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How to wire safety switch
Safety switches are used to cut power to equipment such as HVAC, lathe, compressor etc
There are two types of safety switches: Fused and Non-fused
Outdoor safety switch
Non-fused safety switch
Cuts power to both legs of 240V circuit.
Rated for outdoor.
-3 Hp motor, 17 amps, use 30-60 amp safety switch
-30 amp water heater, use 30-60 amp
Buy from my affiliate links: $44
2-pole outdoor / 60 amp/ non-fusable
2-pole outdoor / 60 amp/ non-fusable
2-pole outdoor / 30 amp/ non-fusable
Heavy duty safety switches at Amazon
non-fusable pull out
Non-fused/ Pull out disconnect
Cuts power to both legs of 240V circuit.
Code for AC units
Rated for outdoor
2-finger pull-out cuts power to both legs of 240V circuit.
No fuse.
Buy $12-20
2 pole/ outdoor/ 30 amp/ non-fusable
2 pole/ outdoor/ 60 amp/ non-fusable
2-pole/ 60 amp w 20 amp GFCI outlet
Pullout Disconnects at Amazon
Rotary disconnect
Wiring
600 volt motor switch
30 amp DPST toggle switch
Cuts power to both legs of 240V circuit.
Motor cut-off switch
30 amp/ max 600 volt

Buy:
30 amp DPST switch
Leviton 30 amp DPST
3-pole 3-phase motor starter
Motor starter switch and cover

Resources:
Figure volts amps watts
Figure breaker and wire size
Lever switch
Lever switch
Install over top of motor switch
Never touch the switch


-Use with single-pole, double-pole, 3PST, 3-way, 4-way switches etc

Buy:
Lever switch
Single-gang lever switch
30 amp safety cut off
fusable safety switch
OK to have more than one fuse on same line.
If you have circuit breaker, then it is ok to install fusable safety switch -or- non-fused
Always match fuse amp rating to load amps.
Buy: $22-35
2-pole indoor / 30 amp/ fusable
2-pole indoor / 30 amp/ fusable
2-pole indoor / 30 amp/ fusable
Safety switches at Amazon
Resource:
Match wire and breaker size
outdoor 30 amp fusible safety switch
fusable safety switch
Buy: $45-65
2 pole/ outdoor/ 30 amp/ fusable
2 pole/ outdoor/ 30 amp/ fusable

Resources:
Figure volts amps watts
Figure breaker and wire size
Safety switches at Amazon
fusible pull-out
Manual pullout/ fused
No switch lever
Manual pull-out disconnect
Buy: $25-35
2 pole/ outdoor/ 60 amp/ fusable
Case of 10 / 30 amp fusable
2 pole/ outdoor/ 30-60 amp/ fusable
Pullout Disconnects at Amazon
60 amp safety switch
fusable safety switch
Buy: $55-120
2-pole / 30 amp heavy-duty
2-pole/ indoor / 60 amp/ fusable
2-pole/ outdoor/ 60 amp/ fusable
2-pole/ indoor/ 100 amp / fusable
Safety switches at Amazon
3-pole non-fusible safety switch
Outdoor
3-pole 600 volt non-fusable safety switch
Heavy duty 600 volt

Buy:$135-350
3-pole/ outdoor/ 30 amp/ non-fusable
3-pole/ outdoor/ 60 amp/ non-fusable
3-pole/ outdoor/ 100 amp/ non-fusable
Safety switches at Amazon
Heavy duty safety switches at Amazon
Resource:
Leviton safety switch/ pdf
3-pole 30 amp outdoor safety switch
Outdoor
3-pole 240 volt non-fusable safety switch

Buy:$75
3-pole/ outdoor/ 30 amp/ non-fusable
3-pole/ outdoor/ 30 amp/ non-fusable
Safety switches at Amazon
3-pole 100 amp indoor safety switch
Indoor
3-pole 240 volt non-fusable safety switch

Buy:$45-130
3-pole/ indoor/ 30 amp/ non-fusable
3-pole/ indoor/ 30 amp/ non-fusable
3-pole/ indoor/ 30 amp/ non-fusable
3-pole/ outdoor/ 60 amp/ non-fusable
3-pole/ 600 volt/ 60 amp/ non-fusable
600 volt 3-phase motor switch
3-phase 30 amp 3PST toggle switch

3PST = 3 pole single throw
3-pole safety switches are 3PST
Rated 30 amp/ max 600 volt
3-phase Motor cut-off switch
Power can connect to either side
Match phase to phase on screw located on opposite side
Buy:
3-pole 3-phase motor starter
3-pole 100 amp indoor safety switch
Indoor
3-pole 240 volt fusable safety switch

Buy: $125
2-pole indoor / 100 amp/ fusable
Safety switches at Amazon

Indoor
3-pole 240 volt fusable safety switch

Buy:$49-145
3-pole/ indoor/ 30 amp/ fusable
3-pole/ indoor/ 60 amp/ fusable
3-pole/ indoor/ 60 amp/ fusable
Safety switches at Amazon
3-pole non-fusible safety switch
Outdoor
3-pole 240 volt fusable safety switch

Buy:$77-135
3-pole/ outdoor/ 30 amp fusable
3-pole/ outdoor/ 30 amp fusable
3-pole/ outdoor/ 60 amp/ fusable
DC safety switch
Non-fusable
DC safety switch 250 Volt
DC safety switch outdoor

Buy: $135
3-pole / outdoor/ 30 amp DC/ non-fuse
30 amp DC 240 volt outdoor
DC safety switch
fusable
DC safety switch 250 Volt
DC safety switch indoor

Buy: $335
3-pole / outdoor/ 30 amp DC/ fusable
AC current is different than DC
AC current reverses direction once each 50-60 seconds because of how AC power is generated. Read more
When AC changes direction, the voltage drops to zero 50-60 times each second.
When voltage drops to zero, the arc is easy to extinguish using AC-rated switches.

DC power is different.
Generally, for this explanation, DC stays at the same voltage at all times.
DC never drops to zero volts like AC.
When you want to switch off DC, there is a larger arc, that is more difficult to extinguish.
Basically the electrons in DC power keep pushing forward at all times.
This forward motion of DC electrons maintains the arc longer, and can cause damage to electrical equipment that is not rated for DC
Rated 250 volt DC
Square D 60 amp DC H222AWK
Square D 30 amp DC HU361RB
30 amp safety cut off     30 amp DC safety switch 30-Amp 120-240-volt Two-Pole Indoor Safety Switch with Neutral/ fusable
Safety switch is important.
Often the circuit breaker panel is locked, or located remotely.
Safety switch, or power cut-off, is installed next to air conditioner, or water heater, or other appliance.
Code often requires fused or unfused safety cut off next to air conditioner or any outdoor appliance
When safety switch is OFF, person is more certain power is OFF.
ALWAYS check if power is actually off before working on appliance.  
NEVER stand on bare ground when touching electrical device... stand on dry boards until power is OFF for certain.

Buy from my affiliate links
2-pole 30 amp non-fusable safety switch/ indoor / power cut-off
2 pole 60 amp non-fusable / outdoor box/ at Amazon
Safety switches at Amazon
Safety switches for power tools

Resource:
You can use fusable or non-fusable
Having more than one fuse on same line is ok by code
power tool safety switch Paddle switch/ safety switch for power tools
Raise red cover before tool can be activated.
Quick shut-off by pushing down red lever

Buy:
Safety switches for power tools
Rotary disconnect


Never assume power is OFF: Use Non-contact voltage tester
Test for power without touching wire
NEVER assume power is OFF
Press button. tester beeps once, and blinks once, when power is OFF.
Tester beeps continually and blinks when power is ON
Buy:

Non-contact voltage tester Amazon
Electric testers at Amazon
Multimeter
Test for breaks in wire/ Test for short circuit/ Test for voltage/ Test if voltage is present
Most appliance require 80% rated voltage to function correctly
Tape tester leads to wood sticks to keep hands away from power.
Never stand on wet or damp surface
Never stand on bare soil... or ground
Always stand on dry boards
Remove metal from pockets, do not lean into or touch anything made of metal
Buy here and support DIY:
Multimeters at Amazon
Electric testers at Amazon
How to wire safety switch
Larger image
30 amp DC safety switch   30 amp DC safety switch 30-60 amp DC safety switch/ fusable/ outdoor
Heavy Duty 250 V Dc Voltage; 60 Ampere
Use 10 gauge wire with 30 amp fuse
Use 6 gauge wire with 60 amp fuse
Buy:
Square D 60 amp DC H222AWK
Square D 30 amp DC HU361RB
30 amp DC 240 volt 600 Volt
3-pole safety switch
Larger image
3-pole safety switch
Example shows fusable/ this is called a 4-wire, but only 3 wires are disconnected by safety switch
It is OK to have breaker and fuse on same line.
More than 1 fuse, and more than 1 breaker on same line is OK.
If load has breaker it is not necessary to use fusable safety switch. You can use non-fused safety switch.

Disconnect rating must be at least 125% of the ampere load...and within sight of the unit...and with ability to lock in open (off) position
If load is 30 amp, then buy safety switch rated for 30 x 125% = 45 amp, so buy safety switch rated for 60 amp
If load is 2o amp, then buy safety switch rated for 25 amp, so buy safety switch rated for 30 amp.
The rating on the safety switch is MAXIMUM amp rating... 60 amp safety switch will handle loads up to 60 amp.

Fuse must match Load.
Always install fuse that is rated same as amp load.
If load is 30 amp, then install 30 amp fuse and 10 gauge wire.
If load is 20 amp, then install 20 amp fuse and 12 gauge wire

Carefully label safety switch

Buy:
3-pole/ indoor/ 60 amp/ fusable
3-pole 30 amp safety switch/ fusable/ at Amazon
3-pole 60 amp safety switch/ non-fused/ at Amazon
3-pole 60 amp safety switch/ fusable/ at Amazon

Resources:
Match wire and breaker size
Figure volts amps watts for water heater
How to wire 3-phase
What is 3-phase
review techluck
Larger image
Example 3-pole safety switch application

disconnect...at least 125% of the ampere load...within sight of the unit...and with ability to lock in open (off) position
Two different voltages arrive at water heater
Household 240 Volt AC power feeds upper element, with 2 hot wires
120 Volt AC from Solar panels feeds lower element, with Hot and neutral
Total 3 hot wires.... use 3-pole safety switch
Carefully label safety switches so people know both switches must be turned off for water heater to be OFF

Buy:
3-pole 30 amp safety switch/ fusable/ at Amazon
3-pole 60 amp safety switch/ non-fused/ at Amazon
3-pole 60 amp safety switch/ fusable/ at Amazon

Resource:
Review Techluck
PV safety switch Example DC safety switch for solar array
Use fused or non-fused
This is one way to use safety switch
Purpose of safety switch is to ensure all power is OFF
The handle is clearly visible and can be latched in place
Locate safety switch in plain sight so people can clearly identity when power is OFF
Remember, a solar panel will produce electricity each time it is exposed to light.
You can get shock from solar panel when panel is exposed to sun.
The array and safety switch must be wired at night

The strings can be combined before connecting to safety switch... match total volts and amps with safety switch rating and with fuse rating
When three panels are wired together, the positive wire connects to negative wire to make a string.
Solar panels are like batteries.
When three panels are connected in series, or in a string, then voltage increases with each additional panel, but amperage stays the same.
Illustration shows 3 strings with 3 panels in each string.
If the strings are combined together in parallel, then the voltage stays the same but amperage increases.
Maximum voltage for wire and safety switch is 600 volts AC/ 300 volt DC

Resources:

Calculate volts and amps for array/ How to set up array
DC safety switch wiring/ pdf

Schneider safety switch wiring for DC/ pdf
Schneider safety switches/ pdf
4-pole DC breaker Example DC safety switch for solar array
Use fused or non-fused
Wired in series..
DC + side is routed through 3 cut-off
DC - side is routed through 1 cut off
Safety switch hub Safety switch hub
Installing subpanel Resources:
How to wire subpanel
See inside main breaker box
What is 3-phase electric: power plant to end user
How to wire 3-phase timer
Light duty/ AC and DC
How to wire safety switch
How to wire safety switch
How to wire safety switch
How to wire safety switch
Heavy duty/ AC and DC
How to wire safety switch
How to wire safety switch
How to wire safety switch
How to wire safety switch
Class R fuses 600 volt AC @ 30 amp fuse/ 300 volt DC @ 15 amp
600 volt AC  @ 600 amp/ 120 volt DC @ 60 amp
6000 volt AC @ 6000 amp/ 300 volt DC 2000 amp
Time delay fuse passes surge currents without sacrifice short circuit limitation
Buy
Class R fuses at Amazon
Bussman LPN-RK-SP heavy amp AC-DC fuses at Amazon
Bussman 600 Vac @ 200 amp/ 300 Vdc @ 100 amp/  at Amazon
Bussman 250VAC/250VDC @ 25 amp
30 amp Cartridge fuse
Bussman fuses at Amazon

Resource:
Bussman fuses/ pdf
Use 10 gauge wire with 30 amp fuse
Use 6 gauge wire with 60 amp fuse

Resource:
Match wire and amp rating
Class R fuses Bussman DC fuses
Buy
60 amp DC cartridge fuse
50 amp DC cartridge fuse
40 amp DC cartridge fuse
35 amp DC cartridge fuse
30 amp DC cartridge fuse
25 amp DC cartridge fuse
20 amp DC cartridge fuse

70 amp DC cartridge fuse
90 amp DC cartridge fuse
80 amp DC cartridge fuse
125 amp DC cartridge fuse
150 amp DC cartridge fuse
175 amp DC cartridge fuse
200 amp DC cartridge fuse
225 amp DC cartridge fuse
250 amp DC cartridge fuse
300 amp DC cartridge fuse
350 amp DC cartridge fuse
600 amp DC cartridge fuse

Resources:
DC safety switches
photovoltaic fuseholder Photovoltaic fuseholder/ DC fuseholder/ rated 1000 volts DC/
Not waterproof... mount inside Nema 3R enclosure
Mount on din rail/ change fuse with flick of finger
Install 25-30 amp fuses
Use 10 x 38 DC fuses
Use ordinary wire size/ 20 amp and 12 gauge wire, 30 amp and 10 gauge wire

Buy
Photovoltaic fuseholder / DC fuseholder/ ultrasafe/ at Amazon
Ultrasafe fuseholders at Amazon
Fuseholder + 15 amp fuse
DC fuse pack/ $9
Buy
10 pack 1000 VDC 15 amp
100 pack 1000 VDC 15 amp
Fuseholder and 15 amp fuse

Multimeter

Test for breaks in wire/ Test for voltage
Most appliance require 80% rated voltage to function correctly
Buy
Multimeters at Amazon
Electric testers at Amazon
Resource:
How to test and replace element
How to test thermocouple
Element tests for 120 volts
How to test wire
Safety when testing wires:
Never touch wet or previously flooded appliance.
Never stand on wet surface when working on electric.
Never stand on bare soil, put down dry boards.
Tape tester leads to wood sticks to keep hands away from power.
Use non-contact voltage tester before touching wires.
Never touch or lean into any made of metal.
Remove metal objects from pockets.
Do not use oxygen or fuel accelerants in same room as electrical repairs

Resource:
Basic house wiring

Non-contact voltage tester

Test for power without touching connectors
NEVER assume power is OFF
Buy:
Non-contact voltage tester Amazon
Electric testers at Amazon
Resource:
How to test electric power is off
wire connector assortment

Twist-on wire connector assortments

Do not reuse old connectors
Buy:
Connector assortment at Amazon
Connector assortment at Amazon
Resource
How to select and install twist-on wire connectors
Weatherproof wire connector

Weatherproof wire connector

Connector cavity is full of silicone
Built-in cover keeps silicone in place
Protect from water, dust etc
Buy from my affiliate links
Weatherproof size 14 to 6 Amazon
Weatherproof size 22 to 8 Amazon

Resource
How to select and install connectors
Wire connector wrench
Wrench to apply wire connectors
Tighten connector

Buy:
Wire connector blaster
Twist connector wrenches at Amazon

Resources:
How to twist wire
How to select and install twist-on wire connectors

Buy:
Blue for 16-14 wire
Yellow for 12-10 wire

Resource:
How to install terminals
Treminals

Terminals

Buy:
Terminal kit
Blue for 16-14 wire
Yellow for 12-10 wire
Push on wire connectors

Push-on wire connectors in place of twist-on connectors

Buy:
Push on wire connectors Amazon
Red 3P connector for 10-14 gauge wire
Lever connectors for stranded wire at Amazon
remove cable staple
Buy
End cutting nippers at Amazon

 
linesman pliers
When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point.
Buy tools:
Wire strippers at Amazon
Linesman pliers
Utility knife at Amazon
End cutting nippers at Amazon

Use solid copper wire
Fire inside timer caused by stranded wire
Keep enclosure door closed at all times
Buy:
soldering guns
Resource

Timer caught fire

Contactors/ relays
Type 1 and type 2 surge protection surge protection
Programmable timers

Woods timers
surge protection
Buy
Electronic parts

Industrial supplies

Tools and home improvement

Home and garden

Hayward pool
Pentair pool

Southwire electric
Buy
Tools

DEWALT
Black and Decker
Stanley
SKIL
Makita
Porter-Cable
Bosch

Irwin Hand tools
Klein hand tools
Fluke electrical testing
Dremel hobby tools

Campbell Hausfeld air powered
Tekton automotive

Powerbuilt automotive
Saws and saw blades
box timers Resource:
Compare box timers
DPDT timers
Intermatic
Control water heater w/ Z-wave
Intermatic control centers Resource:
Intermatic control centers: and parts
Digital control centers and parts
Tork control centers and parts
Subpanels
All control centers and parts
Enclosures
programmable timer Resource:
Programmable timers
Countdown timers
Off delay timers
On delay timers
Timer modules
Din rail
Twin & one-shot
Woods
Intermatic
Tork
Low voltage power packs Recirculation systems
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