Aviation Switch ZKC DC24V 5A~80A

Product Overview

The ZKC DC24V 5A~80A is a versatile Military Aviation Switch series offering scalable current ratings from 5A to 80A at 24V DC, engineered for diverse power control applications in drone systems, aircraft engines, train controls, and Aviation Electronics. This flexible switching solution provides tailored current capacity options within a single product family, allowing system designers to select the exact rating needed for their specific application. As a comprehensive component in YM's aviation solutions portfolio—complementing products like Hydraulic Circuit Breakers and Industrial Power Relays—the ZKC series delivers precision-engineered switching across a wide power spectrum.

 

Technical Specifications

• Series Model: ZKC
• Voltage Rating: 24V DC (aviation standard voltage)
• Current Range: 5A, 10A, 20A, 35A, 50A, 65A, 80A variants
• Switch Type: Scalable current military aviation switch
• Contact Resistance: Initial ≤50mΩ; After durability testing ≤200mΩ
• Electrical Life: Minimum 100,000 switching operations at rated load
• Switching Speed: Action time ≤4ms; Release time ≤4ms; Pulse width (10-50) ms
• Dielectric Strength: 500V RMS @ 50Hz (standard); 250V RMS @ 50Hz (low pressure)
• Insulation Resistance: >500 MΩ initially; >50 MΩ after environmental testing
• Thermal Design: Scalable cooling solutions matched to current rating
• Environmental Sealing: Maximum leakage rate ≤ 1.0 x 10⁻³ Pa·cm³/s (hermetic grade)
• Operating Temperature: Performance validated for aviation conditions, compatible with Aviation Temperature Sensor monitoring
• Terminal Options: Range of terminal sizes matched to current rating
• Mounting Compatibility: Consistent footprint across current ratings for design flexibility
• Weight Range: 3-25g depending on current rating (scaled appropriately)

Product Features & Competitive Advantages

1. Scalable Current Platform: Single product family covers 5A to 80A range, providing design consistency across power requirements while eliminating the need to source from multiple vendors—similar to the scalability approach used in Industrial Power Relay series.
2. Optimized Thermal Management: Each current rating features specifically engineered cooling solutions, from compact designs for lower currents to advanced heat dissipation systems for 80A models.
3. Unified Design Architecture: Consistent mechanical design and mounting footprint across all current ratings simplifies panel design and allows for easy system upgrades without layout changes.
4. Military-Grade Construction Across Range: All variants from 5A to 80A maintain the same rigorous military standards for durability, vibration resistance, and environmental protection.
5. Advanced Arc Suppression Scaling: Arc control features scaled appropriately for each current rating, ensuring safe switching transitions from small control circuits to high-power applications.
6. Superior Environmental Sealing: Hermetic sealing (≤10⁻³ Pa·cm³/s) provides comprehensive protection across all current ratings, matching the protection standards of Aviation Oil Sealed Valves.
7. Cost-Effective Scalability: Economical platform approach allows for appropriate component sizing without over-engineering or compromising performance.

Selection and Installation Guidelines by Current Rating

1. Current Requirement Analysis: Calculate maximum continuous current, peak currents, and duty cycle to select appropriate rating from 5A to 80A range.
2. Proper Current Rating Selection: Choose rating with 20-30% margin above maximum expected continuous current for reliability and longevity.
3. Wire Sizing by Rating:
   • 5A-10A: 16-14 AWG aviation-grade wire
   • 20A-35A: 12-10 AWG with proper insulation
   • 50A-80A: 8-4 AWG with appropriate derating
4. Mounting Considerations: Higher current models (50A+) may require additional mounting support for mechanical stability.
5. Thermal Management Planning: Higher current installations require more attention to ventilation and heat dissipation.
6. Terminal Connection Techniques: Use proper crimping tools and techniques matched to terminal size and current rating.
7. Testing Protocol: Test at 125% of rated current for 1 hour to verify thermal stability before system integration with components like Hydraulic Circuit Breakers.

Application Scenarios by Current Rating

• 5A-10A Models: Control circuits, sensor interfaces, lighting controls, and auxiliary systems in small UAVs and compact avionics.
• 20A-35A Models: Primary power distribution, medium motor controls, heating systems, and main avionics power in commercial aircraft.
• 50A-65A Models: High-power propulsion controls, large motor starters, primary distribution panels, and industrial equipment in rail and heavy Aviation Applications.
• 80A Model: Main power switching, generator controls, heavy industrial equipment, and primary distribution in large aircraft and ground support systems.

The entire ZKC series is suitable for: Aircraft power management across all system sizes, UAV systems from small drones to large unmanned vehicles, Rail vehicle power distribution, Military equipment from portable to stationary systems, and Industrial applications requiring reliable DC switching from control to power levels.

Value Proposition for System Designers

• Design Flexibility: Single product family covering 5A to 80A allows for consistent design approach across different power requirements within the same system.
• Inventory Simplification: Reduced SKU count and standardized components across power ratings simplify inventory management and reduce costs.
• Future-Proof Designs: Consistent footprint allows for easy system upgrades by simply swapping to higher current rated switches without panel redesign.
• Optimized Cost-Performance: Pay only for the current capacity needed, avoiding over-engineering while maintaining full performance specifications.
• Simplified Training and Maintenance: Common installation procedures and maintenance requirements across current ratings reduce training time and errors.
• Supply Chain Reliability: Single source for wide range of current requirements reduces supply chain complexity and risk.
• Design Validation Efficiency: Once qualified, the entire product family benefits from the certification, reducing testing and validation costs for multiple ratings.

Certifications & Compliance

The ZKC DC24V 5A~80A Military Aviation Switch series is designed and manufactured to meet or exceed performance requirements across the entire current spectrum, including military specifications for power switching equipment at various power levels, aviation requirements for DC power control safety and reliability, and industrial standards for scalable power components. Our manufacturing processes comply with rigorous quality management systems specifically addressing performance consistency across the scalable platform, and we provide comprehensive technical documentation including full current-rating performance test reports to support customer qualification, certification, and compliance efforts for diverse power applications.

Customization & OEM/ODM Services

YM offers extensive customization capabilities for the ZKC scalable switch series:

• Custom current ratings within the 5A-80A range for specific application requirements
• Special terminal configurations and sizes for different wiring standards
• Custom thermal management solutions for unique environmental conditions
• Voltage rating variations (12V, 48V DC) while maintaining current capabilities
• Special switching configurations (multi-pole, multi-position) across current ratings
• Enhanced environmental sealing for extreme operating conditions
• Custom markings, color coding, and identification systems
• Application-specific testing and validation protocols for specialized requirements

Our proven OEM and ODM expertise in scalable power components, demonstrated across our Automotive Relay and New Energy Relay product lines, ensures we can develop tailored switch solutions that precisely match your specific current requirements while maintaining design consistency across your product range.

Production Process & Scalable Quality Assurance

1. Scalable Component Manufacturing: Precision manufacturing of contact systems sized appropriately for each current rating from 5A to 80A.
2. Graded Thermal Engineering: Implementation of appropriate cooling solutions matched to the thermal requirements of each current rating.
3. Consistent Quality Standards: Application of identical quality standards and testing protocols across all current variants.
4. Current-Specific Testing: Each rating undergoes testing at 125% of its specific rated current to verify thermal performance and contact integrity.
5. Arc Performance Validation: Testing of arc suppression features appropriate for each current level's switching characteristics.
6. Thermal Cycle Testing: Validation of performance under repeated thermal cycling at each rating's specific current level.
7. Platform Consistency Verification: Confirmation of mechanical and electrical consistency across the entire 5A-80A range.
8. Final Quality Assurance: Comprehensive inspection including dimensional verification, mechanical function testing, current-specific performance validation, thermal performance assessment, and complete manufacturing traceability across all current ratings.

System Integration and Complementary Power Components

The ZKC DC24V 5A~80A Military Aviation Switch series is designed for integration into diverse power control systems requiring different current capacities. For complete scalable system solutions, consider pairing with YM's complementary products such as Aviation Copper Fuse Holders with matching current ratings, Military Pressure Sensors for system monitoring across power levels, and Solid State Relays for automated control in sophisticated power management systems. This integrated approach enables the creation of reliable, scalable power control systems for aerospace, defense, and industrial applications where flexible current capacity and design consistency are essential for system performance and long-term maintainability.