Variac: what should I add when putting it in an enclosure?

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Hallo Andre, I see that you have the live in on M. It looks like M is for 220V and N is for 240. It is better to use the higher voltage due to large voltage fluctuations. Otherwise it looks fine. The best to do is to wire a 60Watt normal lightbulb in series with the input live. If there is a wiring problem then the light will burn bright and no flames and swearing. 🙂 It could be that the input Live and Neutral must be swapped, but I don't think it would make a difference. So it's safer to connect the light to make sure of the wiring. It should work the way its wired now. I have a fuse on the live in and one on the live out to protect the wiper in case of a short.
 
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Hello Jan

Thanks for your good wishes😀

I made some progress yesterday. I changed the wire you mentioned to the 240VAC tap and fitted another 5A fuse to the live of the output. I also added an illuminated 15A rocker switch to the 230VAC current IN loom.

Then late last night, I folded a temporary aluminium enclosure to mount the beast. My bench vise jaw depth wasn't deep enough so I made the folded bends over the steps of a small aluminium ladder...

The fuse holders I bought are quite sturdy panel mount types but Yebo only had slow blow 5A fuses which I hope will be OK?

I still have to bolt the two earth wires to the enclosure and switch on and test will be in a few hours today.

I will rig an incandescent lamp to the contraption's output and see what's up. Will post later today.

If it works, I still will have to drill holes for the fuse holders and make cutouts for two IEC sockets and the rocker switch.

Regds

andre/bulgin
 
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This is bulgin writing - not his wife😀

Aaand, it's working. No fire, blown fuses, circuitbreaker trips or escaping magicke smoke.

Note the extra 'safety measure' on the variac's metal adjusting knob which I hope to replace soon with a bakelite item.

Thank you all and thank you Vrystaat (Jan) for all the help to an old dufus:cheers:.

The next up will be cutting and drilling holes in the enclosure for the switch, IEC sockets and the two fuses.

The enclosure is still temporary until I can get a proper enclosure made which will also accomodate an analogue voltmeter.

Cheers

bulgin
 

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Great stuff Andre ! I see you tested it on the garage floor 😀 Happy it worked out fine. I'll come around at your shop when I go and visit the kids in Capetown !:cheers:

Please do visit Jan, you are most welcome. I work from home in Cape Town's southern suburbs btw. Just send me a PM here for my contact details.

The poor garage floor, yes - it looks a bit worse for wear after 40+ years of diy adventures. It already has been re-screeded back in '88 to cover up welding marks from making my front garden steel fence.

Since then, I do airbrushing my turntables, I anodise and goldplate there when I make cartridges and soon, there will be another paint session when I refurbish a pair of PYE HF25 valve amps. These two amplifiers were actually the main reason for acquiring the variac.

Best regards

andre
 
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The temporary enclosure is done and everything works as it should. Fused ac current IN and OUT. Earthed both sides. Extra thick wiring. Plastic adjusting knob and male and female IEC sockets - male = 230VAC IN and female IEC current out.

I still have to close the sides and find an analogue voltmeter but that's for the final enclosure.

Thanks again for all your help with the wiring (Jan and other diy'ers).

bulgin
 

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