Homemade AC light dimmer

   / Homemade AC light dimmer #1  

joshuabardwell

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Knoxville, TN
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Bobcat CT225
I want a dimmer to dim about 300-500 watts of incandescent lighting, and I think I could probably make something a lot cheaper than I could buy it. Is there any reason why I shouldn't just buy a dimmer switch, a wall box, and a face plate from the hardware store, then cut an extension cord in half and wire it into the switch?

In case it's not obvious, this is to be an inline dimmer, not an in-wall dimmer.
 
   / Homemade AC light dimmer #3  
One thing to watch Joshua, is the heat dissipation. While most of the dimmers as shown are supposed to be good for 600 watts, I wonder if they could really control that much. There are some losses in a dimmer, and those losses would manifest themselves as producing heat. I wonder if a metal box would be a better idea, and if during operation if the dimmer became too warm, perhaps an aluminum heatsink Image Detail for - Heat from dimmers - Electrician Talk - Professional Electrical ...

would be a good idea.. You may be good to go as is, but I would check on the heat after a while before I threw this down on a carpeted floor.

James K0UA
 
   / Homemade AC light dimmer #4  
The prices for items they were showing in your post have probably changed since 2005.

I've got a couple of these, one I use regularly on a floor lamp that's hard to get to the switch (behind a chair). It's probably 10 years old and still dimming. It is just 300 watt max though and might not do what you want. I also see HD is out of stock but others have them also.

Lutron is a good name in dimmers. We've used them for years with fairly good results.

Google this dimmer:
Model # TT-300H-WH
 
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   / Homemade AC light dimmer #5  
Personally i dont see why not. as long as its in a plastic box with a 2 hour rating, i cant see why it would matter.

sure would be mighty ugly though. I see some on ebay for $5, but there just hi/low/off
 
   / Homemade AC light dimmer
  • Thread Starter
#6  
Personally i dont see why not. as long as its in a plastic box with a 2 hour rating, i cant see why it would matter. sure would be mighty ugly though. I see some on ebay for $5, but there just hi/low/off

Ugly don't matter for this particular application. And the cheapest 3-prong dimmer I could find was $50. This project is looking to shape up under $20. If you know of a pre-made project that can do it cheaper, I sure would rather buy something than make something!
 
   / Homemade AC light dimmer #7  
Ugly don't matter for this particular application. And the cheapest 3-prong dimmer I could find was $50. This project is looking to shape up under $20. If you know of a pre-made project that can do it cheaper, I sure would rather buy something than make something!

ive never seen an inline 3 prong dimmer for lamp cord. they only take the flat 2 wire cords.

the flat style run $9 .
 
   / Homemade AC light dimmer #8  
Most of the inline dimmers are made to handle small loads of a single lamp. I'd say you're on the right track by building you one if you need to control over 300 watts.
 
   / Homemade AC light dimmer #9  
I would put one vote for metal box. Reason being that you could install clamp fitting to hold the cable.
Electrical - Electrical Boxes, Conduit & Fittings - Conduit Fittings*at The Home Depot

Here few ready made:
Amazon.com: Westek 6089B 500W Full Range Foot Control Dimmer, Black: Home Improvement

http://www.allelectronics.com/make-a-store/item/DMR-12/500W-DIMMER/1.html

http://www.discountdimmers.com/index.php?main_page=index&cPath=1_27_130

Google 500W in cord dimmer

Any dimmer will work for incadesent but you need special dimmer for anything with transformer (such as low voltage halogen). Dimmers for transformers have symetrical output. Asymetrical output will burn the transformer due to DC component.
 
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   / Homemade AC light dimmer #10  
I would put one vote for metal box. Reason being that you could install clamp fitting to hold the cable.
Electrical - Electrical Boxes, Conduit & Fittings - Conduit Fittings*at The Home Depot

Here few ready made:
Amazon.com: Westek 6089B 500W Full Range Foot Control Dimmer, Black: Home Improvement

500W DIMMER | AllElectronics.com

http://www.discountdimmers.com/index.php?main_page=index&cPath=1_27_130

Google 500W in cord dimmer

Any dimmer will work for incadesent but you need special dimmer for anything with transformer (such as low voltage halogen). Dimmers for transformers have symetrical output. Asymetrical output will burn the transformer due to DC component.

HE STATED he wanted it for a 3 prong plug.
 
   / Homemade AC light dimmer #11  
in my shop I have 2 things that may satisfy what the OP wants to do.

1, is a metal quad outlet box with cover with a dual outlet on one side, and a hd dimmer int he other.. push on, then turn. ( is a triac based drimemr.. not resistive ).. is rated for 600w inc load.

I have used it on lamps, and for limited us on a non variable drill one time.. :)


the next unit is a router speed control.. i didn't build it.. bought it years ago. finally found it months ago.. :) it's rated for something like 15a :)


soundguy
 
   / Homemade AC light dimmer
  • Thread Starter
#14  

I'm familiar with those, but none of them are three-prong. I intend to use this for temporary outdoor lighting. I will have a bunch of "Chinese Lantern" style lamps that will be on an extension cord/cords. The lamps themselves are two-prong, but the extension cords are three-prong, and it seems like a good idea to keep the grounding as far through the circuit as possible. Also, the ones I've found are only 300W max, while I can easily get 600W with a in-wall dimmer.

Before I learned of the router speed control, the cheapest 3-prong dimmer I could find was $50. The speed controller is a really tempting option, but I may end up rolling my own anyway, because it will still be marginally cheaper, and I like making things.
 
   / Homemade AC light dimmer #15  
My guess is that the speed control is more expensive due to inductive load that might generate voltage spikes during commutation. It has to be made from hardened components.
Make you own. Take two gang metal box, put 600 or 1000W dimmer in one and the two outlets in the other gang. One outlet dimmed and the other 110V. Or both dimmed. Toggle or push and rotate dimmers fit in the metal outlet/switch combo cover for the box.
 
   / Homemade AC light dimmer #16  
that's what I did...
 
   / Homemade AC light dimmer
  • Thread Starter
#17  
Thanks for the input, guys. I ended up making one out of about $25 in parts. The extension cord was the most expensive part. I couldn't find much of a cheap one with three prongs. If I had gone two-prong, the whole thing would have come in under $10. With tax, I about broke even with the router speed controller from Harbor Freight. The Harbor Freight speed controller handles up to 1000 watts, while my dimmer only handles 600 watts. The speed controller also has an on/off switch as well as a dimmer. I figured that after shipping, I would still come out ahead, but it turns out there's a Harbor Freight in Knoxville, so I could have just picked one up. Either way, it's not too big a deal. I kind of like the "industrial" look of my home-made dimmer, compared to the professional look of the dimmer.

While I was building it, I tested out the wiring with a multimeter. The multimeter showed no continuity on the hot wire! I decided to just plug in a light bulb and see if it worked, and it didn't. So I pulled everything apart and started testing it all. Well, it turns out that AC light dimmers aren't simple rheostats. They have a diode in there that chops off the tops of the AC signal. So they don't show any continuity with a simple multimeter even when the switch is open. In other words, everything was wired up fine. So why didn't the light turn on when I plugged it in? Because the light bulb was burned out! Duh.
 
   / Homemade AC light dimmer #18  
. Well, it turns out that AC light dimmers aren't simple rheostats. They have a diode in there that chops off the tops of the AC signal. .

I'll bet if you look closer you actually find a triac....

soundguy
 

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