFEL100 and installed in accordance
with PIP PCIEL000.
3.4 Knock-outs shall not be provided in the boxes.

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 PIP PCSEL001
December 1999 Instrument Junction Boxes Specification

3.5 Doors shall be fitted with an oil-resistant gasket. This gasket shall be held in place by
glue or corrosion-resistant clips.
3.6 Terminal strips (type as specified by the user) shall be DIN rail mounted type
terminals that utilize a screw clamp connection for terminating wiring. DIN rails shall
be affixed in enclosure using “terminal strap mounting kits” with stainless steel
mounting bolts.
Comment: Back panels shall be used to mount terminals. These panels shall be
12-gauge steel with a white enamel finish over a phosphatized
surface.
3.7 A drain shall be installed in the bottom of the box, per PIP PCFEL100.
3.8 Junction box number shall be installed on the front of the box using a 2" x 4"
nameplate attached with stainless steel screws. The number shall be in black letters on
a white background. For dedicated Safety Instrumented Systems junction boxes, white
letters on a red background shall be used.
3.9 Terminals shall have permanent identifying numbers or characters as shown on the
wiring diagrams.
3.10 Number of terminals and box size will be as shown on PIP PCFEL100 and specified
in the Data Sheet. Junction boxes of other sizes and number of terminals shall be
selected from Manufacturer’s standard sizes with Owner’s Approval.
3.11 Junction boxes shall be provided with an external grounding lug.
3.12 Top entry into the junction box shall be not be permitted.
3.13 Mounting ears/lugs shall be provided.
3.14 Box shall be free of burrs and sharp edges.

4. Detail Specifications for Carbon Steel Junction Boxes (NEMA 12 or 4)

4.1 Scope
In addition to the requirements of Section 3, carbon steel junction boxes shall meet the
specifications of Section 4.2.

4.2 Detail Specifications

4.2.1 Carbon steel boxes shall be NEMA 12.
4.2.2 Exterior hardware (e.g., full-length hinge, closure clips, etc.) shall be made of
304 stainless steel.
4.2.3 All seams shall have continuous welds.
4.2.4 A rolled lip shall be provided around all sides of the box opening and three
sides of the door opening.
4.2.5 Interior finish shall be white enamel or epoxy over a phosphatized surface.
4.2.6 Exterior finish shall be gray enamel over a high-quality, rust-inhibitive primer.

Process Industry Practices Page 3 of 5

PIP PCSEL001
Instrument Junction Boxes Specification December 1999

5. Detail Specifications for Stainless Steel Junction Boxes (NEMA 4X)

5.1 Scope
In addition to the requirements of Section 3, stainless steel junction boxes shall meet
the specifications of Section 5.2.

5.2 Detail Specifications

5.2.1 Junction boxes (including box, full-length hinge, closure clips, hardware, and
internal plates) shall be 304 stainless steel.
5.2.2 All seams shall have continuous welds.
5.2.3 A rolled lip shall be provided around all sides of the box opening and three
sides of the door opening.
5.2.4 Finish will not normally be required unless the area where the box will be
installed is subject to stress corrosion cracking from chlorides.

6. Detail Specifications for Fiberglass Junction Boxes (NEMA 4X)

6.1 Scope
In addition to the requirements of Section 3, fiberglass junction boxes shall meet the
specifications of Section 6.2.

6.2 Detail Specifications

6.2.1 Fiberglass boxes shall be NEMA Type 4X.
6.2.2 All exterior hardware (e.g., full-length hinge, latches, etc.) shall be 304 or 316
stainless steel.
6.2.3 Finish will not normally be required on the interior of the box.
6.2.4 Exterior finish shall be provided with proper protection from ultraviolet rays.

7. Detail Specifications for Aluminum Junction Boxes (NEMA 4X)

7.1 Scope
In addition to the requirements of Section 3, aluminum junction boxes shall meet the
specifications of Section 7.2.

7.2 Detail Specifications

7.2.1 Aluminum boxes shall be NEMA Type 4X and be copper free, (not exceeding
0.4% copper).
7.2.2 All exterior hardware (e.g., full-length hinge, latches, etc.) shall be 304 or 316
stainless steel.
7.2.3 Finish will not normally be required on the interior of the box.

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 PIP PCSEL001
December 1999 Instrument Junction Boxes Specification

7.2.4 Exterior finish will not normally be required on aluminum boxes.

Comment: Aluminum boxes shall not be used in caustic environments.

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