Aviation Switch ZZK3-2 20A 28V

Product Overview

The ZZK3-2 20A 28V is a high-current Military Aviation Switch specifically engineered for power distribution and control applications in drone systems, aircraft engines, train controls, and Aviation Electronics. Rated for 20A at 28V DC, this robust switch delivers exceptional current-carrying capacity while maintaining reliability in extreme operating environments. As a heavy-duty component in YM's comprehensive aviation solutions portfolio—complementing products like Hydraulic Circuit Breakers and Industrial Power Relays—the ZZK3-2 provides dependable high-current switching for mission-critical power systems where safety and reliability are paramount.

Technical Specifications

• Model Number: ZZK3-2
• Current Rating: 20A continuous at 28V DC
• Voltage Rating: 28V DC (aviation standard)
• Switch Type: High-current military aviation toggle switch
• Contact Configuration: Heavy-duty contacts for high-current applications
• Coil Power Consumption: (0.3 - 0.43) Watts
• Electrical Life: Minimum 100,000 switching operations at rated load
• Contact Resistance: Initial ≤50mΩ; After durability testing ≤200mΩ
• Switching Speed: Action time ≤4ms; Release time ≤4ms; Pulse width (10-50) ms
• Dielectric Strength: 500V RMS @ 50Hz (standard pressure); 250V RMS @ 50Hz (low pressure)
• Insulation Resistance: >500 MΩ initially; >50 MΩ after environmental testing
• Thermal Management: Designed for efficient heat dissipation at full rated current
• Weight: Optimized for high-current applications while maintaining aviation weight constraints
• 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 Design: Heavy-duty terminals for secure high-current connections

Product Features & Competitive Advantages

1. High-Current Capacity: Rated for 20A continuous operation at 28V DC, making it suitable for primary power switching applications where standard aviation switches are inadequate—complementing high-power systems using Industrial Power Relays.
2. Military-Grade Construction: Heavy-duty contacts and reinforced mechanical design withstand the thermal and mechanical stresses of high-current switching operations.
3. Advanced Thermal Management: Engineered for efficient heat dissipation at full rated current, preventing thermal degradation and ensuring long-term reliability.
4. Superior Environmental Sealing: Advanced hermetic sealing (≤10⁻³ Pa·cm³/s) provides comprehensive protection while handling high currents, matching the protection standards of Aviation Oil Sealed Valves in demanding environments.
5. Arc Suppression Design: Contact geometry and materials optimized to minimize arcing during high-current switching, extending contact life and reducing electromagnetic interference.
6. Vibration-Resistant High-Current Design: Engineered to maintain reliable high-current connections under vibration and shock conditions common in aerospace applications.
7. Secure Terminal Connections: Heavy-duty terminals designed for reliable high-current connections with proper torque retention and minimal contact resistance.

Installation and Wiring Procedure for High-Current Applications

1. Current Requirement Verification: Confirm actual current requirements match switch rating (20A maximum continuous at 28V DC).
2. Proper Wire Selection: Use appropriately sized aviation-grade wire capable of carrying 20A continuous current with proper derating for environmental conditions.
3. Secure Mounting: Mount switch on rigid panel using provided heavy-duty hardware to withstand mechanical forces during operation.
4. High-Current Connection: Make secure connections to heavy-duty terminals using proper crimping or soldering techniques for high-current applications.
5. Thermal Management Consideration: Ensure adequate ventilation and heat dissipation around switch, especially in enclosed spaces or high ambient temperatures.
6. Sealing Verification: Confirm environmental seals are properly engaged to maintain protection in the operating environment.
7. Current Testing: Test switch operation at rated current to verify proper thermal performance and contact integrity before system integration with components like Hydraulic Circuit Breakers or Aviation Magnetic Valves.

Application Scenarios

The ZZK3-2 20A 28V Military Aviation Switch is engineered for high-current switching applications across aerospace and industrial sectors:

• Aircraft Primary Power Distribution: Main power switching for avionics systems, lighting circuits, and auxiliary power units in commercial and military aircraft.
• UAV High-Power Systems: Switching for propulsion systems, high-power payloads, and charging systems in large unmanned aerial vehicles.
• Rail Vehicle Power Management: Primary power control for traction systems, HVAC units, and auxiliary power in train applications.
• Military Equipment Power Control: High-current switching for communication systems, weapon systems, and tactical equipment in field applications.
• Industrial Power Control: Primary power switching for machinery, processing equipment, and high-power industrial systems.
• Ground Power Equipment: Switching for aircraft ground power units, battery charging systems, and maintenance equipment.
• Emergency Power Systems: Control switching for backup power systems, emergency lighting, and critical system power distribution.
• Test and Measurement High-Power Applications: Switching for high-power test equipment, load banks, and power supply testing systems.

Value Proposition for High-Current Applications

• Reliable High-Current Switching: Provides dependable switching capability for currents up to 20A, filling the gap between standard aviation switches and heavy-duty contactors.
• Space-Efficient Power Control: Compact design compared to alternative high-current switching solutions, saving valuable space in aerospace applications.
• Reduced System Complexity: Eliminates need for additional current-boosting components or relay systems for moderate high-current applications.
• Enhanced Safety: Designed and tested for safe operation at rated currents, with proper thermal management and arc suppression features.
• Long-Term Reliability: Engineered for extended service life at rated currents, reducing maintenance requirements and system downtime.
• Cost-Effective High-Current Solution: Provides high-current switching capability at competitive cost compared to custom or oversized switching solutions.
• Standardized Design: Compatible with standard aviation practices while providing enhanced current capacity.

Certifications & Compliance

The ZZK3-2 20A 28V Military Aviation Switch is designed and manufactured to meet or exceed performance requirements of international standards relevant to high-current switching components, including military specifications for power distribution equipment, aviation requirements for primary power switching, and industrial standards for moderate high-current applications. Our manufacturing processes comply with stringent quality management systems specifically addressing high-current performance and thermal management, and we provide comprehensive technical documentation including current-carrying capacity test data to support customer qualification, certification, and compliance efforts.

Customization & OEM/ODM Services

YM offers specialized customization options for the ZZK3-2 high-current switch series:

• Custom current ratings up to 20A for specific application requirements
• Special terminal configurations for different wire sizes and connection methods
• Enhanced thermal management features for high ambient temperature applications
• Custom switching configurations (single-pole, double-pole, multi-position)
• Special arc suppression features for specific load types (inductive, capacitive)
• Custom environmental sealing for specific operating conditions
• Special markings and identification for high-current applications
• Application-specific testing and validation for high-current performance

Our demonstrated OEM and ODM expertise in power switching components, proven across our Automotive Relay and New Energy Relay product lines, ensures we can develop tailored high-current switch solutions that precisely match your power requirements and application specifications.

Production Process & Quality Assurance for High-Current Components

1. Heavy-Duty Component Manufacturing: Precision manufacturing of high-current contacts and terminals using materials optimized for current-carrying capacity and thermal performance.
2. Thermal Management Engineering: Design and implementation of effective heat dissipation features for high-current operation.
3. High-Current Contact Assembly: Careful assembly of heavy-duty contacts with proper alignment and pressure for reliable high-current switching.
4. Current-Carrying Capacity Testing: Comprehensive testing at rated current (20A) to verify thermal performance and contact integrity.
5. Arc Performance Evaluation: Testing of arc suppression features and contact performance during switching transitions.
6. Thermal Cycle Testing: Validation of performance under repeated thermal cycling to simulate real-world operating conditions.
7. High-Current Endurance Testing: Extended operation at rated current to verify long-term reliability and contact performance.
8. Final Quality Assurance: Comprehensive inspection including dimensional verification, mechanical function testing, high-current performance validation, thermal performance assessment, and complete manufacturing traceability.

System Integration and Complementary High-Current Components

The ZZK3-2 20A 28V Military Aviation Switch is designed for integration into high-current power distribution and control systems. For enhanced system functionality in high-current applications, consider pairing with YM's complementary products such as Aviation Copper Fuse Holders for circuit protection, Military Pressure Sensors for system monitoring, and Solid State Relays for silent high-current switching in automated systems. This comprehensive approach enables the creation of reliable, high-current control systems for aerospace, defense, and industrial applications where power distribution reliability and safety are critical considerations.