What are Switch-Rated Plugs & Connectors?
Meet the Connector: Switch-Rated Plugs & Connectors
Switch-rated plugs and connectors are specialized electrical components designed to facilitate the safe connection and disconnection of electrical devices or equipment under load. Unlike conventional plugs and connectors, which may pose risks of arcing or electrical faults during switching operations, switch-rated variants are engineered to reduce the dangers associated with load bearing operations and withstand the conditions present in many industrial environments.
Workplace safety concerns prompted the development of switch-rated connectors. In the 1950s, a French electrician witnessed an arc incident that began the search for safer connection solutions. According to Molex, in the United States alone, an average of one worker is killed every day in an average of 20 daily arc flash incidents. Switch-rated connector products help organizations reduce accidents, limit equipment downtime, and achieve code compliance.
The Molex Woodhead ArcArrest connector system protects workers from arcing energy by maintaining a connection with the plug during connection or disconnection.
Design Notes
- Standards: Switch-rated connectors are not a standardized interface, but they are subject to approval by a variety of international agencies, including the National Electrical Code (NEC 430.102(B)(1); Occupational Safety and Health Administration (OSHA) (requirements for lockout/tagout [LOTO] safety), and the low voltage directive (LVD) (2014/35/EU). UL 2682 provides guidelines for switches and related interconnects that can be used to disconnect equipment, even while energized, and applies to switch-rated connectors.
- Sealing: Switch-rated connectors are frequently deployed in industrial settings where IP protection is needed to seal connections against moisture and debris.
- Current rating: Typical current ratings can range from 20 amps to 1000 amps or more. Switch-rated connectors are rated only in AC as a switch.
- Impedance: Generally, switch-rated plugs and connectors are designed to have low impedance to minimize voltage drop and power loss across the connection. This is especially important in high-current applications where efficiency and performance are critical.
- Frequency Range: Most switch-rated plugs and connectors are designed to accommodate the standard frequency used in the region where they are deployed, typically 50 or 60 hz.
- Dielectric Withstanding Voltage: Common DWV ratings for switch-rated connectors may include values such as 1000 volts (1 kV), 2500 volts (2.5 kV), or even higher.
- Durability: 100 cycles min. into a full detent shroud; 500 cycles min. into a limited detent shroud; 1,000 cycles min. into a smooth bore shroud
- Mating Style: Push-on, push-pull, plug and receptacle, panel mount
Phoenix Contact’s ArcZero series provides you with reliable protection against hazardous electric arcs. The capability of being connected under load enables selected components to be fully shut down, thus ensuring high system availability. The impact strength of the low-voltage connectors also enables DC connections to be established under extreme conditions.
Image 2 Phoenix Contact’s ArcZero series provides you with reliable protection against hazardous electric arcs. The capability of being connected under load enables selected components to be fully shut down, thus ensuring high system availability. The impact strength of the low-voltage connectors also enables DC connections to be established under extreme conditions.
Markets, Sectors, and Applications
- Industrial
- Datacom
- Transportation
Manufacturing and automation systems (conveyors, packaging machines, power distribution, process equipment, pumps); Energy industry, Data Centers, Transportation (rail, airports, seaports, and public transportation networks) and Infrastructure (signaling systems, lighting, events A/V systems).
Suppliers
- Molex
- Phoenix Contact,
- Eaton
- Meltric (available from DigiKey)
Related products:
- Circuit breakers
- Control panels
- Power Distribution Units (PDUs)
Like this article? Check out our other Meet the Connector and Harsh Environment articles, our Industrial Market Page, and our 2023 and 2024 Article Archives.
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