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Electrical Applications | Basic Power Analysis | Accessories | PSU | UPS evaluation | Battery analysis | CCTV camera system troubleshooting => Evaluation and Testing of UPS (Uninterruptible Power Supply) => Topic started by: Kiriakos GR on February 04, 2017, 06:05:46 PM

Title: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on February 04, 2017, 06:05:46 PM
2017 - ITTSB project: Assembly of a Variac with Powerstat 226U transformer

Variac transformer (Variable transformer) this is one of the most useful devices ever produced for the smooth, distortion-less adjustment of AC voltage and power, with innumerable uses in testing and in control of voltage dependent parameters - speed, lighting, heat, etc.

Over the years Variac transformer assembly in a box (metal enclosure) this become a challenge and at the same time source of inspiration for thousands of people.
While transformer shape this is unchangeable, there is lots of room for product design improvising, speaking of shape and dimensions.
 
You can add to it items as for example panel meters, switches, fuses, power sockets, and even carrying handle.

ITTSB Blog within 2017 and me in person I got in to a new challenge, assembly of Variable transformer it is always a huge challenge if you think of it seriously.
My choice is a transformer capable for 2100VA (2.1 KVA) with voltage range from 0~270 ACV with input voltage of about 225~230V Mains voltage.

2.1 KVA this translates to seven ampere continues power, and this also translates that when you are thinking  to order switches and fuses, you must do proper research and you to properly indentify true continues current specifications’ of its one component that you are planning to use.
   
Speaking of electrical switches product specifications’, for example I had to select one with name plate of 20A because this was capable for 7~8A nominal (3 Positions On-Off-On Changeover Control Rotary).

Purpose which this Variac is going to serve at ITTSB Blog
1) Testing of ups (Uninterruptible power supply) with supply of low or high input voltage, technically named as Boost & Trim ups condition (status).
One electrically healthy ups this it should respond by activating it inner circuit and electric relay, so this to compensate (adjust) it output and this be at acceptable range of around 230V. 

2) Testing of any SMPS (switching mode power supply), inspection of output stability in all range of input voltage, for example this could be as 90~240ACV.

3) Motor Speed control, lighting tests and more…

4) Power supply for testing of active ACV stabilizers (thyristor based ones) or other type, and also for power quality evaluations.
 
 
ITTSB Blog 2017 Variac transformer project details 
I did all my homework speaking of product design and parts list that I am going to use, I was forced to order parts from several countries.
Many of my parts are in shipping mode, and some others are still in manufacturing stage.

In this thread I am going to attach pictures of arrived goods and quick tests. ;)
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on February 04, 2017, 06:10:41 PM
Variac Powerstat 226U quick tests  ---->
Title: Re: Schurter FPG1 fuse holder & SIBA fuses
Post by: Kiriakos GR on February 10, 2017, 11:35:55 AM
My selection of parts regarding fuses, this was made also by the primary concept of my Variac project, and this is selection of ultimate quality parts, no matter their price.

Schurter FPG1 fuse holder this is great example of top quality part for panel mounting, connectivity this is made by clips.
Rich product specifications and several approvals.
www.schurterinc.com/pdf/english/typ_FPG1.pdf (http://www.schurterinc.com/pdf/english/typ_FPG1.pdf)


For fuses I made a choice of SIBA 173100.8A slow-blow 5x20
www.siba-fuses (http://www.siba-fuses.com/front_content.php?idart=117&nummer=173100.8)
Title: Re: BERKER SCHUKO socket outlet MOBIL R series
Post by: Kiriakos GR on February 10, 2017, 12:52:21 PM
BERKER SCHUKO socket outlet ( MOBIL R  series) this is also a product that does not come cheaply.
My opinion this is that recent pricing of BERKER products, it is extreme, either way I got lucky by finding old stock (production of W.Germany) in pristine condition.
Nowadays BERKER old MOBIL R series this now described as BERKER INTEGRO Series.

This product series qualifying for mobile applications, as for example boats, and laboratory equipment. 
 
My VARIAC this will have double SCHUKO socket outlets, its one fused separately.
And also voltage output due isolated banana sockets,  for voltage measurements by external multimeter.   

http://www.elisch.cz/wp-content/uploads/2015/08/berker_serie_integro_mobilrtwin.pdf (http://www.elisch.cz/wp-content/uploads/2015/08/berker_serie_integro_mobilrtwin.pdf)
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giorgos on February 11, 2017, 09:09:07 AM
I agree with you regarding quality of Berker products.
By the way, I have use Berker socket too, mounted in a distribution cable channel, in front of my workbench.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on February 11, 2017, 09:15:20 AM
I agree with you regarding quality of Berker products.
By the way, I have use Berker socket too, mounted in a distribution cable channel, in front of my workbench.

I have no doubts that they are well made items, but pricing of about 17E retail in EU (per socket), seems as stealing to me.
HAGER this is also distributor of Berker, but not of complete Berker products portfolio.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giorgos on February 11, 2017, 02:02:56 PM
Ι can remember that I had bought them about 3.5 € each. But its a different model than yours which may be more expensive.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on February 13, 2017, 06:49:22 PM
I am celebrating the fact that I did manage to gather most essential parts for my upcoming project.  8)

Required skills: Product design, Metal assembly, surface paint job, electric parts installation, industrial grade wiring and connections.
This going to be an costly project, but unique design this is always priceless.
Enclosure dimensions 335(W) x210(H)x225(D)mm
Aluminum face plate thickness = 5mm

Code name: VARIAC Transformer of 2017
Title: Re: 4PCS HSS Countersink and Deburring bits 2-5mm 5-10mm 10-15mm 15-20mm
Post by: Kiriakos GR on February 16, 2017, 10:57:39 AM
New addition to my hardware tools portfolio   8) 

(got them especially for this project) €9.46 EUR
No storage bag, but I did came with one solution ( floppy disk 1.44 clear case)  ;)
Title: Re: Brushed aluminum Finish over aluminum sheet & professional grade tools
Post by: Kiriakos GR on February 19, 2017, 11:36:26 AM
Quality Metal working job this is essential part of this project.

Brushed aluminum Finish over aluminum sheet this requiring professional grade of tools.
My work around this was to get just the brash and one special axle for using it with my Metabo cutting tool, and variable speed due our New variac transformer  8)

Neither this option came at low price,  but when you aim perfection there is no price tag to that.
Title: Re: HSC8 6-4 End Sleeves Tool - Crimping ferrules
Post by: Kiriakos GR on February 20, 2017, 11:30:55 AM
Another (envelope) unboxing today  8)
One unique tool that mostly industrial electricians using in their work.

HSC8 6-4 End Sleeves Tool 

Arrived totally dry from lubrication, I did a bath to it with SAE 90. 

 
Title: Re: Sneak peek of ITTSB Blog Variac transformer case !!
Post by: Kiriakos GR on February 23, 2017, 10:54:29 PM
This is a true sneak peek  8)   because I did first major step and this is attaching 5mm thick aluminum plate over the box.
I did measurements and drilling of holes with extreme caution, and now there is a face-plate so me to work with.

Metal box this is superb regarding inner design, when specialized tools these arrive from Germany, face-plate will get a special treatment.
In my plans it is metal box this to be painted black.

Personally I feel now thousands times less stressed, because I had the chance to drill this aluminum and to find out, of what is it true composition.  ;)




     
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on March 01, 2017, 04:32:12 PM
Today I had the arrival of last and significant piece of my puzzle.  :)

I am impressed of what Chinese industry deliver for 1/3 of the price of what you get from International brands them also using China as manufacturing base. 
The product LW28-20/3 ( GB14048.5 ) this is 7.5KW  15A  AC-23 = inductive loads
Comes with certification.

I am going to use it about switching between two connectivity modes of VARIAC Transformer. 
Mode 1:  0 ~ 230V  = LINE connection 
Mode 2:  0 ~270V =  BOOST connection 
Title: Re: TESA blue tape - Masking of enclosure face-plate for jigsaw or drilling
Post by: Kiriakos GR on March 06, 2017, 11:49:04 AM
Only place for me having my own Shopping Therapy  ---- This is the hardware store ;)

There is the proper way for Cutting a Square Hole in an Electrical Enclosure

https://youtu.be/Qko4-OF8gyg

But highest secret this is the quality of masking tape it self,  it must be 100% glue residue Free, and it must be perfectly flat.
I am always using TESA 4435 outdoor UV, and I am 100% satisfied !

I did the mistake to order Blue tape from Ebay - China, and I got a plain garbage which costed me 5 EUR and it is close to unusable ( (it is not glue residue free) .  >:(
Today I did manage to find the real thing and I am extremely happy.  8)
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giorgos on March 12, 2017, 01:37:46 PM
Today I had the arrival of last and significant piece of my puzzle.  :)

I am impressed of what Chinese industry deliver for 1/3 of the price of what you get from International brands them also using China as manufacturing base. 
The product LW28-20/3 ( GB14048.5 ) this is 7.5KW  15A  AC-23 = inductive loads
Comes with certification.

I am going to use it about switching between two connectivity modes of VARIAC Transformer. 
Mode 1:  0 ~ 230V  = LINE connection 
Mode 2:  0 ~270V =  BOOST connection

These international brands are ussually demands some quality production standards when they are choosing China for production (e.g. Apple , Sony Philips etc) Conversely purely chinese brands doesnt follow these standards, thats why the lower cost and many times low reliability.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on March 13, 2017, 08:37:48 AM
Today I had the arrival of last and significant piece of my puzzle.  :)

I am impressed of what Chinese industry deliver for 1/3 of the price of what you get from International brands them also using China as manufacturing base. 
The product LW28-20/3 ( GB14048.5 ) this is 7.5KW  15A  AC-23 = inductive loads
Comes with certification.

I am going to use it about switching between two connectivity modes of VARIAC Transformer. 
Mode 1:  0 ~ 230V  = LINE connection 
Mode 2:  0 ~270V =  BOOST connection

These international brands are usually demands some quality production standards when they are choosing China for production (e.g. Apple , Sony Philips etc) Conversely purely Chinese brands doesnt follow these standards, thats why the lower cost and many times low reliability.


I am very close to support the contrary in 2017,  China does not need paying for re-branded goods when their own production this is certified and tested according to domestic and international quality standards.

Additionally I will say that such specific products they do not aim consumers households, in such items for industrial use any product selection this is made from electrician engineers.
Regarding longevity (life cycle) not all electrical circuits are made for frequent manual control.
Specific product (switch ) this comes with supplied documentation this predicting life cycle at full power load and frequency of daily use.

In the end of the day, I did my selection by shopping for the appropriate item this able to handle one specific application, by me taking the time to select the appropriate item.
They are others (electrician installers)  shopping industrial parts and be careless, and live by the hope that what ever they will order, this will be able to sustain crazy overloads and unlimited misuse.

Now because distance this is long ( China to Greece ) all that I am possibly missing this is product warranty in the event that this part suffering from production error issue.
I did my own inspection by measuring contacts resistance and I did not find any fault.
 
WEB site
http://www.glele.com/Product_show.aspx?cateID=1&id=168 (http://www.glele.com/Product_show.aspx?cateID=1&id=168)

Product PDF in English
http://www.glele.com/common/godownloads.ashx?id=168 (http://www.glele.com/common/godownloads.ashx?id=168)

   
Panel mount switch technical parameters ( AC-23 AC-22 AC-3) IEC 60947-3
http://www.ittsb.eu/forum/index.php?topic=1252.0 (http://www.ittsb.eu/forum/index.php?topic=1252.0)
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on March 22, 2017, 08:40:11 PM
I can now assume that all major parts for this upcoming project they are landed in Greece.  :)

Feel free to see detailed Panel meters unboxing topic.  http://www.ittsb.eu/forum/index.php?topic=1270.0 (http://www.ittsb.eu/forum/index.php?topic=1270.0)
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on April 11, 2017, 11:30:43 AM
They are still a few less significant bits that did not arrived at my mail box yet.
But sooner or later they will.   ;)

Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 12, 2017, 04:40:32 PM
Gentlemen  8) with huge pride I am presenting pictures of what a real professional brush this can do regarding scuff marks removal.
This is 120 Grit and I am after classic aluminum surface ( clean - But not polished to mirror finish ).

This is my Before / After test, and the outcome this is amazing.    ;D
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 12, 2017, 07:31:41 PM
Ready for the next level  ;) 

Drilling holes and parts installation.   
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giorgos on May 13, 2017, 04:17:10 PM
Very nice finish!
 I have not ever work with this kind of tool, anyway I think that most important point for this procedure,is to keep brush in stable angle, and pressure on aluminium surface.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 13, 2017, 04:49:08 PM
Actually they are involved allot more details.

Brush alone with axle this is half kilo of weight ... Rotation RPM .... weight of power tool it self ... stable hands and control.
Actually there is dedicated power tool just for this brush, with metal handle and shield against particles.
I could not afford paying around 300E for it, I do not do mass production this justifying cost of ownership.

While I am making the case for the Variac,  Variac transformer this is all ready working in to a wooden test box.
And Variac worked at helping me at controlling power drill RPM   ;)


Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 13, 2017, 05:08:04 PM
After 10 hours so far of workflow I am finally ready to start working at front panel.  ;)
When metal work this is over, next step this is a paint-job.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 16, 2017, 05:58:09 PM
95% of machinist work this is completed and I am getting closer to finish line   8)

For now it looks as this to be a magic picture this getting assembled slowly as the project this moves ahead.

 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 17, 2017, 08:46:22 PM
People if you have long time to see something beautiful here it is your chance.  8)

Product of Made in Greece ingenuity and also hand made !!
It is a fact that speaking of use of hand tools and power-tools, and even my own skills, everything were pushed to their limits.

Spotless execution regarding machinist work,  0% Error in Geometry.

Pictures below are from first testing assembly.

   
 
 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giorgos on May 18, 2017, 06:07:42 PM
Perfect job !
It looks like have been made by cnc machine!
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 18, 2017, 06:43:49 PM
Perfect job !
It looks like have been made by cnc machine!

For every step until final assembly, I did paid the price in advance ( money and patience regarding shipping time) so all necessary tools them to be here for this project.
CNC machine has several cutting heads as tools, some of them have 50 and some others 70 or more.

If our choices are characterized by precision, the outcome this will be always successful. 

Thanks giorgos  :)

Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 19, 2017, 12:08:59 PM
Today I got ready for next step,  this is new paint job for the case.  :)

I did visit most advanced shop specialized at auto paints in my area, and I requested them making for me a custom color identical to original of this box.
End result this is spay can including highest quality of paint (as material) and also this very specific color mixture.

The color specialist were supersized because original color this is beige including metal particles but even so this is matte color.

My planing this is restoring original color by a gentle fix over scratches and a fresh look.  ;)
 
 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 19, 2017, 09:05:58 PM
This is a fact of life, that when you have real paint in your hand you do not need any more software assistance from Photoshop, about making things looks nicer in pictures which you take with your digital camera.    8)  8)  8)

Even the paint job were a huge success !!

Next step this is eight hours additional drying time, so the paint to become totally hardened.
Back plate this were prepared prior get painted speaking of required holes for parts installation.

First new parts assembled this taller high quality rubber feet.    ;) 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 20, 2017, 09:09:23 PM
I am not intending to take a picture of its one wire that I am installing  ;D  but some details cannot be photographed with aluminum front plate in place.

Regarding cooling I made a choice for 12V DC fan even if I will have to add another one smaller transformer making a mini DC power supply.
Unfortunately most case fan 120mm at 220 ACV they are serious source of noise, and my goal this is gentle cooling and noiseless.

This is Variac specially designed for laboratory use, and therefore it is not following usual rules of universe.  ;)
 
 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 24, 2017, 11:27:36 PM
Another journey came to the end and because of that several new journeys they are going to begin.  8) 

Kiriakos Triantafillou proudly presents his very own design of modern made Variac transformer for laboratory use.
Most to all parts used in this project they are all certified and branded, I am now officially an IEC fanboy ;D

While most of my work will look familiar to other professional electricians, I will simply clarify that for DC fan I just added a single diode and a small capacitor, DC output this is 7.5V and this helping the fan to operate silently.

Industrial switch this at zero position it does cut-off neutral and phase.
Position one: This is LINE transformer wiring, and translates to adjustment of Mains available voltage down to zero.
 
Position two:  This is Boost transformer wiring, and translates to boost of 230V up to 270 ACV.
According to specific variac transformer user manual, only LINE mode this warrantied  2.1KVA in complete adjustable range.
In Boost mode with consumption of 8A there is slight loss of boost voltage at about 4~5 volts.

In summary this is one indestructible work horse, combining best technology and parts over planet earth, and this having also an Made in Greece product design. 
Total weight 10 Kilos.  ;)
   
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 24, 2017, 11:34:36 PM
...
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giorgos on May 27, 2017, 08:16:17 AM
Excellent job with factory looking!
Very good construction with care even for any detail.
The bannana plugs are in parallel with AC socket for measurements i suppose?
Also allow me to suggest you to put a handle, in order to make the carrying easier.
Now you have a very useful instrument.
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 27, 2017, 08:42:27 AM
I was puzzled for adding or not a handle, all those months.
Due this transformer design and placement, weight balance this is not equally distributed and 95% of weight this is at front panel.
I did thought for a top handle, but this eliminates the option about to add second equipment at the top of this case.
Then I though to add two handles at the front, but this box it is tremendously space limited speaking of how much wide this is.

Front banana plugs they do serve for voltage confirmation purposes.

Variac transformer this is source device, for example ups equipment will be connected to it and one special electrical break-out box will be connected at ups output.
Right now I am working to make this special electrical break-out box.   ;)

Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on May 30, 2017, 07:17:01 PM
Now it is the correct timing 8) so both topics to be bridged ( due links)

http://www.ittsb.eu/forum/index.php?topic=1304.0 (http://www.ittsb.eu/forum/index.php?topic=1304.0)

Variac Powerstat 226U this is the source of New ITTSB test bed, but this it did not designed to work exclusively as stand alone.
Visit link above for more details.  8) 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giavra on June 04, 2017, 08:17:04 AM
Gentlemen  8) with huge pride I am presenting pictures of what a real professional brush this can do regarding scuff marks removal.
This is 120 Grit and I am after classic aluminum surface ( clean - But not polished to mirror finish ).

This is my Before / After test, and the outcome this is amazing.    ;D

I love this old black decker drill, real monster an undying power drill
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: giavra on June 04, 2017, 08:28:46 AM
...

Magnificent work Kyriakos very Glad that this unit is made in Greece
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on June 04, 2017, 09:18:06 AM
Gentlemen  8) with huge pride I am presenting pictures of what a real professional brush this can do regarding scuff marks removal.
This is 120 Grit and I am after classic aluminum surface ( clean - But not polished to mirror finish ).

This is my Before / After test, and the outcome this is amazing.    ;D

I love this old black decker drill, real monster an undying power drill

Every rechargeable power drill this respecting  rpm limits of drill bits, this is a keeper.  ;) 
Title: Re: 2017 - ITTSB project: Assembly of a Variac Powerstat 226U
Post by: Kiriakos GR on August 12, 2021, 07:04:42 PM
This is my feedback four years later, so to confirm that at that project, I did not make the slightest mistake regarding components selection.   8)
It feels good today, that those 14086 of topic Views up to date, they are a proof of specific content popularity within time.

The only issue worth reporting, this has to do with the longevity in time of recent made HP print ink supplies, the ink over the label start fading after 7~10 months time.
Despite the fact that I do buy genuine HP products (cartridges) and paper, the issue remain.
Does HP sabotage their own products quality?
Does HP using ECO-friendly but low quality chemistry?
Either way my next printer this will not be an HP one. 

This VARIAC device does not have an expiration date.  :)