The 2P+G
plug is the most commonly used theatrical
connector in the United States. My question is: Why?
There are a number of factors working here. The first is the
connector on the individual lighting
instrument. The next is the
connector used on two-fers, jumpers and long runs of
stage cable. Next in
line is, of course, the permanently wired connection at the
raceway or floor box or wall box that is in turn, hardwired to the actual
dimmer. Last, but not least is history and the evolution of lighting equipment including dimmers and distribution.
When pin connectors were first introduced, dimmers were expensive, individually controlled, and one
stage hand could only run 14 to 28 dimmers at most. The result was that dimmers were of large capacity and limited in number. To accommodate a show with different "Looks" and many instruments, loads to a
dimmer were changed, plugged and unplugged several times during a show. The goal was that every
dimmer was used in every
cue. It was a waste of dimmers if one was not involved in a
cue.
When the
pin connector was first introduced and up through the 1950's, 2K instruments were common in
FOH lighting as were 2K loads and larger, from
cyc and strips as was often the case. The parallel blade
Edison connector of that time was not nearly as robust as today. 15 amps was a real stretch code wise and practically, and most lacked even a rudimentary
strain relief. Licensed electricians were taught to tie a "Union Knot" (
underwriter's knot) with the two leads (no grounds on any equipment at the time!) to make a knot too large to pull through the opening in the
connector body. The
stage pin connector had better
strain relief than any
Edison connector of the time and 20 amps was no problem if well maintained.
Between about 1960 and 1980, most instruments evolved to 1K or less, with 500w, 750w and 1000w units as the most common units. At this time the cost of dimmers was still more than the cost of the copper to
build "Patch Panels" and the common practice was to have many circuits for every
dimmer, but nothing hard wired. The result was every
dimmer (except in the case of "specials") had 2 to 4 instruments, or several strip/
cyc units plugged to it. Dimmers were usually in two configurations, 3K or 6K-7K. The 3K to handle up to 4 750W units, the 6 or 7 K dimmers to handle massive strip/
cyc loads or the occasional 5K
stage lights that still showed up.
What this means for our discussion of connectors, is that average loads on connectors then, were larger as a rule than in today's world. Any given
connector might be carrying a full 2k (4 x 500w) or frequently 2.25K (3 x 750w) load. The 2.25K load, while not really the best practice was very common. 3K loads were more common than most of us would like to admit.
Although
DPC (
Dimmer Per
Circuit) technology was emerging in the early 80's, it wasn't until the early 90's and the
introduction of the 575w lamp that it really became a
practical and economical norm on a large scale. Before this, a common
stage layout might be 50-60 dimmers for 300 to 400 circuits and a HUGE, EXPENSIVE,
patch panel. Next step was
DPC with 96 or 192 circuits but maybe only 2/3 or 3/4 of the
dimmer bank populated, a practice that is unfortunetly still practiced today in what I personally believe is false economy, but YMMV.
Now, back up a
bit and it becomes obvious that until recently (relatively speaking,..... within the last 20 years) two-fers, extension cables, raceways, floor pockets or wall boxes all needed to handle a full 20 amps on a regular basis. The standard, parallel blade,
U-ground,
Edison plug simply did not have that capability. I do not really know when
Edison plugs became available that could handle SO cable, but that was also a problem until the last 15 or 20 years. Even in today's world, why have a 2k or 20 amp
dimmer if it only has a single 15amp
receptacle to
plug into? That can be partially resolved by making the final
raceway or wall
outlet a 20amp
Edison which will accept either a 15amp parallel blade or a 20amp "T" blade
Edison plug. If that is done, then every extension cable and
twofer must have a "T" blade male
plug to stay in code within your
system and be capable of plugging in everywhere. This will in turn mean that all your extensions and twofers would have to have a female "T" blade body to accept the "T" blade plugs. In a fully compliant
system, the individual instruments would be the only things with a parallel blade
plug.
So, in a very loose
nut shell, that is why
stage pin connectors evolved into the, IMHO, most common, best for the purpose,
connector we use. It will remain the most common for the time being as long as it is the most robust, easiest to service, most tamper proof (ever seen a
pin connector with the
ground cut off? I have seen twist locks with the
ground missing, can't imagine why but.....?!!) and it will easily handle the electrical load we ask it to, i.e. 20 amps (and more but I never did and I'm looking the other way....!.) I personally "Hate" the 20amp
twist lock. It is bulky, expensive, harder to
wire, doesn't match up with rental or
road company gear or most concert
road rigs. Early 20amp twist locks were also brittle, larger than today and a real PITA. In rental use the
twist lock pins get bent and twisted A LOT and while fairly easy to straighten, it is a a pain and a time waster in the middle of a tight
load-in. Parallel blade,
U-ground Edison plugs can'
t handle, by code, more than 15amps. and even now, many models can'
t handle SO for twofers or extensions.