INNOVATIVE ELECTRICAL APPLICATIONS

Here are some unusual uses for common electrical devices:

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A Feet Heater

The concrete floor was cold, so I wanted a heater to keep my feet warm under a workbench. I tried a standard portable heater, but it had two problems:

  1. The standard heater's thermostat alternately roasted and froze my feet.
  2. The standard heater could not be used when I used the soldering iron at the same workbench or the circuit breaker would trip.

The problem is that nobody sells a heater that puts out less than 500 watts. So I made one:

The calculations I used are as follows:

Heater calculations:

Calculations at 240 Volts:

500 W / 240 V = 2.0833 A

240 V / 2.0833 A = 115.2 Ω
 

Calculations at 120 Volts:

120 V / 115.2 Ω = 1.0417 A

120 V × 1.0417 A = 125 W

I bought a 500 watt 240 volt baseboard heater and put a 120 volt plug on it, as shown at right. Make sure the hot wire goes to the thermal fuse.

The calculations show that the heater is now a 125 watt heater.

This heater does not draw enough current to cause problems when the soldering iron was in use.

The heater worked just as I wanted it without a thermostat.

When I later wanted to adjust this kind of heater's output, I found that an ordinary lamp dimmer worked quite well.

Because of the shape of the case, I had to put the heater upside down so it would set on the floor.

desk heater

Wiring diagram of a 240 V
500 W heater connected as
a 125 W 120 V heater


A Floor Warmer

The floor is cold in the house when the weather is colder outside, so I wanted a way to make the furnace run longer per cycle when the floor is cold, rather than having to monkey with the thermostat when the weather changes.

Lamp calculations:

Calculations at 120 Volts:

10 W / 120 V = 0.0833 A

120 V / 0.0833 A = 1440 Ω

3 W / 120 V = 0.0025 A

120 V / 0.0025 A = 4800 Ω
 

Calculations at 24 Volts:

24 V / 1440 Ω = 0.0167 A

24 V × 0.0167 A = 0.4 W

24 V / 4800 Ω = 0.005 A

24 V × 0.005 A = 0.12 W

I bought a second thermostat and mounted it just above the baseboard at floor level. I used a Honeywell CT31 A1003 with a slotted cover over it to protect it from foot traffic. These thermostats must be simple thermostats, not electronic ones.

I connected the heat connections of the floor thermostat to the terminals across the anticipator heater of the other thermostat, as shown in the diagram.

The connection marked $ has no screw terminal and must be soldered. Also, cut the jumper at x.

The light bulb is optional. Its purpose is to make the anticipator on the floor thermostat operate. Use a 120 V bulb between 3 W and 10 W, and keep it away from the thermostats.

Set the floor thermostat 2 to 4 degrees below the setting on the wall thermostat.

Set the wall anticipator for normal operation. Set the floor anticipator experimentally to get the amount of extra heat needed.

To enable the floor thermostat, set its switch to HEAT.
To disable it, set its switch to OFF.

floor booster

The two switches shown
are ganged.


Another Floor Warmer

The floor is cold in the house when the weather is colder outside, so I wanted a way to make the furnace run a little short cycle to pull the cold air off the floor and heat it.

The return register must be on the floor. This will not work if the return registers are on the ceiling.

I bought two identical thermostats.

I mounted the wall thermostat in the usual place. I mounted the return thermostat on the return air register.

These thermostats must be simple thermostats, not electronic ones.

I connected the heat connections of the return thermostat in parallel with the heat connections of the wall thermostat.

Set the return thermostat 1 to 3 degrees below the setting on the wall thermostat.

Set the wall anticipator for normal operation.

Set the return anticipator for the shortest possible burn time that will start the fan.

Do not set both anticipators to the same values. This will cause alternating extremely hot periods and extremely cold periods.

To enable the return thermostat, set its switch to HEAT.
To disable it, set its switch to OFF.

floor booster 2

An Air Stirrer

The air in the house gets stratified. Also, the air needs to be run through the high efficiency filter periodically. The electric bill goes way up if the fan runs continuously. So I wanted a way to occasionally run the fan to stir the air, whether or not heat is needed.

Light Bulb at 120 Volts:

25 W / 120 V = 0.2083 A

120 V / 0.2083 A = 576 Ω
 

Calculations at 24 Volts:

24 V / 576 Ω = 0.0417 A

24 V × 0.0417 A = 1.0 W

I bought a thermostat and mounted it high on the wall (above normal wall level). I used a Honeywell CT31 A1003 with a slot cut in the bottom edge of the cover to admit heat from the light bulb mounted below it. These thermostats must be simple thermostats, not electronic ones.

Cut the jumper at x.

When enabled, this circuit cycles the system blower on and off. Adjustment of the anticipator and thermostat settings determines the cycle length and the duty cycle of the blower.

The lamp should be mounted in a metal enclosure directly under the thermostat. A 25 W 120 V lamp was used, but is operating on 24 volts. The top of the enclosure must be open

To enable the stir thermostat, set its switch to HEAT.
To disable it, set its switch to OFF.

stir control

The two switches shown
are ganged.


An Air Conditioner Thermostat Controller

One of my window air conditioners has a thermostat with way too much hysteresis. It alternates between letting the room get as hot as 84 F and cooling it down to 76 F. I needed a way to tighten up the temperature band.

Light Bulb at 120 Volts:

25 W / 120 V = 0.2083 A

120 V / 0.2083 A = 576 Ω
 

Calculations at 24 Volts:

24 V / 576 Ω = 0.0417 A

24 V × 0.0417 A = 1.0 W
 

The relay is a 24 V 10A relay. The contacts are normally closed. The A/C is 500 W.
 

When the new thermostat calls for heat, it turns off the A/C.

The LED shows when power is sent to the A/C.

I bought a Honeywell CT31 A1003 thermostat and mounted it to one side of the air conditioner (later I moved it to an inside wall). I built a power supply and relay so the new thermostat can control power to the A/C. The light bulb is used to make the anticipator on the new thermostat work (I had put a baffle in so the A/C did not blow on the new thermostat before I moved the thermostat).

Adjustment of the anticipator and new thermostat settings determines the temperature band.

The lamp should be mounted away from the thermostat. A 25 W 120 V lamp was used, but is operating on 24 volts.

To enable the new thermostat, set its switch to HEAT and turn its fan switch OFF. Turn the A/C's thermostat so it stays on.

To disable the new thermostat, allowing the A/C's own thermostat to control it, set the heat switch to OFF and the fan switch to OFF.

To make the A/C unit stay off, turn the fan switch to ON.

a.c thermostat control

The two 3-position switches shown are ganged.


Timer Control of Air Conditioner

I had a heavy-duty electronic timer controlling a booster air conditioner. The problem was that the surge from the air conditioner starting or stopping erased the settings on the timer.

I bought an Intermatic 15A appliance timer to control the 500W air conditioner. Then I had to add the other parts to keep the surge from the air conditioner from erasing the settings on the timer. I put everything in a 2-gang handy box with 2 duplex outlets feeding the lamps and timer. The orange and black plugs and the orange socket are on cords.

The capacitors and the resistive incandescent lamps offset the inductive load of the air conditioner. This protects the electronics and the contact points from the surges from the air conditioner when it starts and stops.

I colored the outlet faces the indicated colors with permanent markers to prevent them from being used for other uses. The lamps are in plug-in screw sockets.

A/C timer protect

Screw vernier thermostat adjustment

I had trouble being able to adjust the thermostats in small increments and decrements. The lever usually stuck, then moved more than 5 degrees away from the setting.

I bought the thermostat used (was not already there), a small (2-inch) C-clamp, and some super glue gel.

After clamping a thin flat piece of cardboard in the clamp, I put super glue in the swivel of the movable jaw to immobilize it. Then I let the glue set up.

I used a cut-off wheel on my angle grinder to cut the clamp handle in half, so it would come off.

Next, I loosened the clamp and removed the cardboard. Then I put the clamp in a drill-press vice and cut off from the rest of the clamp the threaded hole for the adjusting screw and enough of the clamp frame to line up the movable jaw with the temperature control (see top angle view in lower image).

Then, I super-glued the free end of the stub of the clamp frame to the flange of the thermostat mounting plate so the movable jaw contacts the temperature adjustment control.

Next I connected the wiring to the thermostat.

Finally I mounted the thermostat.

Using it:

To set it up, hold the temperature control and turn the vernier clockwise (as seen from the handle end - left in the photos) until it touches the control.

To increase the temperature a small amount, turn the vernier clockwise the desired amount.

To decrease the temperature a small amount, turn the vernier anticlockwise the desired amount. Then push the temperature control against it.

Be sure to explain this operation to all people using the thermostat.

Vernier thermostat

Vernier Thermostat

Vernier thermostat mount

Traffic-Actuated Stairway Lighting

I wanted to make stairway lighting in my home automatic. The lights come on only when someone is actually using the stairs.

I bought two outdoor motion detector floodlights to use as detectors. They must be the kind that uses a relay to turn on the lights and uses screw shell bulbs. I mounted one at each end of the stairs. If the stairway has a landing between flights, additional detectors can be wired in. This can also be used in a long hallway or on a ramp.

Lights can be connected in anywhere along the run. But the total wattage must be smaller than the capacity of any one of the detector units.

I later had to add a switch (shown) to turn off the lights in the event that a power sag caused some of the detectors to stay on, leaving the lights on. Turning the switch off for 5 minutes fixes it.

Aim the detectors so that the entire stairway and its approaches are covered by their sensory fields.

stairway lights

Black = 120 V Hot   White = Neutral
Red = Switched Lamp Power   Green = Ground (bare)


LED Christmas Light Circuits

LED Christmas Light Circuits

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Surround Sound Field Miking Techniques

Surround Field Recording and Spheround

surfield 3d

Circuits for New Technology Bulbs

Circuits for New Technology Bulbs (scroll down)

swing bell swing bell swing bell

Switching Circuits for Selecting Between Series and Parallel

Selecting Between Series and Parallel

swing bell

Build Special Purpose Lamps

Build a Full Spectrum Lamp

Build a Lamp for Defective Color Vision

Simulate Defective Color Vision

full spec cb sim

My Inventions and Discoveries

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