Specifications are subject to change. Please refer to the current datasheet on www.grayhill.com for the most current published specifications for this product.
Single Deck Rotary Switches
SERIES 56
0.5" Diameter, 200mA,
.355" Behind Panel
FEATURES
• Requires Minimum Distance Behind
the Panel
• Adjustable Stop Types Provide
Prototypes Immediately
• Industrial Quality, Economically
Priced
• RoHS Compliant
DIMENSIONS
in inches (and millimeters)
PC Mount Style
A
.500
Ø
± .015
(12,70
± 0,25)
POS. 1
.250 ± .015
(6,35 ± 0,38)
.375 ± .015
(9,53 ± 0,38)
.377
± .020
(9,58
± 0,51)
PC TERMINAL DETAIL
.110 ± .015
(2,79 ± 0,38)
.110
± .015
(2,79
± 0,38)
.250 ± .015
(6,35 ± 0,38)
Ø .125 ± .002
(3,18 ± 0,06)
GRAYHILL
2 1 10 9
.203 ± .003
(5,16 ± 0,08)
ACROSS
BUSHING
FLATS
.016 ± .004
(0,4 ± 0,10)
.016 ± .004 SQ.
(0,4 ± 0,10)
FOR REAR
VIEWS, SEE
FOLLOWING
PAGE.
.046 ± .004
(1,2 ± 0,10)
PC COMMON
Rotary Switches
.110 ± .015
(2,79 ± 0,38)
1/4-28 UNF-2A
THREAD
.094 ± .010
(2,39 ± 0,25)
Ø .025 ± .002
(0,64 ± 0,05)
ANGLE OF ANGLE
THROW
A
30° 105°
36°
108°
Grayhill part number and date code marked on label.
Customer part number marked on request.
Solder Lug Style
A
.500
Ø
± .015
(12,70
± 0,38)
POS. 1
.250 ± .015
(6,35 ± 0,38)
.375 ± .015
(9,53 ± 0,38)
30°
36°
Ø .125 ± .002
(3,18 ± 0,06)
FOR REAR
VIEWS, SEE
FOLLOWING
PAGE.
.063 ± .005
(1,60 ± 0,13)
.016 ± .004
(0,41 ± 0,10)
1/4-28 UNF-2A
THREAD
Grayhill part number and date code marked on label.
Customer part number marked on request.
Grayhill, Inc. • 561 Hillgrove Avenue • LaGrange, Illinois
.020 ± .004
(0,51 ± 0,10)
.046 ± .004
(1,17 ± 0,10)
SOLDER LUG COMMON
ANGLE
A
105°
108°
SOLDER LUG TERMINAL DETAIL
.125 ± .015
(3,18 ± 0,38)
.250 ± .015
(6,35 ± 0,38)
.094 ± .010
(2,39 ± 0,25)
ANGLE OF
THROW
.480 ± .020
(12,19 ± 0,51)
GRAYHILL
2 1 10 9
.203 ± .003
(5,16 ± 0,08)
ACROSS
BUSHING
FLATS
.125 ± .015
(3,18 ± 0,38)
Ø .062 ± .002
(1,58 ± 0,51)
60525-5997 • USA • Phone: 708-354-1040 • Fax: 708-354-2820 • www.grayhill.com
Single Deck Rotary Switches
CIRCUIT DIAGRAMS AND REAR VIEWS: PC Mountable AND Solder Lug Terminals
Circuit as Viewed From Shaft End
Rear View
.366 ± .015
(9,30 ± 0,38)
DIA. CIRCLE
OF CENTERS
.366 ± .015
(9,30 ± 0,38)
DIA. CIRCLE
OF CENTERS
.190 ± .015 (4,83 ± 0,38)
DIA. CIRCLE OF CENTERS
15°
(PC MOUNT AND
POS. 1
SOLDER LUG)
30° TYP.
COMMON LOCATION
FOR 2 POLE SWITCH
15°
POS. 1
30° TYP.
8
.190 ± .015 (4,83 ± 0,38)
DIA. CIRCLE OF CENTERS
(PC MOUNT AND
SOLDER LUG)
8
6
4
8
7
DIMENSION A
DIA. CIRCLE OF CENTERS
PC Mount
Dimension Terminals
A
.184 ± .015
(4,67 ± 0,38)
Solder Lug
Terminals
CURRENT - MILLIAMPS
100
0
0
10
20
30
CYCLES x 1000
115 Vac 0r 30 Vdc
One cycle is 360° rotation clockwise and 360°
return. The data for the curve was measured at
sea level, 25°C and 68% relative humidity with
the life limiting criteria which follows.
Contact Resistance: 100 milliohms maximum,
(15 milliohms initially).
Insulation Resistance: 10,000 Mohms
minimum between mutually insulated parts
(50,000 Mohms initially).
Voltage Breakdown: 600 Vac minimum
between mutually insulated parts at standard
atmospheric pressure.
Life Expectancy: As determined from the
load-life curve for the current to be switched.
Contact GRAYHILL for more information if any
of the following is true: the life limiting criteria are
more critical than those listed; longer operation
is required; a larger make and break current is
required; the operating environment includes
10
6
11
12
C4
1
C1
4
3
2
FOUR POLES
9
8
7
5
6
9
1
C1
4
36° Angle
of Throw
10
C2
5
2
3
2
TWO POLES
ONE POLE
elevated temperatures or reduced pressures.
Contact Carry Rating: Switch will carry 6
amperes continuously with a maximum
contact temperature rise of 20°C.
Contact Type and Forces: Shorting or nonshorting wiping contacts with over 25 grams of
contact force.
Shaft Flat Orientation: Flat opposite contacting
position of pole number one (see circuit
diagrams).
Terminals: Switches have the full circle of
terminals, regardless of number of active
positions.
Stop Strength: 7.5 lb-in. minimum
Rotational Torque: 3.5 to 9 oz-in. (25-64
mN-m), depending on the number of poles.
Bushing Mounting: Required for switches with
stops, and recommended for switches without
stops.
Operating Temperature Range (Standard
Style): -40 °C to +85 °C
Meets MIL-DTL-3786 for:
High and medium shock; Vibration (10 to 2,000
Hz); Thermal shock (-65° to 85 ° C); Salt spray;
Explosion; Stop strength (7.5 in-lbs. minimum (.85
N-m); Terminal strength; Sealed styles withstand
water pressure of 15 PSI minimum (103 KPa)
without leakage.
Grayhill, Inc. • 561 Hillgrove Avenue • LaGrange, Illinois
2
.126 ± .015
(3,20 ± 0,38)
Additional Characteristics
300
200
30° Angle
of Throw
Materials and Finishes
Housing: Zinc die cast. Tin Zinc or Sulfamate
Nickel Plated
Mounting Nut: Brass. Tin Zinc or Sulfamate
Nickel Plated
Lockwasher: Spring steel, zinc plated
Panel Seal: Silicone rubber
Shaft and Stop Arm: Machined, 303 Stainless
Steel, or Cold Formed, 430 Stainless Steel
Retaining Ring: Stainless steel
Shaft Seal: Fluorosilicone rubber
Stop Pins: Stainless steel
Detent Rotor: Molded thermoplastic
Detent Spring: Music wire
Detent Balls: Steel, nickel-plated
Contact Spring: Stainless steel
Rotor Contact: Brass or zinc alloy, silver over
nickel plate
Common Ring: Brass, gold over silver over
nickel plate
Terminals: Brass, gold over silver over nickel
plate
Recommended Panel Cutout
Ø.254
POS.1
.208
60525-5997 • USA • Phone: 708-354-1040 • Fax: 708-354-2820 • www.grayhill.com
Rotary Switches
Chart shown for non-shorting (break before make)
contacts, resistive load.
9
C2
5
1
3
3
4
C3
7
2
6
SPECIFICATIONS
Electrical Ratings (Tested at Room
Temperature)
8
10
4
36° TYP.
COMMON LOCATION
FOR 1 POLE SWITCH
1
TWO POLES
.340 ± .015
(8,64 ± 0,38) DIA.
CIRCLE OF CENTERS
COMMON LOCATION
FOR 2 POLE SWITCH
6
ONE POLE
1
3
11
12
5
12
C1
10
7
11
C2
5
POS. 1
10
7
COMMON LOCATION
FOR 1 POLE SWITCH
18°
9
9
Single Deck Rotary Switches
SHAFT AND PANEL SEAL: Style S
Panel is sealed by a flat rubber seal washer at the base of
bushing. Shaft is sealed by an
O-ring inside the bushing. After
the switch is mounted, seals do
not alter the dimensions of the
unsealed style.
Shaft and
Panel Seal
SCREWDRIVER SLOTTED SHAFT: Option
Series 56 rotary switches are
available with a screwdriver
slotted shaft with dimensions as
shown. Available in the styles,
angles of throw and pole/positions combinations shown in
the choice and limitations chart.
Screwdriver
Slotted Shaft
ADJUSTABLE STOP SWITCHES
Rotary Switches
Two stop pins and an adhesive backed sticker or
seal washer are provided. Sticker is temporarily
removed to locate stop pins as desired to limit
Adjustable
Stop
the shaft rotation. All dimensions are identical
to the fixed stop switch counterpart.
ACCESSORY: Non-Turn Washer
In Inches (and millimeters)
ADJUSTABLE
STOP PINS
ADJUSTABLE
STOP PINS
REMOVABLE
STICKER FOR
ADJUSTMENT
OF STOPS
REMOVABLE
SEAL WASHER
FOR ADJUSTMENT
OF STOPS
.400
± .005
DIA.
(10,16
± 0,13)
.250 ± .003
(6,35 ± 0,08)
.060 ± .001
(1,52 ± 0,25)
SUGGESTED ADJUSTABLE STOP SUBSTITUTION GUIDE
Fixed Stop
Style
56A
56S
56P
56SP
Adjustable Stop
Style Equivalent
56D
56SD
56DP
56SDP
Fixed Stop
Style
Adjustable Stop
Style Equivalent
56B
56BS
56BP
56BSP
Grayhill, Inc. • 561 Hillgrove Avenue • LaGrange, Illinois
56BD
56BSD
56BDP
56BSDP
.025
± .001
(0,64
± 0,03)
90° ± 1°
.015
(0,38)
RADIUS
MAX.
.125
± .005
(3,16
± 0,13)
Part No. 50J1066
Cut round hole for the bushing and for
the non-turn tab. Washer fits the double
D bushing flats. Washer is sold only when
accompanied by an order for a like number
of switches. Washer is 302 stainless steel.
60525-5997 • USA • Phone: 708-354-1040 • Fax: 708-354-2820 • www.grayhill.com
Single Deck Rotary Switches
CHOICES AND LIMITATIONS: Series 56
A = Standard, 1/8" Shaft
B = Screwdriver Slot Shaft
D = Adjustable Stop (Adj. Stop)
Style
Designation
Solder Lug
Terminals
A
X
S
X
P = PC Mount Terminals
S = Shaft/Panel Seal (S/P Seal)
FEATURES
PC Mount Shaft/Panel
Seal
Terminals
X
SP
X
X
1
Screwdriver
Slotted Shaft
Equivalent
Angle
Number
Of
Of
Throw Poles
Number Of
Positions
Per Pole
Shorting Or
Non-Shorting
Contacts
B
X
P
SD
Adjustable
Stops1
X
DP
X
SDP
X
BS
BP
X
1
2
4
02 thru 12
02 thru 06
02 or 03
N or S
N or S
N or S
36°
1
2
02 thru 10
02 thru 05
N or S
N or S
BSPD
X
BD
X
X
BSD
X
BDP
X
BSDP
X
30°
Adjustable stop versions allow selection of 2 positions to the maximum number of positions per pole.
STANDARD OPTIONS
Available from your local Grayhill Distributor
For prices and discounts, contact a local Sales
Office, an authorized local Distributor, or Grayhill.
Not available thru Distributors when Intermixing
of shorting and non-shorting contacts. Contact
Grayhill.
ORDERING INFORMATION
56A36S–01–1–10N–F
Stop Arrangement: The suffix C or F must be added to a one
pole per deck switch with the maximum number of positions to
indicate continuous rotation (C) or fixed stops (F) between position 1 and the last position.
Type of Contacts: N = Non-shorting, S = Shorting
Positions Per Pole: 02 as a minimum to the maximum
allowable for the angle of throw and number of poles per the
Choices Chart. Use the letters AJ in this location if adjustable
stop switch is to be ordered.
Poles per Deck: Limited by angle of throw. See chart
Number of Decks: 01 only
Shafts: S= Machined, Blank= Cold Formed
60525-5997 • USA • Phone: 708-354-1040 • Fax: 708-354-2820 • www.grayhill.com
Rotary Switches
Grayhill, Inc. • 561 Hillgrove Avenue • LaGrange, Illinois
Series
Style: Letters from Choices Chart
Angle of Throw: 30 or 36°
Adjustable Stop Rotary Switches
Features
• Quick Route to Rotary Switches
• For Prototypes and
Small Production Runs
Series
50/51
Series
42/44
Series
56
Series
71
BEST AVAILABILITY
The Problem
Procurement lead time on rotary switches for
prototypes and small production runs can be long.
This is often a source of headache for design
engineers and production control managers.
Grayhill makes more than 300,000 combinations
of rotary switch styles; number of decks, poles
per deck, positions per pole, military qualified
or commercial grade, etc. This wide variety
makes it impractical for either distributors or
manufacturers to stock completed switches.
Consequently, even small quantities must be
built to order.
The Solution
Grayhill Electronic Distributors can supply a wide
variety of rotary switches with Adjustable Stops.
This feature gives you a switch immediately
with exactly the electrical properties you need.
These Adjustable Stop switches have the basic
mechanical characteristics of their fixed stop
counterparts. To get the right number of positions
per pole for your application, simply adjust the
stop washers or stop pins.
By stocking a few switches, the Distributor
provides over 100,000 possible combinations of
switches. This includes the popular styles, sizes,
angles of throw, number of decks, poles per
deck, positions per pole, and types of contacts.
Availability of these switches through Distributors
speeds prototype development time. There is no
time lag in waiting for factory made samples.
The Substitution
Writing an equivalent part number is easy. To
obtain an adjustable-stop equivalent to a fixedstop rotary switch you must substitute style
letters and possibly series number. Then replace
the positions-per-pole number in the fixed-stop
number with the letters AJ. See the examples
for the scheme.
series, style and angle of throw as well as
the adjustable stop rotary switch series, style
and angle of throw. Then the letters AJ in the
positions-per-pole location, gives you the part
number of the equivalent.
Suppliers
Distributors can supply 1 and 2-deck adjustablestop switches from stock (one or two poles
per deck). They can also quickly secure other
variations from factory stock. Reduce prototype
development time. Use Grayhill Adjustable
Stop Rotary Switches for all of your prototype
requirements.
These electronic distributors also maintain a
representative stock of Grayhill products. Local
availability can often “save the day”, and simplify
your paperwork.
When adjustable equivalents apply, the rotary
switch pages will indicate the substitutions.
A chart will show the fixed stop rotary switch
Fixed Stop Rotary Switch
Adjustable Stop Equivalent
Series
Style
Angle of Throw
No. of Decks
Poles/Deck
Positions/Pole
Type of Contacts
N = Non-Shorting
S = Shorting
42A36-01-1-07N
www.grayhill.com
Series
Style
Angle of Throw
No. of Decks
Poles/Deck
Positions/Pole
Type of Contacts
N = Non-Shorting
S = Shorting
42D36-01-1-AJN
Bulletin 1221
Rev 04/14
Rotary Switch Engineering Information
Catalog Ratings
Are catalog ratings misleading? In most cases,
yes. Load and life ratings shown in most catalogs
are usually invalid for most applications. This
results from the complex interplay of such factors
as environment, duty cycle, life limiting or failure
criteria, actual load, etc. Circuit designers should
be aware of these factors, and the effect they have
on the useful life of the switch in their applications.
The problem of switch rating arises from the wide
variety of requirements placed on the switch. This
includes various applications, and the sensitivity
of the switch to a change in requirements. If we
attempted to establish life ratings for all possible
applications, we would have an almost infinite
variety of ratings.
To simplify the problem, switch manufacturers,
switch users, and the military, have established
certain references for ratings. These include
loads, life requirements, environments, duty
cycles, and failure criteria. These references
are arbitrarily established. But, they allow you to
compare different switch designs. They do not,
however, match the actual requirements for most
applications.
The curves shown here are an example of some
of the life load curves. These curves are life load
characteristics of the Grayhill 42M and 44M
switches. Note that the curves consider only two
voltage sources and two types of loads. These
voltages and loads are, however, considered as
standards for testing procedures by the industry.
Curve data is based on tests conducted at
sea level, 25°C and 68% relative humidity.
Cycle = 360° rotation and return. Cycling rate
is 10 cycles per minute. Switch rating is for
non-shorting contacts.
CURRENT (AMPS)
7
6
5
VOLTAGE 115 VAC
RESISTIVE
4
3
2
1
0
0
10
25
50
CYCLES x 1,000
CURRENT (AMPS)
1.7
1.5
VOLTAGE 30 VDC
RESISTIVE
1.2
1.0
.75
INDUCTIVE
(2.8 HENRIES)
.50
.20
0
0
10
25
50
CYCLES x 1,000
www.grayhill.com
These curves allow you to predict the expected life
of the switch once you know the voltage, current
and type of load. Also note that each cycle is
approximately a 360° rotation and a return. For a
ten position switch this would be a rotation from
position 1 to position 10 and back to 1. This cycle
runs approximately ten times a minute. Thus testing
causes more electrical and mechanical wear than
what the switch incurs in actual use.
Summary
The life and load ratings in this and other catalogs
are probably not totally valid for your application.
The bright side of the picture is that in most
applications the switch will perform better than its
ratings. This is because the standard industry test
conditions are more stringent than those found in
most applications.
This difference can be very dramatic. For example,
Grayhill’s 42A and 44A Series Rotary Switches, are
rated at 1 ampere (115 Vac resistive). However,
they will operate at 5 amperes in many applications.
To see how some major factors influence switch
performance, read on.
USEFUL LIFE CRITERIA
The “useful” life of a switch in your application
depends on what you demand of it. This includes
parameters such as contact resistance, insulation
resistance, torque, detent feel, dielectric strength,
and many other factors. For example, a contact
resistance of 50 milliohms may be totally unusable
in certain applications such as a range switch in a
micro-ohm meter. In other applications a contact
resistance of 5 ohms may be perfectly satisfactory.
In establishing “useful” life for a switch in your
application, you must first determine “failure
criteria,” or “end of life” parameters. At what level
of contact resistance, dielectric strength, etc., is the
switch no longer acceptable for your application?
Most switches are acceptable on all parameters
when new. There is a gradual deterioration in
performance with life. The rate of deterioration
varies greatly with basic switch design. Often,
circuit designers select a switch on the basis of
its performance when new. This is a mistake.
The performance of the switch after several
years of equipment use is more significant. To
estimate this, first determine the life limiting or
failure criteria for your application. In most uses,
important life-limiting (failure) criteria include the
following parameters:
Contact Resistance
Insulation Resistance
Dielectric Strength
Actuating Force
Contact Resistance
This is the resistance of a pair of closed contacts.
This resistance effectively appears in series with
the load. Typical values are in the range of a few
milliohms for new switches. These values usually
increase during life. The rate of increase is greatly
affected by the voltage, current, power factor,
frequency, and environment of the load being
switched. Typical industry standard “end of life”
criteria for this parameter are:
MIL-DTL-3786:
MIL-S-6807:
MIL-S-8805:
MIL-S-83504:
20 milliohms
(Rotary Switches)
20 milliohms
(Snap Pushbuttons)
40 milliohms
(Pushbuttons)
100 milliohms
(DIP Switches)
Contact resistance can be measured by a number
of different methods. All of them are valid depending
upon the switch application and the circuit.
Grayhill uses the method in applicable military
specifications. This method specifies an open
circuit test voltage and a test current. The voltage
drop across the closed contacts is measured. The
contact resistance is determined by Ohm’s Law
from the test current and the measure voltage
drop. MIL-DTL-3786, MIL-S-6807 and MIL-S-8805
require a maximum open circuit test voltage of 2
Vdc; they require a test current of 100 milliamperes.
MIL-S-83504 requires a maximum test voltage of
50 millivolts and a test current of 10 milliamperes.
When a switch is rated to make and break 5 or more
amperes, there is a difference. Contact resistance
is determined by measuring the voltage drop while
the switch is carrying the maximum rated current.
The voltage drop that occurs across the contacts
determines, in part, the contact temperature. If
the temperature rise of the contacts is sufficient,
it affects contact material. A chemical reaction
will take place that can cause an insulating film
to appear on the contacts. This film is present
between the contacts during the next switching
operation. This film formation can cause failure
due to increasing contact resistance. For switching
of very low voltages and currents, this resistance
may be the failure criteria.
Insulation Resistance
This is the resistance between two normally
insulated metal parts, such as a pair of terminals.
It is measured at a specific high DC potential,
usually 100 Vdc or 500 Vdc. Typical values for
new switches are in the range of thousands of
megohms. These values usually decrease during
switch life. This is a result of build-up of surface
contaminants. Typical industry standard “end of
life” criteria for the parameter are:
MIL-DTL-3786:
MIL-S-6807:
MIL-S-8805:
MIL-S-83504:
1000 megohms
(for plastic insulation)
Not specified
2000 megohms
1000 megohms
Another special test condition is commonly
specified. It measures insulation resistance for
switches in a high humidity atmosphere (90%-98%
R.H.). In this condition, condensation of moisture
commonly occurs on the surface of the insulating
material. Some types of insulation will absorb
varying amounts of moisture. This will normally
lower the insulation resistance. Typical industry
values for this condition are:
MIL-DTL-3786:
MIL-S-6807:
MIL-S-8805:
MIL-S-83504:
10 megohms
(for plastic insulation)
3 megohms after
drying
10 megohms
(for plastic material)
10 megohms
Dielectric Strength
This is the ability of the insulation to withstand
high voltage without breaking down. Typical
values for new switches in this test are in excess
of 1500 Vac RMS. During switch life, contaminants
and wear products deposit on the surface of the
insulation. This tends to reduce the dielectric
withstanding voltage. In testing for this condition,
a voltage considerably above rated voltage is
applied. Then, the leakage current is measured
at the end of life. Typical industry standard test
voltages and maximum allowable leakage currents
are as follows:
MIL-DTL-3786:
1000 Vac and 1 mA
maximum leakage
MIL-S-6807:
600 Vac RMS after life
10 microamperes
maximum leakage
MIL-S-8805:
1000 or 1000 plus
twice working voltage
(AC) RMS and 1mA
maximum leakage
MIL-S-83504:
500 Vac and 1 mA
maximum leakage
UL Standard:
900 Vac without
breakdown (UL
Standard (dependent
on test)
Voltage breakdown is another method for
www.grayhill.com
describing the ability of the insulating material
to withstand a high voltage. Voltage breakdown
describes the point at which an arc is struck and
maintained across the insulating surface with the
voltage applied between the conducting members.
ADDITIONAL LIFE FACTORS
Effect of Loads
On any switch, an arc is drawn while breaking a
circuit. This causes electrical erosion of the contacts.
This erosion normally increases contact resistance
and generates wear products. These wear products
contaminate insulating surfaces. This reduces
dielectric strength and insulation resistance.
The amount of this erosion is a function of current,
voltage, power factor, frequency and speed of
operation. The higher the current is, the hotter
the arc and the greater the erosion. The higher
the voltage is, the longer the arc duration and the
greater the erosion.
Inductance acts as an energy storage device. This
returns its energy to the circuit when the circuit
is broken. The amount of erosion in an inductive
circuit is proportionate to the amount of inductance.
Industry standard test inductance as described in
MIL-I-81023 is 140 millihenries. Other test loads
include 250 millihenries and 2.8 henries.
Effect of Ambient Temperature
Temperature extremes may affect switch
performance and life. Very high temperatures
may reduce the viscosity of lubricants. This allows
them to flow out of bearing areas. This can hasten
mechanical wear of shafts, detents, plungers, and
cause early mechanical failure. Contact lubricants
are sometimes used. Too little lubrication can
result in a high rate of mechanical wear. Too much
lubrication flowing from other bearing areas can
adversely affect dielectric strength and insulation
resistance.
Through careful design and selection of lubricants
most manufacturers attempt to minimize these
affects. Nevertheless, continual operation in high
ambient temperatures will shorten the life of a
switch regardless of design.
Extremely low ambient temperatures may also
create problems. Low temperatures may cause an
increase in the viscosity of the contact lubricant.
Higher viscosity can delay or prevent the closing
of contacts, causing high operating contact
resistance. Under certain atmospheric conditions,
ice may form on the contact surfaces. This also
causes high and erratic contact resistance.
Frequency can also affect erosion. The arcing
ends when the voltage passes through zero. To
a certain extent, the following is true. The higher
the frequency, the sooner arcing ends, the lower
the erosion.
Neither of these conditions may materially
reduce the life of the switch. However, it may
cause unsatisfactory operation. If the voltage of
the circuit is high enough, it can break down the
insulating layer. Some current will flow through the
high resistance contacts. A local heating action is
created, which tends to correct the condition in a
short period of time.
The speed of operation affects the duration of the
arc. Fast operation can extinguish the arc sooner.
This reduces the erosion, unless the air within the
switch is completely ionized.
Switches with high contact pressures may minimize
the low ambient temperature effect. This is
particularly true if the application calls for switching
signal level voltages and currents.
Actuating Force
Effects of Altitude
Rotational torque is the actuating force required to
turn a rotary switch through the various positions.
The actual torque or force required depends on
the design of the switch. It varies widely from one
design to another. See appropriate MIL Specs or
manufacturers literature for typical industry values
for specific designs.
When torque or force values are specified, it
is customary to give a minimum and maximum
value. During life, two offsetting factors may occur
to change the initial value. Relaxation of spring
members will tend to lower torque or force values.
Wear or “galling” of mating surfaces, however,
may tend to increase these values. Typical end
of life specifications may require the switch to fall
within the original range. Or, they may specify a
maximum percentage change from original value.
For example, “the rotational torque shall not change
more than 50% from its initial value.
In high altitudes, barometric pressure is lower. Low
pressure reduces the dielectric strength of the air.
The arc strikes at a lower voltage and remains
longer. This increases contact erosion. Switches
for use in high altitudes will therefore require derating in terms of loads and/or life.
Effects of Duty Cycle
Mechanical life testers cause accelerated life
testing. Testers operate switches at a rate of
approximately 10 cycles per minute. This rate is
greatly in excess of normal manual operation in
equipment. It constitutes a severe test of the switch.
Lubricants do not have an opportunity to redistribute
themselves over the bearing surfaces at this duty
cycle. The contact heating caused by arcing does
not have a chance to dissipate.
Thus, the switch runs “hot”, increased mechanical
wear and contact erosion result. Your application
probably requires manual operation of the switch
with an attendant low duty cycle. If so, you can
usually expect much longer switch life than is
shown by the accelerated life laboratory life tests.
Conclusion
Remember, load and life ratings are based
on manufacturers’ selected references. They
include accelerated life tests and an arbitrary
set of application parameters and failure criteria.
These parameters and criteria may not always
fit your application.
Then how do you know if a switch will give reliable
performance in your application?
How do you know if it will last the life of your
equipment?
Ask the switch manufacturer. Grayhill, and most
other reputable manufacturers have compiled
vast quantities of test data. We are in a position
to give a good estimate of a switch’s performance
in many nonstandard applications. You should
provide the following data:
Expected Life:
Load:
Operation:
Application:
Environment:
Failure Criteria:
in number of cycles
voltage, current, power
factor, and frequency
manual or mechanical, duty
cycle
type of equipment
altitude,
ambient
temperature range
relative humidity, corrosive
atmosphere, shock,
vibration, etc.
end of life contact
resistance, dielectric
strength, insulation
resistance, etc.
With this information, we can usually estimate
if a given switch is suitable for your application.
www.grayhill.com
Soldering
What causes failure in a new switch after it
has been installed? The principle failure is high
contact resistance caused by solder flux on the
contact surfaces. To avoid this, be sure to follow
good soldering practices. Use the proper solder
with the proper flux core, maintain the proper
soldering temperature, use the proper soldering
iron tip for the work, and never use liquid flux
when soldering a switch.
initially and 10.0 ohm maximum dc resistance
following environmental and mechanical tests.
Many equipment manufacturers feel they are
satisfying their needs with a measurement of .025
to 10 ohms for the expected life of the switch.
Under most circumstances, standard non-sealed
switches pass the larger value easily. The lower
value (.025 ohms) requires special attention and
parts for compliance over the life of the switch.
Do not use solvent baths or washes with any
unsealed electromechanical parts. Switches,
unless they have been especially protected suffer
badly. Solvents readily dissolve fluxes and carry
them into the contact area of switches. A thin, hard
flux coats the contact surface after the solvent
evaporates. Additionally, solvents may dissolve
and wash away lubricants in switches. Lubricant
loss may prevent proper mechanical action.
Switch Selection
Exercise similar precautions when you mount a
switch to a printed circuit board. Maintain proper
solder temperatures and follow proper cleaning
techniques. Avoid subjecting these switches to
lengthy solder baths. The excessive heat can
deform the plastics.
RFI/EMI Shielding
Some applications require shielding against Radio
Frequency Interference and/or Electro-Magnetic
Interference. Experts feel that the most effective
way to achieve shielding is to provide a conductive
bridge across the component mounting hole.
They also generally agree that there is no good
method for testing shielding. So, the equipment
manufacturers themselves must identify and solve
specific problems. Component manufacturers
can generally assist in the solution of shielding
problems.
RFI/EMI testing is incorporated into MILDTL-3786 for rotary switches. Requirements
are 1.0 ohm maximum dc resistance between
the mounting bushing and operating shaft
Whenever possible, use standard switches and
contact configurations. Standards provide the
greatest economy and the best delivery. When
you need a deviation, it pays to consult with your
suppliers as soon as possible. At the early stages
of the design, there are many low cost options
for achieving the results. At the late stages of
design, some of the options may no longer be
open. For example, size may be restricted. This
might result in a more costly redesign.
Typical standard rotary options are as follows:
coded contacts, homing rotor effect, progressively
shorting contacts, PC mountable terminals, rotary
switch spring return positions, and push-to-turn
or pull-to-turn mechanisms.
Limited panel space may be solved by a concentric
shaft rotary switch. It is two rotary switches,
located one behind the other. There are other
concentric shaft possibilities. A rotary switch can
be combined with another component. These
include a potentiometer, a pushbutton switch, and
a mechanical element. The most cost effective
design may be one of these concentric options.
But, selection must be made at the outset of
equipment design.
1. SELECT A FACTOR
FACTOR: Current Life Rating
All switches are rated to make and break at least 100 milliamperes for 10,000 cycles of operation. Rating becomes a matter of interpretation. Carefully
review the Engineering Information on the previous pages. Ratings which assure a different life are possible; contact Grayhill.
25,000 Cycles At Load (Amps)
10,000 Cycles At Load (Amps)
6,000 Cycles At Load (Amps, UL)
19
Single Deck Switch Series Multi-Deck Switch Series
24 50/51 56 75 77 5000 08/09 42/44 43/54 53,57,59 71
—
—
15
1
—
—
.050
.200
—
—
.200
—
—
.100
—
.050
—
—
1
—
—
.250
.500
—
1,3,5*
1,3,5*
—
1,3,5*
1,3,5*
—
—
.250
.150, .250* —
—
—
* Varies with angle of throw and style.
FACTOR: Size
Maximum Dimension
Single Deck Switch Series
Multi-Deck Switch Series
In Inches (& Millimeters) 19 24 50 51 56 75 77 5000 08 09 42 44 53 57 59 71
Diameter, Behind Panel
2.280 1.015 .500 .561 .500 .298
1.015 .687 .750 1.015 1.170 1.350 1.190 1.190 .750
Length Behind Panel, 1 Deck .950 .580 .698 .698 .355 .500
.470 .960 .960 1.025 1.025 .916 .916 .916 .760
Behind Panel, Add'l Deck
— — — — — — — — .268 .268 .346 .346 .329 .326 .326 .218
Diameter, Behind Panel
(57,9) (25,8) (12,7) (14,2) (12,7) (7,6)
Length Behind Panel, 1 Deck (24,1) (14,7) (17,7) (17,7) (9,0) (12,7)
Behind Panel, Add'l Deck
— — — — — —
() (25,8) (17,4) (19,0) (25,8) (29,7) (34,3) (30,2) (30,2) (19,0)
() (11,9) (24,4) (24,4) (26,0) (26,0) (23,3) (23,3) (23,3) (19,3)
— — (6,8) (6,8) (8,8) (8,8) (8,4) (8,3) (8,3) (5,5)
* If multi-deck switch is needed, contact Grayhill.
FACTOR: Circuitry
Max. Positions
1 Deck (1Pole)*
Angle Of
Throw
Maximum
Decks**
Maximum Poles
Per Deck***
Shorting Or
Non-Shorting
15°
18°
22°30'
22°30'
12
12
12
1
12
10
8
2
N or S
N or S
N or S
N or S
Solder
Solder
Solder
Both
53
59
57
51
12
12
12
12
12
11
30°
30°
30°
30°
30°
30°
12
12
12
1
1
1
6
6
6
4
4
1
N or S
N or S
N or S
N or S
N or S
N
Both
Both
Solder
Both
Both
****
71
9
44
51
56
19
10
10
10
10
10
10
10
10
36°
36°
36°
36°
36°
36°
36°
36°
12
12
12
1
1
1
1
1
2
2
2
2
2
2
1
1
N or S
N or S
N or S
N
N or S
N or S
N or S
N or S
Both
Both
Both
PC
Both
Both
Both
Solder
8
71
42
75/77
50
56
24
5000
8
8
8
6
6
6
4
4
4
45°
45°
45°
60°
60°
60°
90°
90°
90°
12
12
1
6
12
1
12
6
1
4
4
2
3
3
2
2
2
2
N or S
N or S
N
N
N
N
N
N
N
Both
Solder
Both
Both
Solder
Both
Solder
Both
Both
9
44
50
9
44
50
44
9
50
24
20
16
16
* Maximum positions per pole depends
on number of poles per deck.
www.grayhill.com
** Based on 1 pole per deck. Number of decks
is also limited by the total number of poles.
Solder Lug
Or PC
Series
Number
*** Limited by total number of poles per switch.
****Choice of Faston or Solder Lug terminals.
Bulletin 1220
Rev 04/14
Specifications are subject to change. Please refer to the current datasheet on www.grayhill.com for the most current published specifications for this product.
Rotary Switch Standard Options
• Custom Switches With No
Tooling Required
• Easily Ordered Specials
1. Dummy Terminal
Used as tie point, it is not an active switch
position. Can be located at any specified position outside of active switch terminals. Priced
as active position. Example, a three position
switch with 2 dummy terminals would be
priced as a five position switch.
.072 +.000 –.002
(1,83 –0,05)
.034 ± .003
(0,86 ± 0,07)
.045
.047 (1,19)
(1,14)
.096 ± .001
(2,44 ± 0,03)
2. Enlarged Wire Holes
.032 ± .001
(0,81 ± 0,03)
R (2)
5. Notched Terminals
Used in place of the conventional solder lug
terminals.
6. External Shorting Links
.068 ± .005
(1,73 ± 0,13)
.045
(1,14)
.062 ± .003
(1,57 ± 0,08)
DIAMETER
Series 08A, 09A, 42H, 42M, 44H, and 44M:
Lug terminals for several wires; standard in Series
08M, 09M, 53, 57, and 59 switches.
3. High Density Wiring Terminal
.096 ± .001
(2,44 ± 0,03)
.0635 + .002 –.001
(1,61 + 0,05 – 0,02)
DIAMETER
The gold-plated terminal features a slot to accept
wires in addition to the conventional wire hole.
4. Taper Tab Terminals
External shorting links, as shown in the drawing,
can be used in place of conventional solder
lug terminals in the Series 5000, 24, 42 or 43
rotary switches. Shorted terminals can also be
accomplished internally in the Series 71 rotary
switches. Solder lug terminals can be intermixed
on the same deck.
7. Non-Standard, Non-Turn
Devices
Switches without tabs
Series 08, 09, 42 and 44: There is no additional
charge for a front support plate without a nonturn tab.
.095 (2,41)
.280 (7,11)
45°
Switch
Series#
.079 (2,01)
Used in place of conventional solder lug terminals.
Taper tab terminals are gold plated.
1
Options For Styles A and S
2
3 4 5 6 7
Non-turn tab of non-standard projection
Series 08:
All tabs located at .260 inch radius from centerline of switch. The following projections
(inches) are available: .121; .094; .045; .032
Series 44:
From Centerline
Projection
.375" (9,53 mm) .062" (1,57 mm)
.531" (13,49 mm) .121" or .049"
(3,07 or 1,24 mm)
8. RFI Grounding
A silver-plated shaft and wave washer improve
DC grounding of shaft to mounting bushing, thus
minimizing possible radio frequency interference. Example: static and dynamic DC resistance after 25,000 cycle life test is maximum
100 milliohms. For concentric shaft switches,
discuss grounding with factory. Special handling
charges apply to small lots.
9. Electrostatic, Electromagnetic
Shielding
A metallic shield can be added between decks.
Grounding of the shield provides additional RFV
/EMI protection, Size and shape of the shield
depends on the equipment configuration and the
amount of protection required Price is dependant onthe number and type of shields required.
10. Unidirectional Rotation
The detenting system permits rotation in only one
direction. Usable only with continuous rotation
switches. Specify direction of rotation. Applicable
to 30° and 36° throw switches only.
8
9
Options For All Styles
10 11 12 13 14 15 16
08 x x
x
x
x x
09 x x
x
x
x x
24 x
x x x x x
42 x x* x x x x x x x x x x
43 x
x x x x
x* x
x x
44 x x* x x x
x x x x x
x
50/51
x
x
56
x
x
53/57/59
x
54 x
x x x x*
x
x x x
71
x*
x x
5000 x
x x x x x
* See description below for limitations.
www.grayhill.com
Patent Pending
©2013
Specifications are subject to change. Please refer to the current datasheet on www.grayhill.com for the most current published specifications for this product.
11. Intermixing of Shorting and NonShorting Contacts
In some switches, non-shorting and shorting
contacts can be intermixed between decks. A
2-deck switch, for example could have shorting
contacts on deck 1 and non-shorting contacts
on deck 2. In a few switches, non-shorting
and shorting contacts can also be intermixed
between poles. A 2-pole per deck switch, for
example, could have non-shorting on pole #1,
and shorting on pole #2.
Series 08 and 09:
An 09M30 or 08M36 rotary switch can have
shorting and non-shorting contacts intermixed
between decks. Shorting and non-shorting
contacts can be intermixed between poles as
well as decks in styles A, S, P, and SP.
Example: an 08P36, 1-pole, 10 position switch
with terminals on one side of the switch would
be priced as a 2 deck, five position, one pole
per deck switch.
13. Homing Rotor (Bridging and
Shorting Deck) and Progressively
Shorting Deck - Series 44 only
A homing rotor (bridging and shorting) switch
deck connects all terminals to the common except
the terminal in the selected switch position. For
example, in position 1, terminals 2 thru 12 are
CIRCUIT
DIAGRAM
Series 50, 51, and 56:
Non-shorting and shorting contacts can be
intermixed between poles.
Priced the same as standard switches. The
type of contacts on each pole must be precisely
indicated.
12. PC Mount Switches With
Terminals From One Side
of Switch
Series 71 PC mount switch has all terminals
on one side.
Series 08P, 09P, and 42P with non-shorting
contacts are also available with terminals limited
to one side. Contact Grayhill for a special part
number. This is accomplished by using 2 decks
per pole and placing the rotating contacts 180°
out of phase on each deck. The first deck picks
up the first half of the positions; the second
deck picks up the last half of the positions.
Common terminals are tied together by the PC
board circuitry.
A total of 12 decks (6 usable poles) is the
maximum per switch. Switches with the
maximum number of positions (12 for 30°,
or 10 for 36°) will have continuous rotation.
Rotation can be limited to less than the maximum
positions. For example, an 8 position Series 8P36
switch with terminals on one side, would pick
up 5 positions on the first deck and 3 positions
on the second deck.
Price is the same as standard switches with
comparable number of decks and positions.
www.grayhill.com
C
12
HOMING
ROTOR DECK
1
2
11
Series 42, 43, 44, and 54, in 30° or 36°:
Non-shorting and shorting contacts can be
intermixed between poles or decks.
Series 71:
Non-shorting and shorting contacts can be
intermixed between poles in fixed stop switches
only.
decks are used in combination with conventional
decks, it is important to remember that the stop
system limits the rotation of both types of decks.
For example, when a homing rotor deck Is used
in combination with a 6-position conventional
deck, the homing rotor is likewise limited to six
positions.
O-RINGS
10
3
9
4
5
8
6
7
connected to the common, and terminal 1 is
open. In position 2, terminal 3 thru 12 and 1 are
connected to the common, and terminal 2 is
open. A homing rotor deck will function for 25,000
mechanical cycles of operation.
The progressively shorting switch deck connects
consecutive switch positions to the common. For
example, in position 1, terminal 1 is connected
to the common; in position 2, terminals 1 and
2 are connected to the common; in position
CIRCUIT
DIAGRAM
C
PROGRESSIVELY
SHORTING DECK
1
2
14. Shaft and Panel Seal on
Concentric Shaft Switches
The following diagram shows the location of
the O-rings required to seal the shafts to the
bushings. When the concentric shaft switches
are sealed in this manner, the .125 inch diameter
shaft is supplied full round. Bushing-to-panel
sealing is accomplished by the panel seal kit.
15. Fixed Stop, Add-A-Pot
Switches
The rotary switch section of the Add-A-Pot rotary
switches can be built with a fixed mechanism
rather than the standard adjustable stop
mechanism. The front end of a switch of this type
is similar to the Series 43A or Series 54A style
concentric rotary switches. The total number of
decks is limited to three. The Series 43 is limited
to 1 pole per deck. Series 54 to 2 poles per deck.
3
4
5
6
3, terminals 1,2, and 3 are connected to the
common. A progressively shorting deck is limited
to a maximum of 6 positions. A progressively
shorting deck will function for 25,000 mechanical
cycles of operation.
16. Series 54 Concentric Shaft
Switch in 45°, 60°, and 90°
Throws
The Series 54A switch is available with these
angles of throw in Section A of the concentric
rotary switch. Section B is available in 30° angle
of throw only. Section A is limited to 1 to 3 decks,
non-shorting contacts, and 1 or 2 poles per deck.
Homing Rotor or Progressively Shorting decks
can be ordered as a deck of a 44A or 44M style
switch, or their sealed equivalents. Order up to
11 conventional decks and 1 special circuitry
deck. For a good detent feel, the switch is limited
to a total of 12 poles plus the homing rotor or
progressively shorting deck. Example: 6 2-pole
decks and a homing rotor. When these special
Bulletin 1222
Rev 04/14
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