A switch is an electrical component that controls the flow of electricity through a circuit, via a manually controlled mechanical lever. Although switches are produced in several varieties, in their simplest form they effect the turning on or off of any circuit that is connected to them. Usually, switches are installed in devices in which there is a lack of mechanisms for regulating additional operations. For example, you can install a switch in a car to operate a non-stock lighting system. Follow the steps in this article to get started installing your switch!
Steps
Part 1 of 3: Install the Switch in the Panel of your Device
Step 1. Disconnect all power sources before starting
As with any electrical work, it is extremely important to make sure there is no risk of shock before starting work. Trying to work on a device connected to the mains is an easy way to seriously injure yourself or to cause a short circuit and irreparably damage the device.
The precise method of disconnecting the device from the electricity source depends on the device itself. For cars, for example, you will have to disconnect the negative pole of the battery, while for other devices you will have to unplug or manually disconnect the electrical supply in some other way
Step 2. Remove the electrical panel or housing from the device
To install a switch you must have access to the internal wires, which requires removing the external electrical panel. If possible, instead of removing the entire panel, try removing only the part where you plan to install the switch.
- For example, if you want to install a switch in your car, you will need to remove the dashboard. If possible, try to remove only part of it.
- To do this, you will need screwdrivers, case opener bars, dash openers and other special tools.
Step 3. Measure the diameter of the switch mouth that will protrude from the panel
To house the switch, you will need to create a hole of the appropriate size and shape in the panel or electrical housing of the device. For common switches, this will be a circular hole, although depending on the type of switch, the shape of the holes will vary. Measure the diameter of the mouth of the switch (the part in which the actual key is housed) so that you know how big the hole to be drilled must be.
Step 4. Drill or cut the panel to make the hole
Then create the hole to house the switch. For switches with a round mouth, it will be sufficient to create a hole with a diameter slightly larger than that of the mouth. For other types of switches, you will need to use a hacksaw, sandpaper, or other tools.
Use a super high speed steel drill bit (HSS steel) to drill a hole in wood, plastic or mild steel. A spear point may be useful, especially for wood
Step 5. Install the switch from the underside of the panel
Finally, insert the switch into the drilled hole, going through the underside of the panel. Insure the implant. This usually means installing the frame over the hole, passing the switch through, and tightening it with a nut.
For example, when preparing common switches, you will need to insert a nut into the mouth of the switch to secure it to the panel, and then tighten it with an adjustable wrench
Part 2 of 3: Connect the switch to the Device System
Step 1. Always follow the instructions provided with your device switch
The types of devices on which you will be able to install a switch vary considerably. So a single guide will not be able to provide you with suitable solutions for everything. The instructions in this section should be considered as a general guide for a common ON-OFF switch. Never leave out any instructions for installing the switch that comes with your device.
If in doubt, consult a good electrician to save time and avoid accidental damage
Step 2. Cut the wire that came with your device
For a common ON-OFF switch, you will need to connect the latter to the electrical source of the device. Use pliers to cut the wires in a place that will allow you to connect one or both ends of the wire to the switch. Tear off approximately 1.3 cm of insulation material from each end of the cable using special pliers.
Step 3. If one or both ends of the wire don't reach the switch, use a braid
The braid is a small piece of cable (about 15 cm) with both ends uncovered. It can be connected to wires that are not long enough to reach the switch, as if it were a kind of "extension". Add the braid as follows:
- Calculate the gauge of the existing wire and get a black wire of the same gauge.
- Cut a piece of black wire long enough to reach the cut end of the wire that came with the switch.
- Uncover about 1.3 cm of insulation material from both ends of this piece of wire.
- Connect one end of the braid to the wire provided by twisting the ends of both wires clockwise. Turn a nut of the appropriate size clockwise on the wire splice until it is snug.
Step 4. Connect the supplied wire to the switch
At this point, you have created a range in the wire provided by your device. You will then need to put the switch in the range so that it can regulate the flow of electricity through the circuit. How you do this depends on the type of switch you will need to install. Read below:
- If the switch has guide wires, twist each guide to one of the supplied wires (or braid) and turn a nut on the connection until tight.
- If the ends of the switch are to be fixed in housings with screws, loosen the screws at the ends, form a loop with the wires and hook each loop at the end with the screw so that each loop fastens around the axis of each screw. Then tighten the screws in the slots.
- If the switch has tin connections, bend the ends of the wires around the switch terminals. Pointed pliers may be useful. Heat each terminal with a soldering iron while holding the solder wire in contact with the terminal (but not in direct contact with the soldering iron tip). When the solder begins to melt, pull off the tip of the soldering iron and allow the molten solder to flow and cover the joint of the wire.
Step 5. Test the switch
When the switch is well connected, carefully reconnect the device to the power supply, and test the functionality of the switch. If it works as it should, you can reinstall the electrical panel or housing. Congratulations! You have successfully installed a switch.
Part 3 of 3: Buy the right Switch for your Device
Step 1. Choose a switch with the appropriate number of "poles" and "ways" for your intent
In electrical terminology, a switch can have one or more "poles" and "ways". By "poles" is meant the number of circuits controlled by the switch. Usually, this is the number of "levers" visible on the outside of the switch. By "ways" we mean the number of positions that a switch can take. Usually, for a common ON-OFF switch, you will need only one pole and one way.
- However, if the device you're connecting the switch to needs more control than the common ON-OFF function, you'll need a more complex switch. For example, if you are installing a switch to control the car's hydraulic system, you will probably need a multi-pole switch to control the hydraulic circuits on different sides of the car and with multiple ways, to keep the circuit off and to adjust the degrees of operation once it is switched on, rather than simply switching it on and off.
- Note that there are some differences in common switch terminology. Sometimes a switch can be called "two way", while in other contexts it can be called "one way".
Step 2. Choose a switch that can handle more flow (in Amperes) than the flow that will pass through the circuit
Different devices require different amounts of electrical energy to function. When looking for breakers, make sure the breaker charge is equal to or greater than that of the circuit you will need to connect it to.
Step 3. Choose a switch that has the right type of electrical connections for your project
Your switch will be useless if it cannot connect to the device it has to operate on. So make sure you choose a switch that is compatible with the electrical connections inside your device. If you can't, you will have to make improvised connections with a soldering iron, electrical tape, etc., a difficult job for the inexperienced. Together with the common switches you can find:
- Screw connectors.
- Tin nuts, tips or terminals.
- Thread guides.
Step 4. Choose a suitable facility
If your device includes spaces specifically designed to install a switch, you may be able to finish the job without having to make any changes to the device itself. However, there are usually no such configurations. Expect, therefore, to have to drill holes for the switch and to install a structure that can hold it.
