In the U.S. (all states and territories), climates range from tropical, arid, semi-arid, temperate, continental, and polar. Natural elements from these climates provide unique challenges in protecting electrical outlets from humidity, dripping and splashing water, UV exposure, sand, and corrosive dust. The one ever-present danger outside of various climates is the entry of small tools from entering the contacts in electrical outlets to prevent serious injury.
The Dangerous Duo
Corrosive dust, which degrades contacts leading to loss of electrical continuity through corrosion, pitting, and arcing, occurs in every climate. It’s also a prime factor in arcing which can lead to electrical fires. One common occurrence of arcing is when the plug’s blades and pins are not fully seated into the metal contacts.
As current races across the exposed blades (arcing), the metal surfaces become pitted and carbon buildup occurs; now both the pitting and the carbon buildup are prime “checkpoints” for further arcing where open air spaces aren’t wide enough to extinguish the arcs. This continual arcing movement is referred to as “tracking” where melting and fires can occur if left unchecked. Other terms used for tracking include debris, cavities, corrosion, and cracks—imperfections that arc along a given path.
Moreover, arcing and tracking may turn catastrophic. Corrosive dust that is ignited by the smallest electrical arc can cause explosions in buildings containing a large amount of corrosive dust in the air. The dust acts as fuel (Carbonaceous dust, chemical dust, metal and plastics dust) when combined with oxygen, heat, confinement, and ignition source (electrical switch/arcing), and dust.
Not to be outdone by dust, high-voltage current travels farther near water than it does through the air. Then, there’s the more subtle moisture that seeps into the conductor wires of a cord set, or creeps along the crevices around blades and pins, again setting the stage for arcing. Interpower recommends using ingress-protected devices in wet or humid areas, such as its IP54 UL-rated Face Plug Seal Kits for IEC 60320 C14 Inlets. This kit includes a made-to-fit, moisture-resistant polyurethane insert which seals between the base of the C14 inlet and the face of the C13 connector. Such protection for corrosive dust and water provides multiple protection for one inlet.
Protect critical IEC 60320 connections from dust and splashing liquids. Discover UL-tested, IP54-rated C14 seal kits engineered to improve safety, reliability, and equipment longevity.
The Early Path to Ingress Protection
The IEC didn’t publish its first ingress protection rating until 1976 under the guidance of Technical Committee 70, which is umbrellaed under the IEC 60529 standard. The standard includes a scale of numeric protection ratings and nomenclature detailingthe degree of water and dust ingress that reach electrical contacts and potentially leading to short-circuiting.
However, the wheels of IEC move slowly. The initial draft from TC 70 was hammered out in 1971 in Stresa, Italy, known for its lakeside views. The second draft took place in Zurich in ’72, and a third draft in 1974 in Paris (yes, there’s a pattern here). Two years later the committee ratified the document and ingress protection was officially born.
IEC 60529 outlines an international classification system for the sealing effectiveness of enclosures of electrical equipment against the intrusion into the equipment of foreign bodies (i.e., tools, dust, fingers) and moisture.
Purportedly, justification for the standard stemmed from “waterproof” claims from manufacturers that varied from “waterproof,” “water resistant,” and “splash proof.” The committee insisted that the standard was needed for consumer safety, that too few agencies existed to protect consumers. Thus, the IP-rating system moved forward and official testing and certification could be established for manufacturers and consumers alike.
Interpower’s IP54-rated Face and Seal kits are prime examples of ingress protection certified by an independent UL lab that listed the official rating in its report:
(5) “A 1mm diameter probe does not pass through any opening of the enclosure with 1 N test force and test item placed in dust chamber. Ingress of dust not totally prevented but dust does not interfere with operation,” which resulted in a Level 5 designation.
(4) “Test item sprayed with water from all directions using oscillating tube rig for 10 minutes.” Test result: ‘Pass’ with a rating of 4.” Note: the “4” rating is not protected from high-pressure water.
The IP54 rating from UL’s test report confirmed Interpower’s Face Seal and Plug Seal Kits—made for its IEC 60320 C14 inlet and C13 connector—help prevent damage to the equipment as well as bodily harm.
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