One of the inline switches I installed to replace the failed switches for the LED lights got unpleasantly warm enough to prompt an investigation:
Yeah, that is not a nominal outcome, particularly in light of the claimed “10 A 250 V” rating.
The overheated plastic pulled back enough to expose the terminal inside:
There was a reason I’d wrapped those switches with known-good 3M electrical tape before deploying them.
That crimp connector took some heat and its screw looks even more unhappy:
It turned out the screw was an itsy too short to compress both the connector and the bent-metal conductor tab against the terminal block:
A 6 mm brass screw with a brass washer did a better job of compressing all parties into one conductive lump.
Although the switch now runs with the case at normal basement temperature, an allegedly UL listed replacement is on its way; it costs about five times more than that switch. If it behaves as it should, I’ll preemptively replace two other switches.
The Smell of Molten Projects in the Morning 
Comments
2 responses to “Inline Switch FAIL”
What load did this switch control? If it was just LEDs, I should be able to see your shop from here (central florida)
That said, a warm switch is almost never a Good Thing.
-dave
It’s the string of 4 foot LED shop lights along that side of the basement; these are on the other side, but you get the idea. I hates me some dim basement!
I’ve reduced the wiring jank, but the outlet situation remains dire.