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Panel Essentials Series 1: DIN Rail

Introduction

When you first think of an electrical panel, it is likely that you would think of common power and
control products such as circuit breakers, terminal blocks, relays, contactors and more. However, you
likely wouldn’t consider the component that provides the structure and mechanical support needed
for all the electrical products in a panel to function properly — DIN rail. Before discussing this first
panel essential, here’s a first look for you.

If you have any experience working with electrical devices, you probably understand DIN rail and it’s
necessity in the installation, operation and maintenance of control panels. As automation has evolved,
panels have become smarter and smaller. In order to optimize the limited space available, DIN rail
mounting has emerged as the fundamental process for product arrangement within a panel.

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DIN Rail Description and Benefits

DIN rail is a metallic rail that can be fastened to a surface to mount

industrial control equipment. Most commonly, DIN rail is manu-
factured from copper, aluminum or steel with a zinc-plated/chro-
mate finish. Zinc-plated steel is a popular all-around solution con-
sidering its cost-effectiveness, strength and resistance to shock
and corrosion. Despite having a metallic property, the primary
function of DIN rail is to provide support rather than to conduct an
electrical current, as a busbar would. Standard DIN rail is 35mm
wide, slotted and supplied in both 1 and 2 meter lengths. Howev-
er, many enclosures will feature cut-to-size DIN rail to meet spe-
cific panel requirements.

Utilizing DIN rail is far more effective and efficient than mounting individual products directly on the
panel. Not only does DIN rail optimize limited space, it provides a standard for the components it
supports — almost all circuit breakers, terminal blocks and other key electrical products are designed
to comply with standard DIN rail specifications.

History of DIN Rail

While DIN rail is ubiquitous with control panels today, this wasn’t the case almost a century ago. In
the late 1920s, German company RWE, Rheinisch-Westfälisches Elektrizitätswerk, encountered a prob-
lem that required a way to mount electrical products closer together on a panel board. Working with
another German manufacturer, the Phoenix Electrical Supply Company (now Phoenix Contact), the
concept for DIN rail surfaced in 1928 with the G-rail (later, we will discuss types of DIN rail).

The term “DIN” comes from the German national organization for standardization, Deutsches Institut
für Normung, responsible for defining the original industrial specifications for rail assembly. Original-
ly constructed as a porcelain tray housing a busbar, the DIN rail concept was refined in the 1950s
to reflect the current metal design we see today. Compatible standards were then adopted by or-
ganizations such as the International Electrotechnical Commission (IEC) and the National Electrical
Manufacturers Association (NEMA) in the United States. As one of the few products that is widely
accepted as a global standard, DIN rail is now incorporated in almost every panel and electrical proj-
ect across the world.

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Types of DIN Rail

Electrical components and panels are manufactured to fit one of several DIN rail types such as:

1. Miniature Top-Hat Rails

At 15mm wide and 5.5mm deep, miniature top-hat rails are the smallest size of DIN rail. Also
known as TS15 rails, these symmetrical rails are best suited for smaller components or applica-
tions in which limiting space is critical.

2. Top-Hat Rails
Top-hat rails look exactly like their miniature version except they are 35mm wide and 7.5mm
deep. Also known as TS35 rails, there is also a 35mm x 15mm ‘deep hat’ version for added
strength and durability.

3. G32 Rails
As their name suggests, these rails are shaped like the letter ‘G’ and are 32mm wide. Also known
as TS32 or ‘G-rails’, their asymmetrical design helps prevent incorrect installation while offering
additional support for larger and/or heavier products.

4. C32 Rails
As their name suggests, these symmetrical rails are shaped like the letter ‘C’ and are 32mm
wide. With a shape opposite to that of top-hat rails, these rails are less common in modern ap-
plications and often require an adapter for installation.

The variation of DIN rail required depends on the application to which it is being applied. Top-hat rail
is often regarded as the industry standard and is designated IEC/EN 60715. The common configura-
tions of top-hat rail, at both 1 and 2 meter lengths, can be seen below:

Standard - 35mm x 7.5mm Deep Hat - 35mm x 15mm

35 mm 35 mm

15 mm
7.5 mm

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Best Practices for DIN Rail Installation

If you are applying DIN rail to a panel yourself, here are a few best practices to consider:

1. Make sure your DIN rail is compatible with your panel! If your enclosure is metal rather than
polycarbonate (which can safely pair with any DIN rail), you will need a rail constructed of the
same metal as the enclosure.

2. Confirm that your DIN rail meets common standards and is the right size for your products.
While Top-Hat, 35mm DIN rail is standard, some products require 15mm or 32mm mounting.

3. Determine which mounting accessories are required — consider end plates, separator plates,
end barriers and support brackets.

4. Outline how you will mount components prior to installation. Consider the following:
Similar components should be mounted together to limit end/separator plates.

AC products should be kept separate from DC products.

Products should be arranged so that wires don’t pass over other components.

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c3controls DIN Rail Offering

c3controls offers two types of 35mm symmetrical DIN rail; steel and aluminum. Our steel DIN rail is
zinc with clear chromate plating and is available standard or ‘deep hat’ in both 1m (3.28 ft.) and 2m
(6.56 ft.) lengths. Our standard aluminum version is available in a 1m length. All rails are slotted and
simply fasten by screws to the mounting surface — no special bracket or hardware is needed. Circuit
breakers, terminal blocks and other electrical products easily snap on to the rail for fast and easy in-
stallation and removal.

c3controls also offers a variety of mounting accessories such as end plates, separator plates, end
barriers and support brackets.

Check out our DIN Rail offering!

Panel Solutions

For your complete panel needs, c3controls operates a UL508A certified panel shop serving the OEM
and panel builders across a wide variety of industries. Check out our enclosed panel solutions!

c3controls Panel Essentials Papers:

Series 1: DIN Rail

Series 2: Wire Duct and Terminal Blocks (for wire and cable
management)

Series 3: UL508A Control Panel Design Considerations

Series 4: Electrical Control Components

Series 5: Control Panel Industry Trends

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Disclaimer:

The content provided is intended solely for general information purposes and is provided with the understanding that the authors and publishers
are not herein engaged in rendering engineering or other professional advice or services. The practice of engineering is driven by site-specific
circumstances unique to each project. Consequently, any use of this information should be done only in consultation with a qualified and licensed
professional who can take into account all relevant factors and desired outcomes. The information was written with reasonable care and attention.
However, it is possible that some information is incomplete, incorrect, or inapplicable to particular circumstances or conditions. We do not accept
liability for direct or indirect losses resulting from using, relying or acting upon information in this article.

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