Solar Lattice

Hazard

Arc from disconnecting under load

ID
hazard:disconnecting-under-load
IRI
https://solarlattice.org/kb/hazard/disconnecting-under-load
Status
active
Also known as
opening connectors under load, do not disconnect under load, pulling DC connectors, disconnecting under load, switching under load, opening a fuse under load
Category
Electrical

Opening or switching a circuit while current is flowing can strike an arc flash. The arc turns air into hot plasma and adds a burn risk, and it is especially a concern on the DC side. The classic case is pulling a DC fuse under load. Opening a fuse under load can cause property damage, injury or death, so check that no current is flowing, not just that voltage is absent. Manufacturers advise against unplugging AC or DC connectors under load. The NEC requires PV connectors to be either rated for interrupting current or to need a tool to open and be marked Do Not Disconnect Under Load. Screw-type fuse elements have no load-disconnection properties, and contact erosion can destroy or impair them if they are opened under load. Use a circuit breaker to disconnect an inverter from the grid under load. On a beeping Sunny Tripower TL-10, the electronic string fuse is short-circuiting the PV array. Do not pull the DC connectors or the ESS at that point; wait until the beeping stops after dark. To control the hazard, follow the safety rules: disconnect, lock out and tag out, test for absence of voltage, and open the PV breakers before servicing. Wear an arc flash jacket, flame-resistant clothing and a helmet with a full face visor when working where arcs can occur.

Claims

controlled_by

c1 verified · fact DC isolation below safe current

Make sure no current is flowing before opening a fuse or disconnecting. Checking that voltage is absent is not enough on its own; the absence of current must also be verified.

verified by: review-workflowverified on: 2026-10-24

c2 verified · fact Safety isolation

Disconnect the supply, prevent reconnection and test for absence of voltage. Open the PV breakers and make the equipment inoperable before servicing.

verified by: review-workflowverified on: 2026-10-24

c3 drafted · lead Lockout/tagout devices

Padlocks and tags on the switched-off isolators prevent reconnection.

review note: support check: partial - The video describes padlocks and tags on switched-off switches to prevent reconnection, but it does not tie lockout/tagout to controlling arcs from disconnecting under load.

c4 drafted · lead Arc-rated clothing

Scope: products Sunny Central Storage

An arc flash protection jacket and flame-resistant, non-synthetic clothing are recommended for work on Sunny Central and Sunny Central Storage inverters.

review note: support check: partial - The video says an arc flash jacket and flame-resistant non-synthetic clothing are needed (called mandatory). The statement calls them recommended and scopes them to Sunny Central and Storage, which is roughly consistent.

c5 drafted · lead Arc-rated face shield

Scope: products Sunny Central Storage

A helmet with a built-in visor gives full face protection against DC-side arc flash. Goggles alone are not enough.

Referenced by

Data