Dear Rich, Thanks for your comments!
The shape of contact leafs affect the arc flash happening. Based on my experience in this type of industry, the contact leafs are not produced in a precise tooling and process. Even though it is found out the right shape to avoid the arc flash, I am unsure how the mass production can maintain to a satisfactory level. It is my first time to see it happening although I had seen many switches come from such industry. It is by chance to discover it and have no confidence that we can detect such bad design on all units under test in the future. Need to develop a better way to identify such bad design. Regards, Scott > On 2 Oct, 2015, at 2:12 am, Richard Nute <[email protected]> wrote: > > > > Hi Scott: > > > When a switch opens (at something other than the > zero-crossing), an arc is created and molten metal > of the contacts is likely. (In fact, some contact > designs use the molten metal to re-form the > contacts.) > > The molten metal is accelerated (at right angles > to the current direction) by the magnetic field. > > What is unusual is the length of the arc -- 1 > inch. And, that the arc was from the switch > contacts to the earthed parts. The current > through the arc to the earthing conductor can be > sufficient to trip the RCD. > > One hypothesis is that the current in the contacts > created an excessive amount of molten metal which > allowed the arc to also go through the molten > metal droplets to the earthed metal. This would > explain both the metal on the earthed part and the > arc. Excessive contact heating could be caused by > contact resistance being high (but not too high). > > > Based on your description, I would hypothesize > that the switch contact resistance was high; the > switch is worn out, or has inadequate ratings. > > I don't know of any standard that would address > this issue. The situation is analyzed by science > and engineering, and appropriate changes to the > construction to prevent recurrence. > > > Good luck and best regards, > Rich > > > > > >> -----Original Message----- >> From: Scott Xe [mailto:[email protected]] >> Sent: Wednesday, September 30, 2015 11:22 PM >> To: [email protected] >> Subject: [PSES] Arc flash to earthed parts >> >> Dear Members, >> >> I recently encountered a symptom on a toaster. > When >> turning off by pressing the quit button, there > was an arc >> flash from the mains switch contacts to earthed > parts >> where the separation greater than 1 inch apart > in air >> occasionally. The mains contacts have a sign of >> carbonisation on the open/close contact points > and >> melted in a small area of the contact leaf. The > switch >> and the earthed parts are inside the plastic > case without >> the access by the users. It may trip the RCD > during arc >> flash. In addition, there was vaporised copper > layer on >> the earthed part. It did not have immediate > danger to >> the user and definitely not a good product. How >> should we categorise this type of fault and is > there any >> reference standard for it? >> >> Thanks and regards, >> >> Scott >> > - ---------------------------------------------------------------- This message is from the IEEE Product Safety Engineering Society emc-pstc discussion list. To post a message to the list, send your e-mail to <[email protected]> All emc-pstc postings are archived and searchable on the web at: http://www.ieee-pses.org/emc-pstc.html Attachments are not permitted but the IEEE PSES Online Communities site at http://product-compliance.oc.ieee.org/ can be used for graphics (in well-used formats), large files, etc. Website: http://www.ieee-pses.org/ Instructions: http://www.ieee-pses.org/list.html (including how to unsubscribe) List rules: http://www.ieee-pses.org/listrules.html For help, send mail to the list administrators: Scott Douglas <[email protected]> Mike Cantwell <[email protected]> For policy questions, send mail to: Jim Bacher: <[email protected]> David Heald: <[email protected]>
