Power Box Key Switch Mod - NOW FINISHED

[petercr]

Even easier, safer and more reliable...

http://www.jaycar.com.au/productView...d&form=KEYWORD

$65 worth a life??

[TERRA Operative]

Originally Posted by myforwik

You really need to fix some things with that:

-you need stress relief on all the power cords and and appropraitly IP rated grommets... someone could pull the cords right out, and if its the power end they could kill themselves. 'cable ties' don't cut it..... don't cut it at all.

-you appear to be using snap lock connector on netural, at a minimum you should be using a screw connector, looks like you did it that way because they are cheap and easy, but its 100% dodgy and no one actually uses them, let alone on something that should be able to handle 2400W

-because you aren't using double screw terminals, you need insulation between active and neutral. What happens if a neutral comes out of that POS connector (this WILL happen eventually in a mobile box like that)? It could fall onto the active screw terminals of the switch, which will cause the plastic case to catch on fire and burn your house down.

-you have twisted the ends of the wires a rediculous amount and you will almost certainly have damaged strands that are going to weaken and cause the wire to eventually snap

-And worst of all, you must solder those earths together... seriously thats probably the most dangerous part. That two twist crap with a cap is what you put on a 9V kids toy, you don't do that crap on earth for a 2400W power lead that is powering things with exposed chassis like PC's... If that connections becomes poor (And it will) you can forget about RCD's saving you and you can forget about breakers blowing when you have shorts to earth - instead your earth will just come live and kill the next person who touches the pc.

Why risk it when you can buy these devices for $30 or so off the shelf?

- IP rating isn't applicable here. Touch testing is fine, as there are no exposed terminals. (Basically, if you can't poke your finger into any live terminals, it's ok). The box does require strain relief however. Cable ties may or may not provide that...

- The scotch lock style connector appears to be a 240V rated version, they are available and approved for use.

- Double screw terminals aren't required in the latest AS3000, and in the older versions, it was only required on the earth if the terminal was not secured down. Single screw terminals, as in this application are fine.
If the terminal was to come loose, the house won't burn down, it would create a dead short, that will trip the circuit breaker in the switchboard. That's what they're there for.....

- Twisting of wires is fine, although technically, you cannot use screw terminals on flexible leads as the screw can cut into the strands (twist rate isn't an issue). Terminals with inbuilt strain relief (a small tongue of metal between the wire and screw) must be used.

- Do you know what you're talking about? There is NO requirement to solder earths, and if the earth does come loose and he gets electrocuted down to another earth point (ground etc) the RCD will still trip.
Please don't fill this thread with opinionated heresay.
BP (blue point) screw connectors are used everyday by electricians, and they provide a perfectly adequate and legal connection, your house wiring will have them on power and lighting circuits guaranteed. You're still alive yes?

Originally Posted by robnkel

No cord grips anywhere to be seen.
Illegal mod on extension cord.
Just because you can doesn't mean you should.
If your not a licensed electrician you shouldn't be doing this.
Especially posting this sort of thing on a public forum to encourage others to electricute themselves is stupid.

Cord grips are a valid point. Although the practice of building this device is not illegal, as it was passed by a registered electrician, do you people read???

It's only illegal to build a plug in mains powered device in Queensland, and all you need to do if you're in QLD is to get it checked over and passed by an electrician.


Over and out from a 10 year sparky across 3 states. As always, IANAL etc.

[Goth]

Originally Posted by TERRA Operative

It's only illegal to build a plug in mains powered device in Queensland, and all you need to do if you're in QLD is to get it checked over and passed by an electrician.

Right, it would be completely legal even if he was in Australia, since it isn't hardwired into the mains... except for Queensland.

In New Zealand, it's actually entirely legal for unlicensed people to install their own light switches, GPOs, domestic wiring etc.

[Renza]

hah youre not supposed to strip the wires if you're going to use a scotch lock...

[CyberBeat]

Originally Posted by myforwik

You really need to fix some things with that:

-you need stress relief on all the power cords and and appropraitly IP rated grommets... someone could pull the cords right out, and if its the power end they could kill themselves. 'cable ties' don't cut it..... don't cut it at all.

-because you aren't using double screw terminals, you need insulation between active and neutral. What happens if a neutral comes out of that POS connector (this WILL happen eventually in a mobile box like that)? It could fall onto the active screw terminals of the switch, which will cause the plastic case to catch on fire and burn your house down.

Why risk it when you can buy these devices for $30 or so off the shelf?

First Off id like to thank Sleepy Dude for helping me out.

Secondly This box is stationary and never moves from my desk.

and thirdly that $30 or so thing isnt what i want.
I use this every day no problems. Because it is connected to the power-box it has a fuse to trip if anything were to go wrong.

And the cable ties were recommended by my uncle. People need to face it. This is SAFE. It is NOT illegal and works perfectly Fine.

[Renza]

a fuse/rcd wont save you from everything.

[myforwik]

Originally Posted by TERRA Operative

Do you know what you're talking about? There is NO requirement to solder earths, and if the earth does come loose and he gets electrocuted down to another earth point (ground etc) the RCD will still trip.

I agree, i didnt say that it wouldn't in that case. But what if earth comes loose and neutral hits the chassis, then he could get electrocute from active to chassis and the rcd won't trip

I only said he needs to solder it because he has cut a flex extension cord in half and the strands are to small to screw. Is it true that you can go down to any strand size as long as you use a pushing plate?

[petercr]

Originally Posted by CyberBeat

And the cable ties were recommended by my uncle. People need to face it. This is SAFE. It is NOT illegal and works perfectly Fine.

I think you need to understand that those who know their electrical safety rules are telling other people NOT to try it because it IS illegal in certain parts of Australia and if not done safely could be fatally dangerous.

[TERRA Operative]

Originally Posted by myforwik

I agree, i didnt say that it wouldn't in that case. But what if earth comes loose and neutral hits the chassis, then he could get electrocute from active to chassis and the rcd won't trip

I only said he needs to solder it because he has cut a flex extension cord in half and the strands are to small to screw. Is it true that you can go down to any strand size as long as you use a pushing plate?

Same deal with your washing machine... His case is plastic, so livening it up isn't an issue.

Yep, any strand size, so long as you use a bootlace crimp or that plate is there, or there is some other adequate way to prevent the screw damaging or cutting the strands. (that DOESN"T involve solder before the screw).
The only mains wire type you can screw directly onto is the solid core or 7 strand building wire etc. For this application anyway.

[Sundarjee77]

I've been following this thread for a while and I think while the overwhelming consensus is that its dangerous however its non the less a very cool mod!

Big ups for going all the way with this