Speed Controller for 110V-220v power tools, ect...

[americanedgetech]

I am posting this separate from the "Which Buffing Wheels thread for many reasons.
First, and forempost... DO NOT ATTEMPT TO BUILD OR USE THIS CONTROLLER IF YOU ARE NOT FAMILIAR WITH BASIC HOUSEHOLD ELECTRICAL WIRING,

This is a speed controller for 110-220 volt SINGLE phase electric motors, and voltage controller for heating elements.

All of the parts I used came from Fleabay, The Big River site, or the local hardware store. I included links that will expire so I'd suggest at least looking them up to find the part, and bookmark a source of your own.
The build is straight forward, and takes about 2 hours to drill the enclosure for mounting the various pieces, wire it all up, and mount everything.

This consists of an SCR or silicon controlled rectifier: https://en.wikipedia.org/wiki/Voltage_regulator
"SCR regulators[edit]
Regulators powered from AC power circuits can use silicon controlled rectifiers (SCRs) as the series device. Whenever the output voltage is below the desired value, the SCR is triggered, allowing electricity to flow into the load until the AC mains voltage passes through zero (ending the half cycle). SCR regulators have the advantages of being both very efficient and very simple, but because they can not terminate an ongoing half cycle of conduction, they are not capable of very accurate voltage regulation in response to rapidly changing loads. An alternative is the SCR shunt regulator which uses the regulator output as a trigger, both series and shunt designs are noisy, but powerful, as the device has a low on resistance."

A digital volt,amp meter that uses an inductive coil pickup.

A 110v cooling fan.

And a circuit breaker and, or a power switch of your design needs.

I will include the photos, and description for the 110 volt version but both 110, and 220 volt use the same parts. The wiring, and the plug used are the ONLY difference.

This is simple enough... The 110 hot (black wire) wires to the switch/breaker. Opposite side of the switch/breaker wires to the fan, the light, and the control side of the SCR.
The Neutral side of the input wires to the fan, the light, the NON control side of the SCR, and finally to the neutral side of the box outlet.

The control side output of the SCR is the lead that gets the inductive pickup for the amp/meter, and finally to the hot side of the box outlet.

The voltage side of the meter wires into the same spots as the output of the SCR.

Basically that is it.
In the 110 volt mode the potentiometer that controls voltage/speed will only have an effect from the mid point in its travel to zero.
In the 220 volt set up it works from full travel to zero.

I have four of these that I have been using for at least 6 years, and none to date have failed, and I use them almost daily. One on a router, grinder, drill press, and one on infrared heat lamps for curing resins/paints.
The box I show pictured is convertible from 110 to 220v. That is why there are two breakers, and a 220 volt outlet All I have to change is the power cord, and one wire to change the voltage

If you have any questions just ask.

Speed Controller Parts List
10awg power cord (110v 3 conductor) https://www.ebay.com/itm/10-3-SOOW-SO-C ... 4170642bb7
3 prong female outlet (Hardware store)
3 prong male end (Hardware Store)
Gromet for power cord into box https://www.ebay.com/itm/Sky-High-1-0-A ... SwZJBX-AuB
Steel Project box https://www.ebay.com/itm/9-8-x-7-5-x-4- ... SwTm9Z7aRn
Digital Amp/Volt Meter (Inductive type. non shunted) https://www.ebay.com/itm/AC-80-300V-100 ... SwZjJU8C5o
SCR Voltage regulator https://www.ebay.com/itm/10000W-AC110V- ... 1c96f8d791
110 volt case fan https://www.ebay.com/itm/80mm-38mm-New- ... SwOdpXxfaU
110 volt power lamp https://www.ebay.com/itm/120v-110v-Volt ... Swx2dYGNF6
Power switch or circuit braeker https://www.ebay.com/itm/Airpax-15-Amp- ... eT&vxp=mtr
Rubber feet for box https://www.ebay.com/itm/4-Pack-Rubber- ... 3cc0975b58

[QTCut5]

Seems simple enough!
You forgot to include STEP 1: BEFORE BEGINNING THIS PROJECT, make sure your homeowner's fire insurance is up to date!!!

( )

~Q~

[Jeffinn]

Thanks for this post Ken!

[americanedgetech]

Seems simple enough!
You forgot to include STEP 1: BEFORE BEGINNING THIS PROJECT, make sure your homeowner's fire insurance is up to date!!!

( )

~Q~

No worries Q...
Insurance won't cover home made disasters anyway.

There are several different ways to build a controller for single phase motors from a simple dimmer switch to high speed switching relays to frequency control.
I build these for under $100.00, and they last for years. They are simple, and create no electronic "noise" as the other types tend to do, and even tho I use a fan the boxes never even get warm to the touch running 24 hours or more.

You can buy similar controllers at HF or FleaBay even home centers but they do not last because they are not as over built as these so you end up buying several, until you just upgrade your equipment out of frustration. Money wasted...

Budget build, and gets the job done.

Anytime Jeffin If you need help, let me know.

[Jeffinn]

Ordered all my parts last night so hopefully I can get started on this in the next few weeks!
Jeff