2017 - ITTSB project: Assembly of a Variac Powerstat 226U

[Kiriakos GR]

People if you have long time to see something beautiful here it is your chance. 

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.

   
 
 

[giorgos]

Perfect job !
It looks like have been made by cnc machine!

[Kiriakos GR]

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 

[Kiriakos GR]

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. 
 
 

[Kiriakos GR]

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.       

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.     

[Kiriakos GR]

I am not intending to take a picture of its one wire that I am installing    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. 
 
 

[Kiriakos GR]

Another journey came to the end and because of that several new journeys they are going to begin.   

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

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. 
   

[Kiriakos GR]

...

[giorgos]

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.

[Kiriakos GR]

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.   

[Kiriakos GR]

Now it is the correct timing so both topics to be bridged ( due links)

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.   

[giavra]

Gentlemen  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.   

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