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Forget Me Not Design Challenge
Blog Forget Me Not :  eLDERmon  Electrical
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Engagement
  • Author Author: mcb1
  • Date Created: 8 Aug 2014 10:21 AM Date Created
  • Views 2011 views
  • Likes 3 likes
  • Comments 11 comments
  • forget_me_not
  • current_transformer
  • current
  • iot_eldermon
  • mains
  • internet_of_things
  • enocean
  • electrical
  • safety
Related
Recommended

Forget Me Not :  eLDERmon  Electrical

mcb1
mcb1
8 Aug 2014
Link to other posts
Forget Me Not : eLDERmon Intro
Forget Me Not :  eLDERmon  Electrical
Forget Me Not :  eLDERmon  Outlets
Forget Me Not : eLDERmon Planning
Forget Me Not : eLDERmon Parts 1
Forget Me Not :  eLDERmon  Sponsor Parts
Forget Me Not : eLDERmon Hardware Hacking
Forget Me Not : eLDERmon GNUplot
Forget Me Not: eLDERmon Protocol
Forget Me Not : eLDERmon Hardware Hacking #2
Forget Me Not : eLDERmon Hardware Hacking #3
Forget Me Not : eLDERmon OpenHAB

 

 




The Forget Me Not challenge throws up opportunities for interfacing with electrical devices.


There are many ways this can be accomplished, but sadly I do see some dangerous practices, that are posted by the ignorant.

image

 

Dangers
Electrical safety isn't something to be dismissed, since it can kill.
Generally the victim isn't someone working with the Mains voltage, but an unintentional contact (ie by accident)

 

http://www.smh.com.au/nsw/faulty-usb-phone-charger-blamed-for-sheryl-aldeguers-death-20140627-zsoc8.html

Phone kill: Faulty charger electrocutes woman in Australia — RT News
While the above tragic event is linked to poor manufacturing, poor implementation is just as bad and can have the same effect.

 

This post has a very good video showing the construction of a cheap switch-mode power supply.
http://www.austech.info/electronics/92054-cheap-usb-devise-kills-woman.html#post611192


The important bit to note is that the insulation between the mains voltage and the low voltage side was obtained by a single layer of insulation.

 

 

 

Safety
The basic premise of electrical safety is to prevent unintentional contact with voltages exceeding 50V ac or 120V DC.
In order to achieve that, cables that are exposed to contact must have double insulation.


          Photo source Wikipedia  Thermoplastic-sheathed cable - Wikipedia, the free encyclopedia

The picture above shows 2 core  + earth TPS where the wires contain the first layer of insulation and the TPS Sheath the second.
This cable is generally used for fixed wiring (ie inside the wall cavities and in the roof space, etc), and may have a single strand if the size is smaller.


Cables designed to be moved or flexed and may be subjected to greater abrasion have a different construction featuring a higher number of smaller conductors in each 'core' and tougher sheathing that resists abrasion.

image
  Photo source TLC Electrical Supplies
image

 

As you can see there is two layers of insulation BUT if the outer becomes damaged, then it is essential that it is repaired or replaced.

 

 

 

How is this relevant
For this challenge some may be wanting to measure the current used by an appliance, and some practices are NOT SAFE.
Generally the outer insulation is removed, and a measuring device is fitted around the cable, which might be rated (or not) for mains voltages.


This was done by a professional for the purposes of testing AND SHOULD NOT BE USED as a normal practice.

Photo source http://goughlui.com/?p=5184image

 

Placing this arrangement inside an enclosure is marginally better, but the cable leaving the Current Transformer is unlikely to be mains rated and therefore should be 50mm away from cables carrying mains voltages.
Something this person clearly didn't understand when wiring this Death Trap.

imageimage
  Photo credit ...someone with a death wish


 


Switchboards

There is also a requirement that cabling within a switchboard is suitably rated and because of the 50mm distance, these are not safe.


image

The photo source is american and the laws may allow this in a domestic situation, but it isn't legal here or Australia.

While the CT may be rated, the cables aren't double insulated BUT could have been sleeved to make this 100% safe.



 

These clamps may be rated (and of good quality), the cables aren't and the 50mm spacing is compromised, .... especially when you read that he shoves them in to put the cover on.

image

The exposure on the outside is plain wrong and because of this I'm not crediting the source.

 

 

This project is on the OpenEnergyMonitor website and was copied by one of our local members, until we pointed out that the CT cable needed sleeving as it exited the switchboard.

This is a good example where most of the bits are right, but a little more makes it 100% safe.


image

Photo source http://openenergymonitor.org/

A cable clamp (rather than a knot) on the mains cable on the bottom left wouldn't hurt either, but top marks for putting it inside a plastic case to prevent contact by others.

 

 

 

Really DUMB

This person deserves entry into the Darwin awards.

Not only has he put together something that is dangerous, his comments about why it doesn't work so well shows he has little understanding of what he's doing.


imageimage

He did have this warning, BUT he should have wrapped the metal bit FIRST then added wire that was mains rated.


image

 



Show me a SAFE way

The only safe way to measure mains currents is by observing the double insulation requirements.

At work we had a need to easily measure the currents in our racks, and one of our electricians put together this.


image

image

 

This consists of a normal socket outlet (we use the screw retainer) with two cord clamp modules.

A piece of 10mm mains rated sleeving is clamped and forms a U shape that allows any size clamp meter to be applied.

 

image

 

image

 

The neutral wire to the outlet is fed through the loop, before terminating on the socket.

 

This provides a safe means to measure the current (since the phase and neutral currents SHOULD be the same) and therefore any current meter or CT could be used.

The use of the neutral wire also means if something went horribly wrong, the voltage potential above earth is minimal/zero.

 

 

In the next safety blog, I'll show a safe means of controlling an outlet, that is also wireless (RF).

 

Mark

 

 

 

edit ... the first two links seemed to be joined.


 

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Top Comments

  • pmh
    pmh over 8 years ago +2
    Show me a SAFE way The only safe way to measure mains currents is by observing the double insulation requirements. I like the simplicity of your professional solution a real neat and relatively safe way…
  • mcb1
    mcb1 over 8 years ago in reply to pmh +1
    pmh While not disagreeing with the broken neutral, the device would also fail to work, so there will be no neutral or phase current. Hopefully someone would be establishing the lack of power, rather than…
  • mcb1
    mcb1 over 11 years ago in reply to crosseyejack

    You've raised a very good point.

    Perhaps someone at element14 should do a video of de-constructing some of the supplies sold on the site to show the difference.

     

    I decided to pull one of the cheap Asian sourced USB charger/supply apart and was shocked at the poor quality and attention to safety regarding the mains voltage. I didn't pull the transformer apart but looked at and thought ... holy c***.

     

    I should do some photos for later inclusion in a blog.

     

    Hopefully our contestants think about how they implement/interface with Mains voltages ....

    Mark

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  • crosseyejack
    crosseyejack over 11 years ago

    Even though I have watched this video a good number of times, there is something about mike explaining stuff that just can make me watch it over and over and over again.

     

    I'm am surprised we don't have a video of him going though this xray machine whist explaining why not to go though his xray machine.

     

    (Does he still have it for did it sell it by now? I wouldn't be surprised if its still in his garage.)

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  • DAB
    DAB over 11 years ago

    Hi Mark

     

    Good post.

    I am always amazed at how little most people understand about basic household wiring.

    They seem oblivious to the idea that they could kill themselves or set their houses on fire.

    Even when you tell them that their modifications void their house insurance, they still think they can do as they please.

     

    Thanks for alerting people to always be safe.

     

    DAB

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  • fvan
    fvan over 11 years ago in reply to tekmeister

    Quote of the week image

    Photo credit ...someone with a death wish

     

    Very informative!

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  • tekmeister
    tekmeister over 11 years ago

    I like those last images, a nice and elegant solution.

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