When working on a new application, engineers need to consider certain design needs and parameters that will ultimately influence the specific kind of electromechanical switches required by the device. Some applications require sealed, tamper-proof durability, others need to dependably switch high voltages and currents, or maybe the final form and fit requires a miniature size with a low profile design.
There are many types of switches with variances in shape, size, functionality, power ratings and mechanical behavior. Typically, the process for selecting a switch begins with finding the appropriate form factor that fits the application’s ergonomic and physical needs, and then considerations for the appropriate electrical and environmental specifications enter play.
This article will help designers sort through some common selection parameters and how they apply to popular, in-demand applications.
VIEW: PDF Guide for Selecting the Right Switch
READ: Seven Steps for Selecting the Right Switch
Protection Against Vandalism and Harsh, Frequent Use
VIEW: Complete Selection of E-Switch Anti-Vandal Pushbuttons
READ: What are Anti-Vandal Switches and What are Their Uses?
Public-facing switches are subjected to harsh use and may even be the target of tampering or vandalism. However, E-Switch’s industry leading selection of anti-vandal pushbuttons include design features and benefits to combat deliberate attempts to breach or pry the switch free.
- Low profile and can be mounted flush to the panel, making it more resistant to tampering than high-profile buttons.
- Panel cutout sizes ranging from 6mm to 40mm in diameter; many options for popular sizes (16mm, 19mm, 22mm).
- Mounting panel thickness typically from 1-8mm, but thicker panels provide more robust protection.
- Body and actuator finish options include polished or brushed stainless steel, black anodized, nickel or gold.
- LED illumination potential for visual feedback, including RGB and custom markings
EXAMPLE: PV1 Series Anti-Vandal Switch
- 19mm diameter panel cutout
- IP65 rated environmental protection
- Numerous body and actuator finish options
- Electrical Rating: 2A, 36VDC
- -40°C to +85°C operating temperature
- Solder, screw or wire leads (300mm long) termination
Sealed Protection Against Moisture, Dust and Physical Objects
VIEW: Complete Selection of Sealed E-Switch Products
READ: Best Sealed Switches Across Product Types
The sealed feature can be crucial because it protects the internal switch components from dust, moisture, chemicals and other contaminants. This is especially important in harsh environments like industrial plants, outdoor equipment, medical devices and marine applications, where exposure can lead to corrosion, short circuits or mechanical failure. Sealing also enhances reliability and longevity, reduces maintenance needs and ensures consistent performance under extreme conditions.
The IP Rating Chart (Ingress Protection), also known as the IP Code, is a standardized system used to classify and rate the degree of protection provided by an electrical enclosure or electronic device against the intrusion of solids and liquids.
Common IP Ratings for Switches:
- IP40 – Many tactile switches fall within this rating, where there is protection from solid objects larger than 1mm.
- IP54 – Typically referred to as “weather resistant,” meaning it is resistant to rain but not a soaking with a hose.
- IP65 – Same as above, but can actually protect against a water hose.
- IP66 – Protected against strong jets of water.
- IP67 – Protected against temporary immersion in water less than one meter deep.
- IP68 – Protected against long periods of immersion under pressure.
EXAMPLE: ST4 Series Toggle Switch
- IP68 rated protection against moisture and dust
- 12mm diameter panel cutout
- Quick connect, solder, screw or wire leads
- SP or DP; two or three positions
- Power rated up to 20A, 125VAC/30VDC (UL listed)
Power Rated for Controlling High Voltages and Currents
VIEW: Complete Selection of Power Rated E-Switch Products
READ: Power Rated Switch Products for Demanding Applications
Sometimes a simple, hard control of voltage and current is needed. For these situations, a power rated switch can provide safe control of voltages and current with high reliability. These types of switches excel in hostile industrial environments, where they’re typically able to withstand robust operating temperatures while offering contact resistance capable of minimizing heat at high voltages.
Power ratings define the maximum voltage and current the switch can safely handle without overheating, arcing or failing. Using a switch beyond its rated power can lead to electrical damage or reduced lifespan. Proper power ratings ensure safe, reliable operation and help match the switch to the specific demands of the electrical circuit or device it’s controlling.
EXAMPLE: PVHC4 Series Anti-Vandal Switch
- Electrical Rating: 20A, 250VAC; 25A, 30VDC
- Contact Resistance: 100mΩ Max.
- Illuminated option with ring or ring/power symbol LED
- 19mm diameter panel cutout (PVHC7 offers 22mm)
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