Concerns with my first test run - please help :/

[Matilda]

Hi all,

I'm running a 50l keg boiler with a 3kw immersion attached to a power controller.
I've had it running for around 20-30 mins and the keg is heating up, which seems positive.

However - my plug, controller and cables are also getting warm. Is this dangerous?

For the sake of testing, I'm running without my condenser attached, and using only water.

[sambedded]

Could you provide more details about cords and controller you are using? Some pictures will be also helpful .

[Matilda]

Cords are -
http://www.tlc-direct.co.uk/Products/CA ... ash50.html" onclick="window.open(this.href);return false;" rel="nofollow
Plugs are basic household plugs from B and Q
And the controller is -
http://www.ebay.co.uk/itm/Adjust-10000W ... 1170845558" onclick="window.open(this.href);return false;" rel="nofollow?

Controller is housed in a hobby box, and also has an LCD display showing V and amps

I have a pigtail female plug socket on my boiler
An extension lead in the middle
And my controller has a male and male end.

Does that help?

[Sungy]

The wire seems small. 16 amp max rated tells me it is 14 gauge wire. You are 3000 watts at220 volts = 13.6 amps. yup gonna get warm when you are that close to its maximum (its probably 14 or 16 gauge). Your controller is rated at 10000 watts which works out to 45 amps. way over that extension cord wire your using.

[sambedded]

your cord rating is OK for 3000Watt, but I'd reccomend to use cord with at least 25Amp rating.
Have no idea what "B and Q " means . Do you know your plug load rating?
Controller is OK but heatsink should be outside of box or you need a fan.

[Matilda]

Using a cooking thermometer against the heat sink, it read at around 60 degrees.
The water in keg was boiling at this point, so I figured the hard work was done, and in real life I can then turn down the amps and steady the heat?

Warm is ok, as long as it stays safe...do we think it's safe?

Thanks guys

[Soggy Bottom Boy]

.
Running 240 volt, correct?

....I have a pigtail female plug socket on my boiler
An extension lead in the middle
And my controller has a male and male end.

Does that help?

First of all, having a female plug pigtail on the boiler and an energized male plug end coming out of controller can create an extremely dangerous situation if unplugged from the boiler and still plugged in at the wall outlet, very unsafe and frowned upon. Definitely not on par with any known electrical code, ...and for good reason!

electrocuted.jpg (16.61 KiB) Viewed 2176 times

Warm is OK, hot is not. Keep a very close eye on the plug ends, look for any signs of discoloration or melting plastic caused from being over heated. If it is happening, you would most likely see it first occurring at the base of the male plug blades.

BurnedSkt4.jpg (15.44 KiB) Viewed 2176 times

How long is the wire run from the electrical panel of the house to the wall outlet, amp rating of the breaker that serves the circuit, and how long is the wiring of your controller from the wall outlet to the element? If you are getting any significant voltage drop serving the controller, the amperage being drawn will go up some too.

Do you have an actual voltage reading serving the controller, as that will affect the total amp draw on the circuit.

As previously brought up, what is the rating of your plugs used on the controller wiring?

Make sure the plug terminals have good contact with the wires, and screws are tight. Check the connections in the wall outlet too.

[Matilda]

Apologies, I mistyped while concentrating on the boiler happenings.
I have a 15cm lead with normal household male plug coming off of the boiler.
I have a 3m extension lead (normal household male and female on other end)
And lastly, the controller - which is approx 50cm from male plug to box, and about 25cm from box to female socket.
This gives me the option to use the controller for other things, and gives me enough length to use the still inside or outside.

Plugs are 13a if that helps?

The wall socket is one which which previously served a cooker. I guess it's 20 m from the breaker which serves 63amps and has a 30mA breaker. I don't know if this is what you're asking? I just read it on my mains inlet.

Yes, the voltage reading on the voltmeter was reading between 235 and 254v's under load.

Does that help?

[skow69]

That cord is most likely 18 awg. It is going to get warm but won't fail. Keep a close eye on the connections. Soggy Bottom Boy is right on the money. That is where the heat will cause problems. Upgrade to 14 awg will be much more reliable.

That controller won't last. Sorry. Been there. Next round use an SSR. They are tough as nails.

You don't have 254 volts unless there is a transformer in there somewhere. Calibrate your voltmeter if you are concerned about accuracy.

the voltage reading on the voltmeter was reading between 235 and 254v's under load.

If that means 254 at no load and 235 at full power, full load, then the 19 volt drop is an indication of how much power is being lost to heat in the cord, connections, and controller. 19 volts is a lot.

Best recommendation: Use 14 awg cable, an SSR controller, and 30 amp rated plugs.

[still_stirrin]

That cord is most likely 18 awg.

Best recommendation: Use 14 awg cable, an SSR controller, and 30 amp rated plugs.

+1, from another engineer onboard. Your power cable is dangerous. Your safety is paramount. An upgrade is in order.

[Prairiepiss]

I would agree. A 19 volt drop is a little much. Most everything I work with recommends a 2 volt drop max. And keeping it under 1 volt drop is best. I have designed my off grid solar to have under a .3 volt drop.

As far as having 254 v available. Not knowing what the standards are in your area. I couldn't say if you could or couldn't have that. Assuming from what you have posted. You are not in the US. Not all countries keep the voltages as tight as others. Things like outside temps, proximity to the nearest transformer, length of power line serving your house, and any number of other things can change this.

Here in the US the standard is 115 Vac + or - 5 Vac and 230vac + or - 10 Vac.
But yet I have seen 125 Vac at circuit breaker. With a calibrated VOM. That would be 250vac across two phase.

[Soggy Bottom Boy]

1.5mm stranded conductor size is just under .060" dia., which equates to 16 gauge.

Stranded wire gauge(AWG) chart.

Set-up seems to be right at the upper limits of the plugs being used. Just be vigilant on the condition of the plugs and whether the wire gets more than warm on a long-term distilling session. An upgrade of both might be a prudent move for a bit more peace of mind.

[skow69]

As far as having 254 v available. Not knowing what the standards are in your area. I couldn't say if you could or couldn't have that. Assuming from what you have posted. You are not in the US. Not all countries keep the voltages as tight as others. Things like outside temps, proximity to the nearest transformer, length of power line serving your house, and any number of other things can change this.

Quite right. I jumped the gun there. Matilda, I agree, the 254 number of itself could well be in spec, but the 19 volt drop is still concerning.

Here in the US the standard is 115 Vac + or - 5 Vac and 230vac + or - 10 Vac.
But yet I have seen 125 Vac at circuit breaker. With a calibrated VOM. That would be 250vac across two phase.

I'm OK with 125, but I've seen 160 at the breaker, too. And 70 on the other leg. I used to do a lot of motorhome ralleys, before the economy went to hell. Older RV parks often have very creative wiring. It's always the neutral that gets loose and overheats. Then everybody down the line is at the mercy of whichever leg happens to get more load. One side goes down and the other side goes up. Customer came to the desk one time and said, "Boy, this place sure has good power, my meter shows 155! But my TVs quit working. Would you come and check it out?"

I hate high voltages.

[shadylane]

1.5mm stranded conductor size is just under .060" dia., which equates to 16 gauge.

Stranded wire gauge(AWG) chart.

Set-up seems to be right at the upper limits of the plugs being used. Just be vigilant on the condition of the plugs and whether the wire gets more than warm on a long-term distilling session. An upgrade of both might be a prudent move for a bit more peace of mind.

+1 SBB