Avoid These Common Errors While Operating Changeover Switches

Changeover switches are not just another component in your electrical setup, they’re essential, especially where backup power is needed. Whether you’re managing a home, shop, office, or an industrial unit, a changeover switch ensures that the transition between main power & backup happens safely and efficiently. But the problem is that a lot of  people unknowingly make mistakes while using them. And these aren’t small issues. They can lead to system failure, damaged appliances, or even fire.

Let’s talk about six common errors people make while operating these switches and what’s the right way to handle them settings.

1. Wiring Mistakes That Can Cost You Dearly

Improper wiring is by far the most common issue. Many homeowners rely on local electricians who may not have formal training. Wiring errors like reverse polarity, wrong phase alignment & mixing up neutral lines can cause backfeed meaning power flows in the wrong direction. This can fry your generator or cause electrocution.

Fix:

• Always use a wiring diagram recommended by the manufacturer.
  
  
• Don’t experiment. Hire a licensed electrician with experience in changeover switches.
  
  
• Make sure phase indicators and earthing are properly connected and tested using a multimeter.

2. Using the Wrong Type of Changeover Switch

This mistake happens when people don’t understand the difference between manual and automatic types. A manual changeover requires someone to flip the switch which may not always be possible during emergencies. Businesses, especially, can’t afford that delay.

Fix:

• For houses with low-power appliances, manual switches are okay.
  
  
• For businesses, hospitals, or places where power continuity matters, automatic changeover switches (ATS) with in-built sensing and switching are safer and faster.

3. Overloading the Switch Beyond Its Limit

People often look at only the average usage and ignore peak loads. But when multiple appliances like air conditioners or motors start at once, the load spikes. An underrated switch will heat up, trip, or burn out.

Fix:

• Calculate the starting current (inrush) of your major appliances.
  
  
• Select a switch that supports at least 25-30% more than your total load.
  
  
• When in doubt, consult a load management technician.

4. No Maintenance Until It Fails

Changeover switches are mechanical and electrical devices. They need maintenance. But many just install and forget them. Over time, dust, moisture, and rust affect performance. When you need them the most during an outage they don’t work.

Fix:

• Test the switch every month. Switch it from main to backup and back.
  
  
• Visually inspect for rust, loose wiring, and heating.
  
  
• Schedule professional servicing at least once a year, especially in high-load setups.

5. Switching Sources While Appliances Are Running

One major mistake is flipping the switch while your TV, fridge, or machines are still running. This causes sudden voltage spikes, which may not be absorbed even by surge protectors.

Fix:

• Always shut off all connected appliances before switching power sources.
  
  
• Wait 5-10 seconds after switching before turning appliances back on.

6. No Proper Earthing Setup

Skipping a proper earthing system is risky. It puts people at risk of electric shock and damages sensitive equipment, especially in rainy or high-moisture areas.

Fix:

• Get your earthing resistance checked. It should ideally be less than 5 ohms.
  
  
• Install copper or chemical earthing rods if you’re in a moisture-prone zone.
  
  
• Make sure the generator and the changeover are both properly grounded.

Mistakes with changeover switches can lead to equipment damage, downtime, or even injury. Most of these issues happen because people don’t have the right information or don’t ask the right questions. But now you do.

If you’re setting up or upgrading your system, always choose certified, trusted products. At HPL India we offer the best changeover switches in India, backed by proper technical specs and safety certifications. Our lineup also covers consumer lighting, wires, the best electric switches in India and other electrical equipment that professionals trust.

A little care during selection, installation & maintenance goes a long way in keeping your setup safe and running smoothly.