Yet another thread about power controller build

sambedded · Post by **sambedded** » Mon Oct 27, 2014 5:59 pm

I'd like to describe here a build of universal (110-240 V) controlled based on SSVR. This controller has some safety features like overload and overheating protection.

Schematic diagram:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 6:05 pm

Required components:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 6:25 pm

I have a small SNC machine at home. So cutting a front panel is not a big problem.

sambedded · Post by **sambedded** » Mon Oct 27, 2014 6:29 pm

Then you need to cut holes in a box for In and Out cords and for a fan:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 6:35 pm

Preparing holes for DIN-rail mounting. I'm using it to secure a breaker.

sambedded · Post by **sambedded** » Mon Oct 27, 2014 6:49 pm

To mount a DIN-rail I'm using #10 screws and a spacer made from aluminum tube:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 6:56 pm

Breaker is mounted on a DIN rail like this:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:00 pm

Now it's time to install 12V DC 80mm fan and a heatsink:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:12 pm

To power a fan I'm using 12V adapter for car's chargers. Just disassemble it and take out a board.

: ps.jpg (10.72 KiB) Viewed 8061 times

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:16 pm

Front panel assembly is quite easy.

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:21 pm

Use some thermal compound on SSR

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:27 pm

Now it's time to start and complete wiring

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:34 pm

Before heating element connection I'm using incandescent lamp for testing:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:38 pm

Power supply LED inside the box makes some kind of modding effect:

sambedded · Post by **sambedded** » Mon Oct 27, 2014 7:39 pm

Thanks for viewing this thread.
Any questions?

wv_cooker · Post by **wv_cooker** » Mon Oct 27, 2014 8:11 pm

Nice work Sam. The power actually shuts off in this one excellent!

InglisHill · Post by **InglisHill** » Tue Oct 28, 2014 11:17 am

Nice job!

bellybuster · Post by **bellybuster** » Tue Oct 28, 2014 3:17 pm

Nice one, gotta ask about the course and fine pots, do you really find the fine necessary? I,m able to adjust to a 10th of an amp with a single pot.

sambedded · Post by **sambedded** » Tue Oct 28, 2014 3:59 pm

Of course "Fine" dial is not necessary. But if you try to use it for couple runs - you will never want to use only one dial again. And it costs very little to implement.

Post by **Halfbaked** » Tue Oct 28, 2014 4:39 pm

Sam you really should think about posting more. Your stuff is precise on point and really great. It sux I don't have access to the machinery that you have. Keep the info and PIX comeing.

Post by **still_stirrin** » Tue Oct 28, 2014 6:30 pm

+1. Very professional. Excellant thread. Thanks.
ss

Maritimer · Post by **Maritimer** » Thu Oct 30, 2014 5:27 am

Hi sambedded,

This looks like a good place to harp on the flow switch theme. May I suggest that a flow switch be installed in series with the thermal switch?

This will turn off the power to the element when there is no coolant flow.

To make the circuit usable for purposes where the flow switch is not needed (for example, boiling water for wash) a bypass switch can be added:

The flow switch could be connected to the controller through a plug to a receptacle on the housing.

M

commonsense · Post by **commonsense** » Tue Nov 04, 2014 2:03 am

Estimated price

Post by **lampshade** » Tue Jan 06, 2015 3:09 pm

Maritimer wrote:Hi sambedded,

This looks like a good place to harp on the flow switch theme. May I suggest that a flow switch be installed in series with the thermal switch?

Hi Maritimer,

Have you researched flow switches and do you have any recommendations (besides, of course, your own

)

Post by **shadylane** » Tue Jan 06, 2015 3:36 pm

sambedded wrote:Thanks for viewing this thread.
Any questions?

Instead of using a DC fan motor, use a shaded pole AC fan motor.
Add a timer to the control circuit. If you don't reset it every so many minutes, the heater will shut off.
I use a 60 minute mechanic timer from lowes. I like it because it ticks like a time bomb.

Maritimer · Post by **Maritimer** » Wed Jan 07, 2015 7:32 am

Hi lampshade,

See here for a reply: http://homedistiller.org/forum/viewtopi ... 2#p7277642

M

Gundar · Post by **Gundar** » Mon Feb 16, 2015 8:55 pm

This looks like a nice controller. Very clean looking. I have a couple questions about it. Does it work with both 120V and also 240V? I would like the option to do either or. My second question is how does the course/fine tuning work? It looks like the course dial adjusts the power at a greater level and the fine dial adjusts the power on a minute level. My third question is, are the two dials the same, or are they different? Is one a course dial and one a fine dial? Last question, is there a parts list for this build?

Thanks

Gundar · Post by **Gundar** » Mon Feb 16, 2015 9:02 pm

I answered one of the questions by reading the diagram. Looks like the is a 500 pot and a 50 pot.

Drunk-N-Smurf · Post by **Drunk-N-Smurf** » Sat Feb 21, 2015 2:05 pm

Does there have to be a load attached for the ssr to function properly? I wired mine up following your diagram, and I don't have a load attached yet. When I check the resistance on the pots loop, I can watch it go from 0 resistance to 555ohms, so that's good there, but on the voltage side, when I check the voltage the best it does is vary between 240 and 244 volts....

Not sure what I'm missing.

Post by **shadylane** » Sat Feb 21, 2015 2:16 pm

The controller needs a load to work properly.

Home Distiller

Yet another thread about power controller build

Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build

Re: Yet another thread about power controller build