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I am building funhouse type cars that are powered by a 1200 watt electric motor that is rated at 32 amps. I want to install a roller switch that will turn the car off when it comes into the loading dock and turn it back on when the car is shoved into the ride. All the roller switches I have found are 15 amps max. What is the safest, cheapest way to do this?
And got the following answer:
Use the roller switch to open/close a relay. Select a single-pole relay with at least a 32A contact rating, and a coil voltage approximately equal to the car battery voltage. www.digikey.com is one source. [REPOST] The poster below me is incorrect. You do not use a 15A switch for a 32A circuit, even if the voltage rating of the switch is 5 times higher than your app. The voltage rating of a switch is primarily according to the voltage it can stand off in the open postition, and secondarily, how robustly the contacts can handle inevitable arcing upon opening. The current rating is according to the contact resistance relative to power handling capability in the closed position, and since the switch is in the closed position, it doesn't matter what the voltage was across it when it was open, the small voltage across it closed will be only a factor of the current through it. So definitely use a relay, unless you want to be replacing switches every few weeks. In fact, if the relay is to be opened under full motor load, you may need some sort of snubbing across the contacts and high-wattage zeners across the motor to prevent premature failure of the relay contacts. Inductance like in your motors has the property of resisting a change in current by building up a high voltage, potentially much higher than your battery voltage. Email me if you need more details.