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Hardware Hacking
Forum Hardware hacking an electric fan heater without burning the house down
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  • hardwarehackingch
Related

Hardware hacking an electric fan heater without burning the house down

BigG
BigG over 5 years ago

I recently purchased a 2kW electric fan heater for $12 (it was on sale). This was an offer too good to refuse, especially as the latest Project14 competition is hardware hacking.

 

image

 

These fan heaters, like any other personal heater, are great for the winter months.

 

However, as I have on the very odd occasion left an oil heater on over night (it is very easily done), I certainly wouldn't want to do the same with an electric fan heater.

 

So I want to add in some "smarts" or electronics to ensure that it can automatically turn off if I leave the room etc. and it would also be handy to remotely adjust heat and fan speed.

 

The nice thing about this particular fan heater is that it has a safety cut off switch, should it tip over. I thought that this would be my starting point for my project, as this part can be readily enhanced.

 

image

 

 

The part I am struggling with is how to or what electronic options could I use to hack the heater settings switch, which is mechanical. How could I do this electronically, bearing in mind we are dealing with mains voltage.

 

{gallery:autoplay=false} Heater Settings Switch

image

image

 

And the other question is what options are out there on how to hack the fan speed controller... this also is mains voltage, so I'm out of my depth in terms of using a digital potentiometer, for example.

 

image

 

Any suggestions / ideas would be greatly appreciated.

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Top Replies

  • BigG
    BigG over 5 years ago in reply to shabaz +1
    I am still unpacking and tearing it down myself to understand the wiring and the rest. I've yet to sketch out a wiring diagram and it's quite hard to capture the key elements in photos. It looks like two…
  • shabaz
    shabaz over 5 years ago in reply to BigG +1
    Hi Colin, I was looking at your photos earlier, and think that's a bimetallic strip (it bends when it gets hot, and self-disconnects). the rotary control just adjusts the point it occurs by moving it closer…
  • ralphjy
    ralphjy over 5 years ago +1
    Very interesting teardown. Always fun figuring out these electromechanical gadgets. You've almost inspired me to hack an old thermostatically controlled window fan but summer is here and I use it all the…
Parents
  • BigG
    BigG over 5 years ago

    I'm assuming the switch on the heater is a 4-way 2 pole switch, similar to this more robust version: https://uk.farnell.com/schneider-electric/k1f013qch/rotary-switch-2-pole-5-6a-230v/dp/3108333

     

    As such, I started looking at 4 way double pole power relays and I found that there are a few options available, such as this one:

     

    https://uk.farnell.com/schneider-electric/rxm4ab2jd/relay-4pdt-250vac-6a/dp/2056435

     

    Looking at the photo of the fan switch, it looks like there are two ratings one at 6A and the other at 15A. Now, if I went for a 4PDT relay rated at 15A, the price shoots up for that rated current and for the price of one 4PDT relay I could buy two fans.

     

    So I am wondering if I could craft my own hybrid relay circuit using a suitably rated DPDT or SPST power relay, where one is for 15A and the other one is for 6A. This could saves quite a few bob but the circuit wiring will need thought as I wouldn't want a case of two relays turning on at the same time.

     

    Any suggestions?

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  • BigG
    BigG over 5 years ago

    I'm assuming the switch on the heater is a 4-way 2 pole switch, similar to this more robust version: https://uk.farnell.com/schneider-electric/k1f013qch/rotary-switch-2-pole-5-6a-230v/dp/3108333

     

    As such, I started looking at 4 way double pole power relays and I found that there are a few options available, such as this one:

     

    https://uk.farnell.com/schneider-electric/rxm4ab2jd/relay-4pdt-250vac-6a/dp/2056435

     

    Looking at the photo of the fan switch, it looks like there are two ratings one at 6A and the other at 15A. Now, if I went for a 4PDT relay rated at 15A, the price shoots up for that rated current and for the price of one 4PDT relay I could buy two fans.

     

    So I am wondering if I could craft my own hybrid relay circuit using a suitably rated DPDT or SPST power relay, where one is for 15A and the other one is for 6A. This could saves quite a few bob but the circuit wiring will need thought as I wouldn't want a case of two relays turning on at the same time.

     

    Any suggestions?

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