Please help with me flip flop........DB.......Please?

[megatrom]

Hey guys, I'm new here.....well new to posting. I've learned sooooooooooo much from this site, and for that I must express my gratitude, thanks folks. Also thank you pontiac and contributing authors and editors for the link-o-rama!!!! A wealth of info there.

Okay enough kissing ass. I've made my own remote ballast hps lamps, cool tubes, dwc, and an assortment of cabinets. So....my next challenge is building a flip flop. Hopefully anyone with the appropriate knowledge can help me stay safe.

I want to build a 4 ballast relay. So far my purchase have been 4 open style dpdt 600v 1-1/2hp 30amp at 120\240vac 1ph 2hp or 20amp at 600vac. I've also purchased an appropriate sized metal enclosure by square D, all the reseptacles and cords rated for 600v. I conpletely understand how to wire the relays and everything else on the very basic level.

My main purpose, aside from the obvious reasons of comendearing such a task is....safety. I would like to supercede any mandated safety regulations.

My first concern is, the coils on my relays are rated at 24vac. An oversite on my part. So, I realized that I would need a 24vac transformer. I then purchased a multi purpose transformer made for a doorbell system. (biting my nails). I did a test run, and wired the transformer to one relay, and then 2 relays, and it worked. I don't know if this is safe. Should I run some inline fuses to the relays?

Also, would it be wise to install breakers on the flip, or build a seperate load center? If I was to install breakers on the flip, would i need 1 30amp breaker on a 120 rail for each relay? Is there an equation or mathematical solution to figuring out what size breakers to use on a circuit of any size, whether it be just receptacles or fans etc..

Now my last concern is the "welding" of the contacts on the relay after prolonged use. I've read somewhere else that an additional relay be used as redundancey for this. I don't know if it's another dpdt type relay, or a safety relay.

Any help would be greatly appreciated!!!!!
DB any suggestions?

Thanks in advance
Mega

 

[DB2004]

Building Flips is pretty standard. When you start combining, time delay circuits, thermal protection, etc, it becomes more complicated. The relays used for a Flip are pretty much the ones you have. After about a year, there will be a small build-up of carbon on the contacts. Flips will usually last 1 to 2 years, but there are ways to make them last much longer. By turning off the ballasts fro ten to sixty seconds before and after the Flip cycle, you will have no arcing of the contacts. When the relay switches bulbs, the ballast is off, momentarily, then ballast turns back on from ten to sixty seconds later. All that's needed is two digital AUBE timers, and they keep exact timing, within a few seconds per year. A couple time delay relays also would work. A seperate loadcenter is your best bet. Standard code says no more than 80% max of breaker rating, 15A is about 12A, or about 1500W. Only other advice I can suggest, is when you are doing your terminations, don't use the crimps in a pair of wire strippers. For about $40 you can get a set of ratchet crimps for 10AWG to 16AWG wire. They make a more solid connection. Good luck with your build....

Best Regards

DB

 

[megatrom]

DB you are the man, that was the info i needed!!! Thanks for the tip on the ratchet crimp set! So, the doorbell transformer will suffice for the coils then? That was my biggest concern.

Many Thanks
Mega

 

[Guest]

As long as the transformer is the voltage and the current AC/dc Your fine. The transformer only flips the switch no higher current than the 24 volts.

FWIW I have used my own flips for over 2 years. No problems ever and I don't turn the ballast off.

The only breakers I use are on the ballast itself Its hardwired into my Panel. No other breakers are needed. If there is a Problem downline the ballast breaker will trip. I have never had a problem.

 

[megatrom]

cool!!! thanks for the reply guys!! I'm phsyched now!! Time for a new project!! Once me gets me camera, i'll be posting some pics.

 

[gregor_mendel]

Just a little off topic:

What triggers the coil on the relays?

A timer which is off for 12 hours, with the relay switch on side A, then on for 12 hours, powering the coil to hold the switch on side B?

Like normally open or normally closed?

Can anyone help?

gregor

 

[Guest]

Just a little off topic:

What triggers the coil on the relays?

A timer which is off for 12 hours, with the relay switch on side A, then on for 12 hours, powering the coil to hold the switch on side B?

Like normally open or normally closed?

Can anyone help?

gregor

What ever the coil voltage is 120v 12 V 24 v what ever, that must be supplied to the coil the entire time you want it held in the flip postion. You can use a cheap timer for that.